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Bussing W58 Series Breakers
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jluckey(at)pacbell.net
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PostPosted: Tue Nov 05, 2013 4:55 pm    Post subject: Bussing W58 Series Breakers Reply with quote

Does anyone have a picture showing a row of W58 series (reset-only) circuit breakers w/ .250 quick connect terminals and how the feed side was bussed?

I can see using several quick connect terminals jumpered together but i'm curious about other more elegant solutions.

TIA

-Jeff

[quote][b]


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rene(at)felker.com
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PostPosted: Tue Nov 05, 2013 5:17 pm    Post subject: Bussing W58 Series Breakers Reply with quote

No pictures…but copper bus bar across the terminals.

Rene' Felker
N423CF
801-721-6080


From: owner-aeroelectric-list-server(at)matronics.com [mailto:owner-aeroelectric-list-server(at)matronics.com] On Behalf Of Jeff Luckey
Sent: Tuesday, November 05, 2013 7:54 PM
To: aeroelectric-list(at)matronics.com
Subject: Bussing W58 Series Breakers


Does anyone have a picture showing a row of W58 series (reset-only) circuit breakers w/ .250 quick connect terminals and how the feed side was bussed?

I can see using several quick connect terminals jumpered together but i'm curious about other more elegant solutions.

TIA

-Jeff


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nuckolls.bob(at)aeroelect
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PostPosted: Tue Nov 05, 2013 8:53 pm    Post subject: Bussing W58 Series Breakers Reply with quote

At 06:53 PM 11/5/2013, you wrote:

Quote:
Does anyone have a picture showing a row of W58 series (reset-only) circuit breakers w/ .250 quick connect terminals and how the feed side was bussed?

I can see using several quick connect terminals jumpered together but i'm curious about other more elegant solutions.


Keystone electronics makes a .250 wide
faston socket for use on etched circuit
boards. A bus-board could be fabricated
to accept a row of these clips spaced at
what ever matches your breaker layout.


[img]cid:7.1.0.9.0.20131105224658.01f16878(at)aeroelectric.com.0[/img]

This would make a very low parts count
bus-bar for fast-on tabbed breakers.



Bob . . .


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uuccio(at)gmail.com
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PostPosted: Tue Nov 05, 2013 9:46 pm    Post subject: Bussing W58 Series Breakers Reply with quote



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jluckey(at)pacbell.net
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PostPosted: Wed Nov 06, 2013 11:50 am    Post subject: Bussing W58 Series Breakers Reply with quote

Now, why didn't I think of that???

I may have a few of those clips left over from a previous project. Don't even need a circuit board, I could simply solder them to a brass strip to form a buss.
Thx Bob,

-Jeff

From: "Robert L. Nuckolls, III" <nuckolls.bob(at)aeroelectric.com>
To: aeroelectric-list(at)matronics.com
Sent: Tuesday, November 5, 2013 8:53 PM
Subject: Re: Bussing W58 Series Breakers


At 06:53 PM 11/5/2013, you wrote:

Quote:
Does anyone have a picture showing a row of W58 series (reset-only) circuit breakers w/ .250 quick connect terminals and how the feed side was bussed?

I can see using several quick connect terminals jumpered together but i'm curious about other more elegant solutions.


Keystone electronics makes a .250 wide
faston socket for use on etched circuit
boards. A bus-board could be fabricated
to accept a row of these clips spaced at
what ever matches your breaker layout.


[img]cid:1.1028564332(at)web184904.mail.gq1.yahoo.com[/img]

This would make a very low parts count
bus-bar for fast-on tabbed breakers.


Bob . . .


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uuccio(at)gmail.com
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PostPosted: Wed Nov 06, 2013 12:10 pm    Post subject: Bussing W58 Series Breakers Reply with quote

I think I’d like to give that a go too when I upgrade my current wiring… Can a circuit board carry enough current though? The copper layers don’t look very thick. On the other hand, the brass strips that are found in home electrical stores seem a bit oversized to the task.

Now, why didn't I think of that???

I may have a few of those clips left over from a previous project. Don't even need a circuit board, I could simply solder them to a brass strip to form a buss.





[quote][b]


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mrspudandcompany(at)veriz
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PostPosted: Wed Nov 06, 2013 12:44 pm    Post subject: Bussing W58 Series Breakers Reply with quote

Quote:



Can a circuit board carry enough current though? The copper layers don’t look very thick. On the other hand, the brass strips that are found in home electrical stores seem a bit oversized to the task.
Quote:
Something I have found that works great is soft copper tubing.  You can purchase by the foot at your local hardware store. Take a 1/4" diameter piece and flatten gently with a hammer and it makes a great bus bar. If you want to attach it to the CB's with screws you can drill holes and screw it on or solder if you prefer. a similar method makes a nice forrest of tabs for grounding.

Roger

I am using the Free version of SPAMfighter.SPAMfighter has removed 1371 of my spam emails to date.Do you have a slow PC? Try a free scan! [quote][b]


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nuckolls.bob(at)aeroelect
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PostPosted: Wed Nov 06, 2013 3:58 pm    Post subject: Bussing W58 Series Breakers Reply with quote

At 06:53 PM 11/5/2013, you wrote:

Does anyone have a picture showing a row of W58 series (reset-only) circuit breakers w/ .250 quick connect terminals and how the feed side was bussed?

I can see using several quick connect terminals jumpered together but i'm curious about other more elegant solutions.


Keystone electronics makes a .250 wide
FastOn socket for use on etched circuit
boards. A bus-board could be fabricated
to accept a row of these clips spaced at
what ever matches your breaker layout.

If you're really handy with sheet metal and
getting rows of holes accurately located, you
could fabricate from scratch . . .

[img]cid:.0[/img]

Suggest you not try to bus more than 5 breakers
at once. The finished bus-bar needs to press-on/
pry-off of n-terminals all at once. Unless
I could locate the holes on a digitally indicated
milling machine, I'd probably go the etched
circuit board route. $60 will get you 3 boards
5 breakers long that can be sheared into 3
bus bars each. Enough material with precisely
located holes to neatly tie 45 breakers together
in groups of up to 5.

Have you bought the breakers? They are available
in screw terminal versions . . .

Bob . . .


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nuckolls.bob(at)aeroelect
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PostPosted: Wed Nov 06, 2013 5:30 pm    Post subject: Bussing W58 Series Breakers Reply with quote

At 02:09 PM 11/6/2013, you wrote:
Quote:
I think I’d like to give that a go too when I
upgrade my current wiring… Can a circuit board
carry enough current though? The copper layers
don’t look very thick. On the other hand, the
brass strips that are found in home electrical
stores seem a bit oversized to the task.


Yes, the number of breakers that can be fed
from one piece of double sided board won't
overheat it. You also connect the feeder
wire as close as practical to the center
so that copper clad is only 'feeding'
two breakers.

Bob . . .


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nuckolls.bob(at)aeroelect
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PostPosted: Wed Nov 06, 2013 5:32 pm    Post subject: Bussing W58 Series Breakers Reply with quote

At 01:49 PM 11/6/2013, you wrote:
Quote:
Now, why didn't I think of that???

I may have a few of those clips left over from a previous project.
Don't even need a circuit board, I could simply solder them to a
brass strip to form a buss.

yes. you need to fixture them to be
VERY well aligned before soldering.
Normal to the buss surface and no
twisting of the breaker terminal.

Bob . . .


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jluckey(at)pacbell.net
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PostPosted: Wed Nov 06, 2013 6:30 pm    Post subject: Bussing W58 Series Breakers Reply with quote

The nice thing about using 3 or 4 insulated quick connect terminals
like this:

jumped together is that it makes the buss well insulated. There would be no exposed B+ or metal bar. (For the purposes of this discussion lets call this a "jumper buss")

With a buss bar like the one shown below we lose that insulation -- also could be difficult to work with for several reasons: difficult to pry on and off, easily bend brass bar or break circuit board, etc.

What are the problems, issues, cons of a "jumper buss"?
-Jeff

From: "Robert L. Nuckolls, III" <nuckolls.bob(at)aeroelectric.com>
To: aeroelectric-list(at)matronics.com
Sent: Wednesday, November 6, 2013 2:07 PM
Subject: Re: Bussing W58 Series Breakers


At 06:53 PM 11/5/2013, you wrote:

Does anyone have a picture showing a row of W58 series (reset-only) circuit breakers w/ .250 quick connect terminals and how the feed side was bussed?

I can see using several quick connect terminals jumpered together but i'm curious about other more elegant solutions.


Keystone electronics makes a .250 wide
FastOn socket for use on etched circuit
boards. A bus-board could be fabricated
to accept a row of these clips spaced at
what ever matches your breaker layout.

If you're really handy with sheet metal and
getting rows of holes accurately located, you
could fabricate from scratch . . .

[img]cid:1.1031637242(at)web184906.mail.gq1.yahoo.com[/img]

Suggest you not try to bus more than 5 breakers
at once. The finished bus-bar needs to press-on/
pry-off of n-terminals all at once. Unless
I could locate the holes on a digitally indicated
milling machine, I'd probably go the etched
  circuit board route. $60 will get you 3 boards
5 breakers long that can be sheared into 3
bus bars each. Enough material with precisely
located holes to neatly tie 45 breakers together
in groups of up to 5.

Have you bought the breakers? They are available
in screw terminal versions . . .
Bob . . .


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nuckolls.bob(at)aeroelect
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PostPosted: Wed Nov 06, 2013 7:07 pm    Post subject: Bussing W58 Series Breakers Reply with quote

At 08:29 PM 11/6/2013, you wrote:

Quote:
The nice thing about using 3 or 4 insulated quick connect terminals
like this:

jumped together is that it makes the buss well insulated. There would be no exposed B+ or metal bar. (For the purposes of this discussion lets call this a "jumper buss")

With a buss bar like the one shown below we lose that insulation -- also could be difficult to work with for several reasons: difficult to pry on and off, easily bend brass bar or break circuit board, etc.

What are the problems, issues, cons of a "jumper buss"?


Technically not a 'buss' due to the
daisy chain of serial connections . . .
but lots of those breakers have
been wired that way. Probably not
high risk . . . but what's wrong
with a nice fuse-block?



Bob . . . [quote][b]


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jay(at)horriblehyde.com
Guest





PostPosted: Thu Nov 07, 2013 2:28 am    Post subject: Bussing W58 Series Breakers Reply with quote

I do the same, however, the copper tube (I use the stuff that is used as
water pipes in houses) is hard drawn and slightly brittle. To get around
that I use a small blowtorch to heat it up until it glows red hot and then
let it cool in air. That anneals it and makes it softer and more resistant
to cracking and easier to form- like when you flatten it.



Jay





From: owner-aeroelectric-list-server(at)matronics.com
[mailto:owner-aeroelectric-list-server(at)matronics.com] On Behalf Of R. curtis
Sent: 06 November 2013 10:43 PM
To: aeroelectric-list(at)matronics.com
Subject: Re: Bussing W58 Series Breakers







Can a circuit board carry enough current though? The copper layers don't
look very thick. On the other hand, the brass strips that are found in
home electrical stores seem a bit oversized to the task.



Something I have found that works great is soft copper tubing. You can
purchase by the foot at your local hardware store. Take a 1/4" diameter
piece and flatten gently with a hammer and it makes a great bus bar. If you
want to attach it to the CB's with screws you can drill holes and screw it
on or solder if you prefer. a similar method makes a nice forrest of tabs
for grounding.



Roger



_____


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bob.verwey(at)gmail.com
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PostPosted: Thu Nov 07, 2013 2:39 am    Post subject: Bussing W58 Series Breakers Reply with quote

C'mon guys, you can buy copper strip cut to size, and save yourself a lot of hassle. Plus it looks better!

Best...
Bob Verwey

IO 470  A35  ZU-DLW


On 7 November 2013 12:27, Jay Hyde <jay(at)horriblehyde.com (jay(at)horriblehyde.com)> wrote:
[quote]
I do the same, however, the copper tube (I use the stuff that is used as water pipes in houses) is hard drawn and slightly brittle.  To get around that I use a small blowtorch to heat it up until it glows red hot and then let it cool in air.  That anneals it and makes it softer and more resistant to cracking and easier to form- like when you flatten it.
 
Jay
 
 
From: owner-aeroelectric-list-server(at)matronics.com (owner-aeroelectric-list-server(at)matronics.com) [mailto:owner-aeroelectric-list-server(at)matronics.com (owner-aeroelectric-list-server(at)matronics.com)] On Behalf Of R. curtis
Sent: 06 November 2013 10:43 PM
To: aeroelectric-list(at)matronics.com (aeroelectric-list(at)matronics.com)
Subject: Re: Bussing W58 Series Breakers
 
 
Quote:

 

 Can a circuit board carry enough current though? The copper layers don’t look very thick.   On the other hand, the brass strips that are found in home electrical stores seem a bit oversized to the task.
 
Quote:

Something I have found that works great is soft copper tubing.  You can purchase by the foot at your local hardware store.  Take a 1/4" diameter piece and flatten gently with a hammer and it makes a great bus bar.  If you want to attach it to the CB's with screws you can drill holes and screw it on or solder if you prefer.  a similar method makes a nice forrest of tabs for grounding.

 

Roger

 

I am using the Free version of SPAMfighter.
SPAMfighter href="http://www.spamfighter.com/SLOW-PCfighter?cid=sigen">slow PC? Try a free scan!
Quote:
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[b][/b][b]www.aeroelectric.com[/b] 
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nuckolls.bob(at)aeroelect
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PostPosted: Thu Nov 07, 2013 6:37 am    Post subject: Bussing W58 Series Breakers Reply with quote

At 04:38 AM 11/7/2013, you wrote:
Quote:
C'mon guys, you can buy copper strip cut to size, and save yourself a lot of hassle. Plus it looks better!


I'll second that but with foundations in physics. Review
the articles on our website that cite the term "gas tight"

http://tinyurl.com/mjjl9dt

I'll remind Listers that connectivity-magic happens
when two conductors are held together with such force
and rigidity across compliant surfaces that (1) ingress
of moisture laden air and (2) relative motion between
conductors is prevented.

This design goal is the reason why round-wires and
terminals become decidedly un-round under the crush
of a crimped joint -OR- encapsulated in a cocoon of
metal in the soldered joint.

The most problematic joints in a wiring system are
installer-fabricated with poor regard for process.
Threaded fasteners are particularly needful of
attention to details of flatness, force and
rigidity.

This is why the fuse-blocks dropped onto B&C's
counter at OSH turned out to be a kind of
installer's dream for relief of worries about
knowledge and skill sets. First, the metal to
metal joints were minimized. All but the threaded
stud on the end of the assembly are manufactured
for integrity and service life. If the builder
can get a nice flat flag on an AMP terminal
cinched down on a 10-32 stud, probabilities for
very low risk and cost of ownership are good.

The circuit breakers under discussion are
suited to service in appliances and/or systems
were design goals call for protection of a single
feeder. But lining a bunch of them up on a panel
with some notion of bussing their supply terminals
is a mis-application of original design goals.

The technical definition of a buss is a conductive
structure ideally comprised of one piece of
metal from which numerous taps supply power to
various loads in the system with an architecture
that prevents any single failure from propagating
beyond the single feeder. Here's a collection
of pictures for a 'buss and breaker' structure
removed from a legacy Piper airplane . . .

http://tinyurl.com/lmbcm66

http://tinyurl.com/lucl439

http://tinyurl.com/myhmoew

The OBAM aviation builder-sphere is replete
with arguments against religious observation
of legacy design goals, "Well, the guy next
to me in the hanger has been flying this
(you fill in the blank) for years and hasn't
had a bit of trouble."

Given that our art is beginning its second
century of real-life application, there are
constellations of lessons-learned derived
from a distillation of proven recipes for
success re-enforced by understanding of the
physics upon which they're built.

Nobody stands over us with a rule book under
one arm and a citation book under the other . . .
but there ARE folks who we pay to worry that
would be glad to assume that role in our
craft. That event will mark the time when
innovation and exploration of new ideas will
slow to a crawl . . . if not halt completely.

We would do well to expand our understanding of
the arts and science while propagating it to
the greatest number of interested individuals.
There will always be those who don't find
value in this endeavor . . . most will survive
with little more than an elevated cost of
ownership and laundry soap for the underwear.
But a few will become candidates for trial in the Court
of Dark-n-Stormy Nights where the narrator
was not on board the airplane.

The short response is, "buy already mill-flat
materials from which to craft buss bars and
fat-terminal jumpers". It is the exceedingly
rare OBAM aviation shop that can take a round
piece of metal and achieve such flatness.

See: http://tinyurl.com/khymmf3

http://tinyurl.com/leunhah




Bob . . . [quote][b]


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bbradburry(at)bellsouth.n
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PostPosted: Thu Nov 07, 2013 7:08 am    Post subject: Bussing W58 Series Breakers Reply with quote

There seems to be a typo on this ebay site. I don’t think that one cubic inch of copper weighs 4 pounds! ??

http://www.ebay.com/itm/48-oz-1-16-Flat-Copper-Sheet-Plate-4-x-4-/271192124476?pt=LH_DefaultDomain_0&hash=item3f244f6c3c

Bill


From: owner-aeroelectric-list-server(at)matronics.com [mailto:owner-aeroelectric-list-server(at)matronics.com] On Behalf Of Robert L. Nuckolls, III
Sent: Thursday, November 07, 2013 9:36 AM
To: aeroelectric-list(at)matronics.com
Subject: Re: AeroElectric-List: Bussing W58 Series Breakers


At 04:38 AM 11/7/2013, you wrote:


C'mon guys, you can buy copper strip cut to size, and save yourself a lot of hassle. Plus it looks better!

I'll second that but with foundations in physics. Review
the articles on our website that cite the term "gas tight"

http://tinyurl.com/mjjl9dt

I'll remind Listers that connectivity-magic happens
when two conductors are held together with such force
and rigidity across compliant surfaces that (1) ingress
of moisture laden air and (2) relative motion between
conductors is prevented.

This design goal is the reason why round-wires and
terminals become decidedly un-round under the crush
of a crimped joint -OR- encapsulated in a cocoon of
metal in the soldered joint.

The most problematic joints in a wiring system are
installer-fabricated with poor regard for process.
Threaded fasteners are particularly needful of
attention to details of flatness, force and
rigidity.

This is why the fuse-blocks dropped onto B&C's
counter at OSH turned out to be a kind of
installer's dream for relief of worries about
knowledge and skill sets. First, the metal to
metal joints were minimized. All but the threaded
stud on the end of the assembly are manufactured
for integrity and service life. If the builder
can get a nice flat flag on an AMP terminal
cinched down on a 10-32 stud, probabilities for
very low risk and cost of ownership are good.

The circuit breakers under discussion are
suited to service in appliances and/or systems
were design goals call for protection of a single
feeder. But lining a bunch of them up on a panel
with some notion of bussing their supply terminals
is a mis-application of original design goals.

The technical definition of a buss is a conductive
structure ideally comprised of one piece of
metal from which numerous taps supply power to
various loads in the system with an architecture
that prevents any single failure from propagating
beyond the single feeder. Here's a collection
of pictures for a 'buss and breaker' structure
removed from a legacy Piper airplane . . .

http://tinyurl.com/lmbcm66

http://tinyurl.com/lucl439

http://tinyurl.com/myhmoew

The OBAM aviation builder-sphere is replete
with arguments against religious observation
of legacy design goals, "Well, the guy next
to me in the hanger has been flying this
(you fill in the blank) for years and hasn't
had a bit of trouble."

Given that our art is beginning its second
century of real-life application, there are
constellations of lessons-learned derived
from a distillation of proven recipes for
success re-enforced by understanding of the
physics upon which they're built.

Nobody stands over us with a rule book under
one arm and a citation book under the other . . .
but there ARE folks who we pay to worry that
would be glad to assume that role in our
craft. That event will mark the time when
innovation and exploration of new ideas will
slow to a crawl . . . if not halt completely.

We would do well to expand our understanding of
the arts and science while propagating it to
the greatest number of interested individuals.
There will always be those who don't find
value in this endeavor . . . most will survive
with little more than an elevated cost of
ownership and laundry soap for the underwear.
But a few will become candidates for trial in the Court
of Dark-n-Stormy Nights where the narrator
was not on board the airplane.

The short response is, "buy already mill-flat
materials from which to craft buss bars and
fat-terminal jumpers". It is the exceedingly
rare OBAM aviation shop that can take a round
piece of metal and achieve such flatness.

See: http://tinyurl.com/khymmf3

http://tinyurl.com/leunhah





Bob . . .
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[quote][b]


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wtmills



Joined: 05 Feb 2007
Posts: 32

PostPosted: Thu Nov 07, 2013 9:05 am    Post subject: Bussing W58 Series Breakers Reply with quote

I disagree with letting it "cool in air" unless the alloys of copper water-pipe and spark-plug gaskets differ significantly which I doubt.


As a fledgling A&P in 1973 we were taught to heat copper spark-plug gaskets to "cherry red" and quench immediately in water.
I admit having no experience with allowing the gaskets to cool in air. 


Here's an EAA demo:

http://www.eaavideo.org/video.aspx?v=57437956001



Respectfully -
Bill
SF bay area


 
[quote] On 7 November 2013 12:27, you 
wrote:

Quote:

I do the same, however, the copper tube (I use the stuff that is used as water pipes in houses) is hard drawn and slightly brittle.  To get around that I use a small blowtorch to heat it up until it glows red hot and then let it cool in air.  That anneals it and makes it softer and more resistant to cracking and easier to form- like when you flatten it.

[b]


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nuckolls.bob(at)aeroelect
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PostPosted: Thu Nov 07, 2013 9:33 am    Post subject: Bussing W58 Series Breakers Reply with quote

At 09:08 AM 11/7/2013, you wrote:
Quote:
There seems to be a typo on this ebay site. I don’t think that one cubic inch of copper weighs 4 pounds! ??

http://www.ebay.com/itm/48-oz-1-16-Flat-Copper-Sheet-Plate-4-x-4-/271192124476?pt=LH_DefaultDomain_0&hash=item3f244f6c3c

Bill



That's an unfortunate citation. In the time
before etched circuit boards, copper was rated/sold
by gage and/or thickness times some dimension
that described area. Then came copper clad ecb
materials where somebody thought it was a good
idea to speak to the thickness of copper not in
terms of thickness but in some new convention
like 'ounces per square foot'.

It's a close cousin to logic that speaks of 'circular
mil area' of a wire. A 10AWG solid wire is 102 mils
in diameter with a real cross section of
3.14 x (.051)^2 = 0.00816 square inches. 10AWG
said to have a CMA of 102^2 or 10,400 'circular
mils'. It's 'handier' to rate current density in
a wire in Amps per CMA . . . it's a discipline
specific vernacular for folks who work with wires
a lot . . . but it bugs a physicist.

The ounces per square foot are easier to measure/verify
than the actual thickness of the copper where
1 ounce per square foot is 1.344 mils.

Copper has a density of 5.168 oz/cu-in. So a
sheet of copper 1" square and ".001344" thick
will have weight of 5.168 x 0.001344 = .006945
oz/sq-in x 144 = 1.000 oz/sq foot.

Getting back to the eBay ad, we have .062"
thick for 0.323 oz/sq-in x 144 = 46.5
oz/sq-ft. Hence the citation for "48 oz"
copper . . . a description that would be
meaningless to guys who do copper gutters
and flashing . . . or buss bars in airplanes.




Bob . . . [quote][b]


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mrspudandcompany(at)veriz
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PostPosted: Thu Nov 07, 2013 10:33 am    Post subject: Bussing W58 Series Breakers Reply with quote

Quote:
I disagree with letting it "cool in air" unless the alloys of copper water-pipe and spark-plug gaskets differ significantly which I doubt.

Quote:
Air cooling of the cherry red hot copper will anneal it, however it will anneal to a softer state if you quench the copper in water.

Roger



I am using the Free version of SPAMfighter.SPAMfighter has removed 1378 of my spam emails to date.Do you have a slow PC? Try a free scan! [quote][b]


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wtmills



Joined: 05 Feb 2007
Posts: 32

PostPosted: Thu Nov 07, 2013 10:45 am    Post subject: Bussing W58 Series Breakers Reply with quote

Thank you for this clarification. 

Bill

Do not archive


Sent via the Samsung Galaxy Note® II, an AT&T 4G LTE smartphone

-------- Original message --------
From: "R. curtis" <mrspudandcompany(at)verizon.net>
Date: 11/07/2013 10:32 AM (GMT-08:00)
To: aeroelectric-list(at)matronics.com
Subject: Re: AeroElectric-List: Bussing W58 Series Breakers


 
I disagree with letting it "cool in air" unless the alloys of copper water-pipe and spark-plug gaskets differ significantly which I doubt.
 
Air cooling of the cherry red hot copper will anneal it, however it will anneal to a softer state if you quench the copper in water.
 
Roger

I am using the Free version of SPAMfighter.
SPAMfighter has removed 1378 of my spam emails to date.

Do you have a slow PC? Try a free scan!


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