ALL INTERNATIONAL RIGHTS RESERVED. COPYRIGHT 1992 BY AMP INCORPORATED ANE QUALIFICATION TEST REPORT POWER RING, HOUSING AND TERMINAL ASSEMBLY 501-164 Rev. 0 Product Specification: 108-1191 Rev. 0 CTL No.: CTL1071-013-005 Date: January 30, 1992 Classification: Unrestricted Prepared By: Terrance M. Shingara *Trademark of AMP Incorporated Le Corporate Test Laboratory Harrisburg, Pennsylvaniaa ee ee On & WwW hr M POP BO BM RO RO BD Bo RO RO PRS RO RS BO BO _ 8 s 8 = 8 & wos oe whe Oo te 6 Go OF Oo Od Oo Oo Go Oo Go Oo Go Oo Lo 8 8 501-164, Rev. 0 Table of Contents INtroduction ..... cc ccc ccc ween e reer eee n ne eer esererees Page PULPOSE 2. cece ccc c ec eee cette recent ene e ete eeeeennes Page SCOPE wo cccrcvc rece eee rece setae ee teen eee n ees teseeaenees Page COMCTUSTION ..... cc cece cee cere eee reece cere eee eeeenereee Page Product Description ...... cece eee eee cece eee eter eee Page Test Samples 22... ccc cece cece e reece nee n ener eaeeeenree Page Qualification Test Sequence .......... 2. ccc eee e eres Page Summary Of TeSting ........ ccc ese cen cent ees r nse ventaue Page Examination of Product .......0cc cece cece ere e rece nereee Page Termination Resistance, Dry Circuit .........2.eeee ree Page Dielectric Withstanding Voltage ....... cc cece eee eee eees Page Insulation R@SiStanc ....ce cece cect eer ee erect erences Page Current Cycling ........- eee eee ec ee eee ene eens Page Temperature Rise vs. Current 2.2... cece eee ee eee eer nee Page Static Heating, Contact ........ 02. ee ccc eee eres Page Vibration 2... ccc cece wee eee cece erence ere enes Page Strength Of HOUSING ......c ceca cece eee erence c ee eneenes Page Contact Insertion FOrce ....ce cece cece eee cee e mene rees Page Contact Retention ....... ccc eee ec cece ene eevee erees Page Crimp Tensile ......... ccc cece cece crete eee e eee eeeees Page Thermal SHOCK .. ccc ccc cece cece eee cere cere neat eeenees Page Humidity-Temperature Cycling ...-.......... cece nace nee Page Temperature Life ..... cece cece eect c ee ree eee eeeenaneee Page Test Methods 2... .. cece cece ccc e eee s weet mene ener ee eeeenen Page Examination of Product ....... cece ee nees Save veeeerees Page Termination Resistance, Dry Circuit ........ ccc ee ereee Page Dielectric Withstanding Voltage ........ cece ces eee nace Page Insulation Resistance ........ cece c cere rete teen rece Page Current CYCLING .... cc cece cece cee eee teen teen eeensnees Page Temperature Rise vs. Current ............ 0.20. ee eee eee Page Static Heating, Contact ...... ce cece eee eee cree tees Page Vibration 2.0... ce cee cee teen este eeereee Page Strength of Housing ........c cece scence ene e ere eeeeerens Page Contact Insertion Force .... ccc cc ccc eet eee e eras Page Contact Retention 2... ccc cc cc ccc eee e cater eesee scenes Page Crimp Tensile 2.0... .. cee ccc ccc cect e nee twee eee sees Page Thermal SHOCK cc... ccc cece cece ene tee een ene neeeneeenens Page Humidity-Temperature Cycling ..... ccc cece cove neve ccces Page Temperature Life .... ccc cece eect cee tee eee e eee e eee Page Validation .... 0... cl ec cece eee ee een ween nee Page (R1071TS) POD PD te et .o 0 SI SS ES Oo on on cr on on APPA P PP LP fh bw Wo) WwW501-164, Rev. 0 ANF AMP INCORPORATED HARRISBURG, PENNSYLVANIA 17105 PHONE: 717-564-0100 TWX: 510-657-4110 CORPORATE TEST LABORATORY Qualification Test Report POWER RING, Housing and Terminal Assembly 1.1 1.2 1.3 Introduction Purpose Testing was performed on the AMP Power Ring housing and terminal to determine its conformance te the requirements of AMP Product Specification 108-1191] Rev.0. Scope This report covers the electrical, mechanical, and environmental performance of the AMP Power Ring manufactured by the Consumer Products Business Unit of the Automotive/Consumer Business Group. The testing was performed between April 20 1991 and December 16,1991. Conclusion The AMP Power Ring housing and terminal meets the electrical, mechanical, and environmental performance requirements of AMP Praduct Specification 108-1191 Rev. 0.501-164, Rev. 0 Page 2 1.4 1.5 1.6 Product Description The Power Block and Power Rings allow easy attachment of power cords or direct wiring of appliances to 10 through 6 AWG cable in accordance with National Electrical Code requirements. The housings are made of black Phenolic with steel (zinc or nickel plated) hardware. The contacts are Brass or tin plated Brass. Test Samples The test samples were randomly selected from normal current production lots, and the following part numbers were used for test: Test Group Quantity Part Number Description 1,2,3,4,5 18 ea. 520943-1 Power Ring Assy AWG12 1,3 18 ea. 520943-1 Power Ring Assy AWG18 1,2,3,5 6 ea. 520942-2 Power Block Qualification Test Sequence Test Groups Test or Examination 1 2 3 4 5 Examination of Product 1 1 Termination Resistance, Dry Circuit 3,5 2 Dielectric Withstanding Voltage 3 Insulation Resistance 2 Current Cycling 3 T-Rise vs. Current 3,8 Static Heating, Contact 2 Vibration Strength of Housing Contact Insertion Force Contact Retention Crimp Tensile Thermal Shock Humidity-Temperature Cycling 4 Temperature Life 5 Col 4 PO] yy cr The numbers indicate sequence in which tests were performed.501-164, Rev. 0 Page 3 2.1 2.2 2.3 2.4 2.5 Summary of Testing Examination of Product - All Groups All samples submitted for testing were selected from normal current production lots. They were inspected and accepted by the Product Assurance Department of the Automotive/Consumer Business Group. Termination Resistance, Dry Circuit - Groups 1,2,5 All crimp resistance measurements, taken at 100 milliamperes dc. and 50 millivolts open circuit voltage, were less than 1.00 milliohms. Test No. of Group Samples Condition Min. Max. Mean 1 18 Initial 0.21 0.88 0.379 After Vibration 0.29 0.79 0.427 2 9 Initial 0.29 0.36 0.312 After Current Ver. 0.22 0.68 0.455 5 9 Initial 0.30 0.41 0.359 After Current Cyc. 0.32 0.56 0.401 All values in milliohms All total (crimp & front end) resistance measurements, taken at 100 milliamperes dc. and 50 millivolts open circuit voltage, were less than 2.00 milliohms. Test No. of Group Samples Condition Min. Max. Mean 2 9 Initial 0.61 0.68 0.630 After Current Ver. 0.68 1.21 0.959 All values in milliohms Dielectric Withstanding Voltage - Group 3 No dielectric breakdown or flashover occurred when a test voltage was applied between adjacent contacts. Insulation Resistance - Group 3 All insulation resistance measurements were greater than 5000 megohms. Current Cycling - Group 5 No evidence of physical damage was visible to the test samples, after 500 cycles of cycling the current on and off at a current of 37.5 amperes. The cycling current represented 125% of the specified current.501-164 Rev. 0 Page 4 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 Temperature Rise vs. Current - Group 2 All samples had a temperature rise of less than 50 C above ambient when a specified current of 30.0 amperes dc was applied. Static Heating, Contacts - Group 4 All contacts had a temperature rise of less than 50 above ambient when a specified current of 95.0 amperes dc was applied. Vibration - Groups 1,2 No discontinuities of the contacts were detected, on group ] samples, during vibration. Following vibration, no cracks, breaks, or loose parts on the connector assemblies were visible. Housing Lock Strength - Group 1 With 50 in/lb applied to each screw no cracks, breaks, or loose parts on the connector assemblies were visible. Contact Insertion Force - Group 1 The force required to insert each contact into the housing was less than 10 pounds. Contact Retention - Group 1 No physical damage occurred to either the contacts or the housing, and no contacts dislodged from the housings as a result of applying an axial load of 30 pounds to each contact. Crimp Tensile - Group 1 All tensile values were greater than 70 pounds for AWG12 and 20 pounds for AWG18. Thermal Shock - Group 3 No evidence of physical damage to either the terminals or the housing was visible as a result of thermal shock. Humidity-Temperature Cycling - Groups 2,3 No evidence of physical damage to either the terminals or the housing was visible as a result of exposure to humidity- temperature cycling. Temperature Life - Group 2 No evidence of physical damage to either the terminals or the housing was visible as a result of exposure to an elevated temperature.501-164 Rev. 0 Page 5 3.2 3.3 3.4 Test Methods Examination of Product Product drawings and inspection plans were used to examine the samples. They were examined visually and functionally. Termination Resistance, Low Level Termination resistance measurements at low level current were made, using a four terminal measuring technique (Figure 1}. The test current was maintained at 100 milliamperes dc, with an open circuit voltage of 50 millivolts dec. Screw Torqued to 45 Inch-Pounds 6 AWG, Thermocouple Location ? Strands 12 AWG, 7 Strands pt 3.0002. 125 Tnches of Wire 1 | lowe He 0 [lo - | Termination Resiscance | Measurement Points Power (,- YY Supply Figure 1 Typical Termination Resistance Measurement Points Dielectric Withstanding Voltage A test potential of 1500 vac was applied between the adjacent contacts. This potential was applied for one minute and then returned to zero. Insulation Resistance Insulation resistance was measured between adjacent contacts, using a test voltage of 500 volts dc. This voltage was applied for one minutes before the resistance was measured.501-164 Rev. 0 Page 6 3.5 3.6 3.7 Current Cycling The connectors were cycled on and off at 125% of the specified current. Testing consisted of 500 cycles, with each cycle having current on for 45 minutes and current off for 15 minutes. Temperature Rise vs Specified Current Connector temperature was measured, while energized at the specified current of 30 amperes ac. Thermocouples were attached to the connectors to measure their temperatures. This temperature was then subtracted from the ambient temperature to find the temperature rise. When three readings at five minute intervals were the same, the readings were recorded. Static Heating, Contact Static Heating was performed to verify the current carrying capability of the friction interface between the Power Ring Terminal and screw assembly(Figure 2}. Connector temperature was measured, while energized at the specified current of 95 amperes ac. Thermocouples were attached to the connectors to measure their temperatures. This temperature was then subtracted from the ambient temperature to find the temperature rise. When three readings at five minute intervals were the same, the readings were recorded. 6 AWG, 7 Strands Screw Torqued to 45 Inch-Pounds Seldered to Contace as Shown Thermocouple / 5 AWG, 7 Serands Location Power La Supply Figure 2 Static Heating501-164 Rev. 0 Page 7 3.8 3.9 3.10 3.11 3.12 3.13 Vibration, Sine Mated connectors were subjected to sinusoidal vibration, having a simple harmonic motion with an amplitude of 0.06 inch, double amplitude. The vibration frequency was varied uniformly between the limits of 10 and 55 Hz and returned to 10 Hz in 1 minutes. This cycle was performed for 2 hours in each of three mutually perpendicular planes, for a total vibration time of 6 hours. Connectors were monitored for discontinuities greater than one microsecond, using a current of 100 milliamperes in the monitoring circuit. Strength of Housing An rotational load of 50 inch/pounds was applied to each screw assembly mounted in the housing. Contact Insertion The force required to insert the Power Ring Terminal into the Power Block was measured. Contact Retention An axial load of 30 pounds was applied to each contact and held for 60 seconds. The force was applied in a direction to cause removal of the contacts from the housing. Crimp Tensile An axial load was applied to each contact at a crosshead rate of 1.0 inch per minute. This force was applied until the contact and the wire separated. Therma? Shock Mated connectors were subjected to 25 cycles of temperature extremes, with each cycle consisting of 30 minutes at each temperature. The temperature extremes were -40 C and 125 C. The transition between temperatures was less than one minute.501-164 Rev. 0 Page & 3.14 3.15 Humidity-Temperature Cycling Mated connectors were exposed to 10 cycles of humidity- temperature cycling. Each cycle lasted 24 hours and consisted of cycling the temperature between 25 C and 65 C twice, while the relative humidity was held at 95%. Temperature Life Mated samples were exposed to a temperature of 150 C for 24 hours.501-164, Rev. 0 Page 9 Validation Prepared by: Mes FL ad 2/2 /52- Terrance M. Shingar Test Engineer Design Assurance Testing Corporate Test Laboratory Reviewed by: | 26 C0 G Hoje BIR G2 Richard A. Groft Supervisor Design Assurance Testing Corporate Test Laboratory Approved by: Winn BQe ot /iad/Fa. William Zetne ) Sf S/72 Manager Product Assurance Automotive/Consumer Business Group (North)