46817-1002

PRODUCT SPECIFICATION GUARDIAN CONNECTOR SYSTEM REVISION: C4 ECR/ECN INFORMATION: TITLE: Guardian Wire to Board Interconnect System EC No: UCP2013-5363 DATE: 2013/06/12 DOCUMENT NUMBER: PS-46819-001 SHEET No. 1 of 19 CREATED / REVISED BY: CHECKED BY: APPROVED BY: J.QUILES J.SCHAFER A.PATEL TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A](V.1).DOC PRODUCT SPECIFICATION TABLE OF CONTENTS : 1.0 SCOPE 2.0 SUMMARY OF RESULTS 3.0 DOCUMENTS & SPECIFICATIONS 3.1 Testing Procedure & Sequences 3.2 Other Documents 4.0 MECHANICAL PERFORMANCE 4.1 Component Level 4.2 Free Hanging Load Test 5.0 ELECTRICAL REQUIREMENTS 5.1 Crimp Stress Test-Millivolt Drop 5.1.1 Crimp Stress Acceptance Criteria 5.2 Electrical Performance and Rating 5.3 Temperature Rise Current Charts 6.0 TEST PLAN, ENVIRONMENTAL TEST PER EIA-364-1000.01 7.0 TEST RESULTS, ENVIRONMENTAL TESTING 8.0 SOLDER PROFILE 9.0 SAFETY AGENCY RATING APPROVAL 9.1 C.S.A. File Number – LR 19980 9.2 U.L. File Number – E29179 REVISION: C4 ECR/ECN INFORMATION: TITLE: Guardian Wire to Board Interconnect System EC No: UCP2013-5363 DATE: 2013/06/12 DOCUMENT NUMBER: PS-46819-001 SHEET No. 2 of 19 CREATED / REVISED BY: CHECKED BY: APPROVED BY: J.QUILES J.SCHAFER A.PATEL TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A](V.1).DOC PRODUCT SPECIFICATION 1.0 SCOPE The specification covers the test sequence performance of the high current wire-to-board interconnect system: 2.0 SUMMARY OF RESULTS The product meets all the Mechanical, Electrical and Environmental test criteria at component and harness level, and is considered a qualified product. 3.0 DOCUMENTS AND SPECIFICATIONS 3.1 Testing Procedure & Sequences: Item Test Report Test Description 1 TR-1.8582 Qualification Test Per EIA-364-1000 Group 1,2,3, & 5 2 TR-1.8583 Electrical Crimp Qualification of 8 & 10 AWG 3 TR-1.8584 Construction analysis 4 TR-1.8733 Harness Pull Force and Torque Retention Test, in mated condition 5 TR-1.8570 T-Rise Test per EIA-364B 6 TR-1.8595 Normal Force Analysis 7 63801-7900 Mech. Crimp Qualification 8 EIA-364-1000 Group 4 Mixed Flowing Gases 9 TR-1.8931 3.2 Hot-mating/Resistance to Arc Other Documents: See series specific sales drawings for additional information. HEADER HARNESS 2 CKT 3 CKT 2 CKT 3 CKT . 46817 SERIES 46817 SERIES 68790 SERIES 111119 SERIES Ref. terminal in harness - 46819-**** REVISION: C4 ECR/ECN INFORMATION: TITLE: Guardian Wire to Board Interconnect System EC No: UCP2013-5363 DATE: 2013/06/12 DOCUMENT NUMBER: PS-46819-001 SHEET No. 3 of 19 CREATED / REVISED BY: CHECKED BY: APPROVED BY: J.QUILES J.SCHAFER A.PATEL TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A](V.1).DOC PRODUCT SPECIFICATION 4.0 MECHANICAL PERFORMANCE 4.1 MECHANICAL PERFORMANCE AT COMPONENT LEVEL TEST DESCRIPTION EQUIPMENT/FIXTURE TEST RESULT Terminal Retention to the Housing (Header) per EIA-364-29 Force Gauge Avg.(3 CKT) 13.83 N St. Dev. 0.56 Solder Pot Solderability Test (Header) per EIA364-52 Meets 95% min Coverage X-Ray Fluoroscope Plating Verification (Plug & Crimp Terminal) Meets Specification Instron Normal Force per EIA-364-04, Method A, 3.90 g (Avg)/Beam @ 0.45 mm deflection Insertion Force (Newtons) st 1 Cycle Instron Force Gauge Insertion/Withdrawal Force per EIA-364-13 Withdrawal Force (Newtons) 1 ckt 2 ckt 3 ckt 1 ckt 2 ckt 3 ckt Min 7.23 11.27 26.71 6.86 10.31 28.21 Max 9.23 19.11 36.60 8.53 19.12 34.39 Avg 7.92 15.60 31.06 7.36 15.87 30.75 Std Dev 0.68 3.15 3.70 0.68 3.85 2.20 Crimp Terminal Retention to Housing N/A Overmold *On 3 ckt configuration, 1 of the ckts is ground (pre-mate) Above forces are peak force. Force Gauge REVISION: C4 6 AWG 8 AWG 10 AWG Avg (lbs) 315 302 216 Std Dev 11.17 5.06 4.45 Failure Mode Wire Pull-out Wire Break Wire Break Crimp Terminal to Wire Pull Force (lbs) ECR/ECN INFORMATION: TITLE: Guardian Wire to Board Interconnect System EC No: UCP2013-5363 DATE: 2013/06/12 DOCUMENT NUMBER: PS-46819-001 SHEET No. 4 of 19 CREATED / REVISED BY: CHECKED BY: APPROVED BY: J.QUILES J.SCHAFER A.PATEL TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A](V.1).DOC PRODUCT SPECIFICATION 4.2 MECHANICAL TEST: FREE HANGING LOAD TEST (MATED CONDITION - 2.5 M CABLE) EQUIPMENT/FIXTURE TEST DESCRIPTION TEST RESULT Rigid Fixture 100 Newtons Weight Straight Inline Loading For 60 Seconds (See Figure 1) Visually Inspected No Damage Rigid Fixture 200 Newtons Weight at 90 degrees Loading For 60 Seconds (Both North-South and East-West directions – see Figure 2) Visually Inspected No Damage Rigid Fixture 150 Newtons Weight 45 degrees loading For 60 Seconds (See Figure 3) Visually Inspected No Damage Fig. 1 Fig. 2 Fig. 3 5.0 ELECTRICAL REQUIREMENTS 5.1 CRIMP STRESS TEST-MILLIVOLT DROP CRIMP WIRE SIZE TEST DESCRIPTION • • • • • • 8 AWG SAMPLE SIZE Initial Voltage Drop Thermal Shock Vibration Accelerated Aging Final Voltage Drop End Testing C4 ECR/ECN INFORMATION: TITLE: Qty 30 Height (Grp. B) DATE: 2013/06/12 PS-46819-001 Qty 30 Lower Crimp Height (Grp C) Guardian Wire to Board Interconnect System EC No: UCP2013-5363 DOCUMENT NUMBER: 0.30 Millivolts σ = 0.053 Upper Crimp test setup and measurements REVISION: Qty 75 Nominal Crimp Height (Grp A) Applied 10 Amps See Figure 4 & 5 for ∆ RESULT 0.20 Millivolts σ = 0.045 0.45 Millivolts σ = 0.101 SHEET No. 5 of 19 CREATED / REVISED BY: CHECKED BY: APPROVED BY: J.QUILES J.SCHAFER A.PATEL TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A](V.1).DOC PRODUCT SPECIFICATION • • • • • • 10 AWG Qty 75 Initial Voltage Drop Thermal Shock Vibration Accelerated Aging Final Voltage Drop End Testing Nominal Crimp Height. (Grp A) Qty 30 Upper Crimp Height (Grp. B) Qty 30 Applied 10 Amps See Figures 4 & 5 for test set-up and measurements Lower Crimp Height (Grp C) 0.66 Millivolts σ = 0.118 0.76 Millivolts σ = 0.177 0.56 Millivolts σ =0.120 * Acceptance criteria appears on page 4 of this specification 5.1.1 CRIMP STRESS ACCEPTANCE CRITERIA ∆ = Change in Millivolts after test sequence σ = Standard Deviation Requirements to pass 8 AWG wire: ∆ = Average Change + 5.46 σ