501-37005

Qualification Test Report

06-Feb-2001 Rev. O
LB00-0048-01
SGC - Stamped Grounding Connector

1. INTRODUCTION

This report has been made to describe the characteristics of the product according to Tyco
specification 108-37048 , which was based on standard IEEE-837 .
All tests have been performed according to specification above and all samples met the specified
requirements . This report was written based on test reports number 2296/97 , 3149/97 , 1147/97 ,
010061 and 010062 , issued by Product Engineering Laboratory from Tyco Electronics Brasil.

2. PRODUCT DESCRIPTION

The product tested is a grounding connector, which shall be considered applicable on Electrical Power
System , specifically for Electrical Substation and Transmission Lines , Electrical Distribution Systems
and Industrial Systems , according to particular project and material specification .
Following components composes the product and their respective raw materials :

• Large and Small Bodies: Stainless Steel Alloy

• Wedge Member: Stainless Steel Alloy
• Large and Small Nests: Copper
• Fixing Blocks: Bronze
• Shear Head Bolt: Stainless Steel and Zamak 5 (Fuse nut component)

3. TEST SEQUENCE

The test sequence showed below has been made according to Tyco specification 108-37048 .

Test or Test Group and Sequence

Examination 1 2 3
Examination of the product 1 1 1
Mechanical Pullout Test 2
Electromagnetic Force Test 2
Current – Temperature Cycling Test 2
Freeze-Thaw Test 3
Corrosion Test (Nitric Acid) 4
Fault Current Test 5

4. SUMMARY OF TESTS

4.1 Mechanical Pullout Test

4.1.1 Requirements: The samples shall meet the minimum pullout values specified in the
standard IEEE-837 (Table 2), with no visible movement of the conductor with respect
to the connector.

Preparado por: Walter Bellini Jr. Aprovado por: José Alexandre La Salvia

AMP do Brasil Conectores Elétricos e Eletrônicos Ltda . Esta especificação é um documento controlado .
Consulte a AMP do Brasil para última revisão aplicável . 1 de 4
© Copyright 2000 Tyco Electronics Corporation . Todos os direitos reservados .
* Trademark
| Indica alterações .

Loc. AP

TYELE 724 –SEP/2000

SGC – Stamped Grounding Connector 501-37005

4.1.2 Procedure: Four samples applied with cables 185mm2 x 35mm2 and four samples
applied with Rod ¾” Copperweld x cable 50mm2, have been subjected to mechanical
pullout test. They were placed in the tensile testing machine with the length of free
conductor between the gripping device and the connector not lesser than 254mm, and
the load has been applied at a crosshead speed 6,35mm/minute.

4.2 Electromagnetic Force Test

4.2.1 Requirements: After testing, the connection resistance shall not exceed by more than
50% of the initial resistance value.
4.2.2 Procedure: Two loops have been assembled with the cable combination below with
four connectors applied in each one, and they were subjected to electromagnetic force
test. The loops were submitted to a three 0,2 seconds fault current, which was
calculated by item 7.3.4 of the standard IEEE-837.

Connector Type Cable Combination Fault Current

Small Type – PN. 493315-1 70 mm2 x 70 mm2 Copper Cable 35kA
Large Type – PN. 493310-1 120 mm2 x 120 mm2 Copper Cable 54kA

4.3 Current – Temperature Cycling Test

4.3.1 Requirements: After testing, the connection resistance shall not exceed by more than
150% of the initial resistance value.
4.3.2 Procedure: A loop mounted with four samples applied with cables 70mm2 x 70mm2,
was submitted to 25 current cycles. It was carried a current of 590Aac to raise the
temperature of the control conductor to 350oC. Each cycle consisted of 60 minutes on
and 40 minutes off.

4.4 Freeze-Thaw Test

4.4.1 Requirements: After testing, the connection resistance shall not exceed by more than
150% of the initial resistance value.
4.4.2 Procedure: The same samples used to the Current-Temperature Cycling Test have
been used to the Freeze-Thaw Test. One freezing and thawing cycle consisted of
lowering the temperature of the test connector to –10oC and after raising the
temperature to +20oC, by 120 minutes in each one. The connectors were submitted to
10 freeze-thaw cycles.

4.5 Corrosion Test (Nitric Acid)

4.5.1 Requirements: After testing, the connection resistance shall not exceed by more than
150% of the initial resistance value.
4.5.2 Procedure: After Freeze-Thaw Test, the samples have been submitted to the
Corrosion Test. The samples were submerged in a 10% acid solution for a time, which
reduced the control conductor to 80% of its original cross sectional area. The
reduction was determined by the weight reduction per unit length.

4.6 Fault Current Test

4.6.1 Requirements: After testing, the connection resistance shall not exceed by more than
150% of the initial resistance value.
4.6.2 Procedure: This is the last test of group 3, and it was performed after Corrosion Test
in the same samples. It was carried 90% of fusion current of the cable (4,5kA for
2
cable 70mm ) in three applications, with 10 seconds of duration for each one.

Revisão “O” 2 de 4
SGC – Stamped Grounding Connector 501-37005

5. TEST RESULTS

5.1 Group 1

5.1.1 Samples Identification : See table below.

5.1.2 Examination of the product : According to product drawing.

5.1.3 Mechanical Pullout Test: All samples met the requirements of the Tyco specification.
They have been submitted to a load specified in the table below and no visible
movement of the conductor with respect to the connector was detected.

Connector Conductor Combination Load (N)

Small Type 185 mm2 x 35 mm2 Copper Cable 1335
PN. 493312-1 Rod ¾” x 50 mm2 Copper Cable 1335
Large Type – PN. 493303-1 240 mm2 x 240 mm2 Copper Cable 4450

5.2 Group 2

5.2.1 Samples Identification:

• 04 Connectors PN. 493315-1 (Small Type) applied with copper cable 70mm2 x 70mm2.
• 04 Connectors PN. 493310-1 (Large Type) applied with copper cable 120mm2 x 120mm2.

5.2.2 Examination of the product: According to product drawing.

5.2.2 Electromagnetic Force Test: All samples met the requirements of Tyco specification,
see resistance variation showed below :

Connector Sample number Initial resistance (µΩ ) Final Resistance (µΩ ) Variation (%)
1 200 / 200 243 / 244 21,5 / 22,0
2 194 / 193 241 / 243 24,2 / 25,9
493315-1 3 216 / 217 289 / 289 33,8 / 33,18
4 235 / 235 280 / 282 19,15 / 20,0
Control Conductor 168 / 171 220 / 222 30,9 / 29,8
1 188 / 188 214 / 215 13,8 / 14,3
2 189 / 189 208 / 208 10,1 / 10,1
493310-1 3 188 / 188 196 / 195 4,2 / 3,7
4 185 / 185 195 / 194 5,4 / 4,8
Control Conductor 183 / 182 184 / 183 0,5 / 0,5

5.3 Group 3

5.3.1 Samples Identification: 04 Connectors PN. 493315-1 applied with copper cable
70mm2 x 70mm2.

5.3.2 Examination of the product: According to product drawing.

5.3.3 Current-Temperature Cycling Test: All samples met the requirements of Tyco
specification . See table below :

Electrical Resistance Measurement (µΩ )

Cycle number Control Conductor Sample 1 Sample 2 Sample 3 Sample 4
0 159,30 164,52 155,34 156,31 164,08
13 157,22 158,13 152,22 151,81 162,20
25 158,55 157,95 151,63 151,69 161,88
Variation - 0,47% - 3,99% - 2,39% - 2,96% - 1,34%

Revisão “O” 3 de 4
SGC – Stamped Grounding Connector 501-37005

Temperature Measurement (oC)

Cycle Number Control Conductor Sample 1 Sample 2 Sample 3 Sample 4 Ambient
5 343,9 200,8 201,6 192,8 184,9 26,0
10 332,6 194,7 194,3 187,1 178,5 26,5
15 341,0 201,2 202,7 189,6 198,3 26,5
20 331,4 196,3 198,7 187,9 194,8 26,0
25 347,4 205,5 208,6 194,9 204,9 26,5

5.3.4 Freeze-Thaw Test: After Current-Temperature Cycling Test, the samples have been
submitted to this test and all of them met the requirements of Tyco specification .
See table below :

Resistance Samples
Conductor Sample 1 Sample 2 Sample 3 Sample 4
Before Freeze-thaw Cycles (µΩ ) 147,06 153,59 147,06 143,79 153,59
After Freezer-thaw Cycles (µΩ ) 147,06 153,59 130,72 130,72 143,79
Variation (%) 0 0 - 11,11 - 9,09 - 6,38

5.3.5 Corrosion Test: After Freeze-thaw Test, the samples have been submitted to this test
and all of them met the requirements of Tyco specification . See table below :

Resistance Samples
Conductor Sample 1 Sample 2 Sample 3 Sample 4
Before Corrosion Test (µΩ ) 147,06 153,59 130,72 130,72 143,79
After Corrosion Test (µΩ ) 192,81 169,93 169,93 169,93 173,20
Variation (%) + 31,11 + 10,64 + 30,00 + 30,00 + 20,45

5.3.6 Fault Current Test: After Corrosion Test, the samples have been submitted to this test
and all of them met the requirements of Tyco specification . See table below :

Resistance Samples
Conductor Sample 1 Sample 2 Sample 3 Sample 4
Before Fault Current Test (µΩ ) 192,81 169,93 169,93 169,93 173,20
After Fault Current Test (µΩ ) 171,28 164,69 177,87 171,28 174,57
Variation (%) - 11,17 - 3,08 + 4,67 + 0,79 + 0,79

6. CONCLUSION

All tests performed met the requirements of Tyco specification 108-37048 . For further information ,
see detailed test reports described on item 1 .

REVISION RECORDS
REVISION DATE DESCRIPTION
O 06-Feb-2001 Issued by EC-LB00-0048-01

Edited by Engineering Technical Services

Revisão “O” 4 de 4