Qualification 501-37007

Test Report 19-May-2001 Rev. O

LB00-0215-01
TGC - Transversal Grounding Connector

1. INTRODUCTION

This report has been made to describe the characteristics of the product according to Tyco
Specification 108-37051 , which was based on standards UL 486A , UL 467 and Bellcore TR-NWT-
001075 .
All tests have been performed according to specification above and all samples met the specified
requirements. This report was written based on test report number 000894 , issued by Product
Engineering Laboratory from Tyco Electronics Brazil .

2. PRODUCT DESCRIPTION

The product tested is a connector designed to be used in grounding system of equipments for
electrical distribution , telecommunication and industrial/residential applications , according to
particular project and material specification .
Following components composes the product and their respective raw materials :

• “C” Body: Stainless Steel Alloy

• “Wing”Member: Copper

3. TEST SEQUENCE

The test sequence showed below has been made according to Tyco specification 108-37051 .

Test or Test Group and Sequence

Examination 1 2 3
Static Heating Test (UL 486A) 1
Current Test (UL 467) 1
Pullout Test (UL 467) 2
1,4,6,8,
Resistance Test (Bellcore)
10 , 13 , 15 .
Vibration Test (Bellcore) 2
Tensile Test (Bellcore) 3
Temperature and Humidity Cycling Test (Bellcore) 5
Hydrogen Sulfide Exposure (Bellcore) 7
Salt Fog Test (Bellcore) 9
AC Fault Current Test (Bellcore) 11
Pullout Test (Bellcore) 12, 16
Lightning Surge Test (Bellcore) 14

Prepared by : Walter Bellini Jr. Approved by : José Alexandre La Salvia

Tyco Electronics Brasil Ltda. This specification is a controlled document .

For latest revision , call the AMP FAX or E-Catalog . 1 of 6
© 2001 – Tyco Electronics Corporation - Harrisburg PA
All international rights reserved .

* Trademark
| Indicates changes

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TGC - Transversal Grounding Connector 501-37007

4. SUMMARY OF TESTS

4.1 Static Heating Test

4.1.1 Requirements : The temperature of connector shall not rise more than 50oC above
ambient temperature .

4.1.2 Procedure : Samples shall be submitted to the current value of 170Aac until stable
temperature is reached. The current value is based on wire size tested and, in this
case, the current was set-up to cable 35mm2.

4.2 Current Test

4.2.1 Requirements : After carried the current specified , shall exist continuity on the test
sample assembly. Crack, break or melt, are not acceptable .

4.2.2 Procedure : Samples shall be subjected to a current of 3900A for 6 minutes . The
current value shall be based on smaller cable used to assemble the loop and , in this
case , the smaller cable used was 35mm2 .

4.3 Pullout Test (UL 467)

4.3.1 Requirements : The connectors shall withstand for 5 minutes a pull of 667N .

4.3.2 Procedure : The same samples subjected to Current Test shall be subjected to a direct
pull value above , during the time specified .

4.4 Resistance Test

4.4.1 Requirements : The electrical resistance shall not exceed 10mΩ .

4.4.2 Procedure : Nine samples shall be prepared with 153mm minimum of exposure
lengths of conductive elements outside the connector on each side .
The resistance shall be measured through each sample from one cable end to
another . Each consecutive measurement of a particular sample shall be made with
the probes in the same location .
Prior to each measurement , the test points shall be cleaned to assure good contact
between the instruments probes and tested sample .
The current through the test sample during the measurement shall not exceed 100mA.

4.5 Vibration Test

4.5.1 Requirements : No evidence of cracks, breaks or loose parts on any of connector

assemblies .

4.5.2 Procedure : The samples shall be subjected to a simple harmonic motion having an
amplitude of 0,75mm minimum , 1,5mm maximum total excursion , the frequency
being varied uniformly between the limits of 10 to 55Hz and return to 10Hz , shall be
traversed in approximately one minute . This motion shall be applied for a period of 2
hours in each of three mutually perpendicular directions .
Afterwards , the samples shall be subjected to Tensile Test .

4.6 Tensile Test

4.6.1 Requirements : Connectors shall remain firmly attached and fully engaged , with no
slippage , under stress of a sustained load of 445N for one-minute minimum .
After testing , the connection resistance shall not exceed 30mΩ .

4.6.2 Procedure : Apply a sustained load of 445N in the connectors secured to their
conductive element for one minute in an axially direction away from the conductive
element .

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4.7 Temperature and Humidity Cycling Test

4.7.1 Requirements : After testing , connection resistance shall not exceed 30mΩ .

4.7.2 Procedure : Samples shall be subjected to the temperature and humidity cycles
specified in chart below for 30 days .

100

Temperature (oF)
80
60
40
20
0
1 2 3 4 5 6 7 8 9 10
Number of hours

The relative humidity shall be 90 – 95 %.

After 30 days of cycling the samples shall be allowed to return to ambient temperature
and stabilize for 24 hours .

4.8 Hydrogen Sulfide Exposure Test

4.8.1 Requirements : After testing , connection resistance shall not exceed 30mΩ .

4.8.2 Procedure : Samples shall be placed in a vacuum desiccator having a volume of

approximately 0,03m3 . The desiccators shall remain open .
The open desiccator shall be placed in an oven operating at a test temperature of
65oC (149oF) .
After the desiccator and samples have stabilized to the test temperature ,
approximately one hour, the desiccator shall be sealed and evacuated to a pressure of
10 mmHg (1.332 Pa) .
H2S shall be added to the desiccator as follow :

(1) Add H2S until the pressure reaches 200 mmHg (27 kPa).
(2) Inject 1 cc of water into the chamber.
(3) Add H2S until the pressure reaches 750 mmHg (100 kPa).
(4) The samples shall be exposed to the H2S, at the test temperature, for a
minimum period of one hour .

Upon completion of the exposure period , the samples shall be immediately removed
from the desiccator and subjected to a temperature of 65oC (149oF) for a minimum
period of one hour . Afterwards , samples shall be stabilized at ambient temperature
before connection resistance evaluation .

4.9 Salt Fog Test

4.9.1 Requirements : Any component of connector shall display no significant signs of

corrosion penetration when compared to a non-exposed sample . Surface
discoloration does not constitute a non-compliance .
After exposure , the connection resistance shall not exceed 30mΩ .

4.9.2 Procedure : Samples shall be subjected to a salt fog test for duration of 30 days ,
according to ASTM B117 .
Upon completion of exposure , the samples shall be rinsed in running tap water and
dried at 40oC for a period of 24 hours . Return samples to ambient conditions for a
period of 24 hours before testing continue .

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4.10 AC Fault Test

4.10.1 Requirements : There shall be no arcing between connector and conductive element .
After application of the test current , the requirements of pullout test (Bellcore) shall
be met .

4.10.2 Procedure : One end of the sample assembly shall be connected to the terminal of a
60 Hz source using a wire or wires equivalent a No. 4 AWG copper conductor .
In the other end of the sample, the cable shall be connected to the second terminal of
the AC source with No. 6 AWG bare solid conductor . A current of 1000 A rms shall be
applied to the sample for a minimum of twenty seconds or until the No. 6 AWG wire
fuses open .

4.11 Pullout Test (Bellcore)

4.11.1 Requirements : Connector shall withstand a pull of 155 N for one minute . There shall
be no displacement of either conductor in the conector . Afterwards , the connection
resistance shall be evaluated and shall not exceed a change of 5 mΩ over the
previous measurement .

4.11.2 Procedure : Apply a pull of 155 N for one minute between the free ends of each
conductor and there shall be no sudden application of force .

4.12 Lightning Surge Test

4.12.1 Requirements : There shall be no arcing between connector and conductive element.
After application of the test current , the connection resistance shall not exceed a
change of 5 mΩ over the previous measurement . Also , the requirement of pullout
test (Bellcore) shall be met .

4.12.2 Procedure : The cables of a test sample shall be attached to the terminals of an
impulse generator and a 20kA , 8/20µs current shall be applied .

5. TEST RESULTS

5.1 Group 1

5.1.1 Static Heating Test : All samples met the requirements of the Tyco specification .
It was assembled a loop with two connectors P/N. 493643-1 applied with Rod
copperweld ¾" and copper cable 35mm2 . They have been submitted to a current of
170Aac .

Temperature (oC)
Heating Sample #1 Sample #2
Cable
Time (h) Ambient 2 “C” “Wing” “C” “Wing”
35mm
Body Member Body Member
0:00 30 23,8 23,8 24,2 24,2 24,1
0:30 30 85,4 42,7 47,2 44,1 50,0
1:00 30 90,8 59,8 63,4 61,7 68,7
1:30 30 90,7 63,5 66,4 65,3 71,9
2:00 30 90,6 64,1 67,1 65,9 72,6
2:30 30 90,0 64,4 67,4 66,2 73,0
3:00 30 91,3 64,2 66,4 66,1 73,0

5.2 Group 2

5.2.1 Current Test : All samples met the requirements of the Tyco specification. It was
assembled a loop with two connectors P/N. 493643-1 applied with Rod copperweld ¾”
and copper cable 35mm2 . They have been submitted to a current of 3900A during 6
seconds and after testing there were not evidence of crack , break or melt point on
samples , and also electrical continuity was observed .

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5.2.2 Pullout Test : The same samples used in Current Test were used in this test and all
samples met the requirements of the Tyco specification . The connectors withstood the
load of 667N during 5 minutes and no movement between the cable and the connector
was observed .

5.3 Group 3

All samples subjected to the test sequence described in this group met the resistance
requirements specified on Tyco Specification 108-37051 . It were assembled nine samples of
P/N 493643-1 according to described on item 4.4.2 , applied with Rod copperweld ¾” and
copper cable 35mm2 . See results below :

• Initial Resistance – 10mΩ maximum

1 2 3 4 5 6 7 8 9
0,18mΩ 0,20mΩ 0,18mΩ 0,24mΩ 0,16mΩ 0,24mΩ 0,18mΩ 0,19mΩ 0,16mΩ

• Resistance after Vibration and Tensile Test – 30mΩ maximum

1 2 3 4 5 6 7 8 9
0,23mΩ 0,22mΩ 0,30mΩ 0,28mΩ 0,28mΩ 0,20mΩ 0,16mΩ 0,22mΩ 0,18mΩ

• Resistance after Temperature and Humidity Cycling Test – 30mΩ maximum

1 2 3 4 5 6 7 8 9
0,23mΩ 0,21mΩ 0,20mΩ 0,22mΩ 0,24mΩ 0,20mΩ 0,20mΩ 0,29mΩ 0,19mΩ

• Resistance after H2S Exposure Test – 30mΩ maximum

1 2 3 4 5 6 7 8 9
0,25mΩ 0,86mΩ 0,78mΩ 0,31mΩ 0,45mΩ 0,60mΩ 0,34mΩ 0,23mΩ 0,34mΩ

• Resistance after Salt Fog Test – 30mΩ maximum

1 2 3 4 5 6 7 8 9
0,21mΩ 0,79mΩ 0,32mΩ 0,42mΩ 0,26mΩ 0,41mΩ 0,36mΩ 0,32mΩ 0,37mΩ

• Resistance after AC Fault and Pullout Test – Changing of 5mΩ max. over previous
measurement .

1 2 3 4 5 6 7 8 9
0,30mΩ 1,67mΩ 0,41mΩ 2,24mΩ 0,21mΩ 2,03mΩ 3,90mΩ 0,21mΩ 3,50mΩ

• Resistance after Lightning Surge Test – Changing of 5mΩ max. over previous
measurement .

1 2 3 4 5 6 7 8 9
0,20mΩ 0,26mΩ 0,25mΩ 0,25mΩ 0,22mΩ 0,19mΩ 0,25mΩ 0,25mΩ 0,29mΩ

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6. CONCLUSION

All tests performed met the requirements of Tyco specification 108-37051 . For further information ,
see detailed test reports described on item 1 .

Revision Record
Revision Date Description
O 19-May-2001 Released by EC LB00-0215-01

Edited by Engineering Technical Services

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