1601041-1 - Tyco Electronics

Qualification Test

Report 501-723

15Dec09 Rev A

Standard Range SIAMEZE* Insulation Displacement

Terminals

Harrisburg, PA

All International Rights Reserved

* Trademark

| Indicates change 1 of 6

LOC B

1. INTRODUCTION

1.1. Purpose

Testing was performed on Standard Range SIAMEZE* Insulation Displacement Terminals to determine

their conformance to the requirements of Product Specification 108-2085, Revision A.

1.2. Scope

This report covers the electrical, mechanical, and environmental performance of the Standard Range

SIAMEZE Insulation Displacement Terminals. Testing was performed at the Engineering Assurance

Product Testing Laboratory between 13Nov08 and 04Dec09. The test file number for this testing is

EA20090930T, additional testing was performed under test file numbers EA20081013T, EA20090857T

and EA20090884T. This documentation is on file at and available from the Engineering Assurance

Product Testing Laboratory.

1.3. Conclusion

The Standard Range SIAMEZE Insulation Displacement Terminals listed in paragraph 1.5., conformed

to the electrical, mechanical, and environmental performance requirements of Product Specification

108-2085 Revision A.

1.4. Test Specimens

Test specimens were representative of normal production lots. Specimens identified with the following

part numbers were used for test:

Part Number Description

4-1601000-1

Wire to Wire

Bobbin 1601486-1 (standard 6/6 Nylon 20% GF) with 2, 4-1601000-1 SIAMEZE terminals connecting

18 AWG copper magnet wire in the bottom contact and 18 AWG stranded lead wire in the top contact

secured with 4-1601140-1 Lead Lok

Bobbin 1601486-1 (standard 6/6 Nylon 20% GF) with 2, 4-1601000-1 SIAMEZE terminals connecting

34 AWG copper magnet wire in the bottom contact and 22 AWG stranded lead wire in the top contact

secured with 4-1601140-1 Lead Lok

4-1601009-4

PC Tab Single Barb Terminal 2, 4-1601009-4 terminals with single barbs in a bobbin connecting 18 AWG copper magnet wire

2, 4-1601009-4 terminals with single barbs in a bobbin connecting 34 AWG copper magnet wire

4-1601039-2

.110 Tab Triple Barb Terminal 2, 4-1601039-2 terminals with triple barbs in a bobbin connecting 18 AWG copper magnet wire

2, 4-1601039-2 terminals with triple barbs in a bobbin connecting 34 AWG copper magnet wire

1601058-2

.187 Tab Double Barb Terminal 2, 1601058-2 terminals with double barbs in a bobbin connecting 18 AWG copper magnet wire

2, 1601058-2 terminals with double barbs in a bobbin connecting 34 AWG copper magnet wire

Figure 1

1.5. Environmental Conditions

Unless otherwise stated, the following environmental conditions prevailed during testing:

!Temperature: 15 to 35°C

!Relative Humidity: 25 to 75%

501-723

Rev A 2 of 6

1.6. Test Sequence

Test or Examination Test Group (a)

1234

Test Sequence (b)

Initial examination of product 1111

Low Level Contact Resistance (LLCR) 2,5 2,4 2,4

Current cycling 3

Retention force 2

Thermal shock 4

Humidity/temperature cycling 3

Temperature life 3

Final examination of product 6535

(a) See paragraph 1.4.

NOTE (b) Numbers indicate sequence in which tests are performed.

Figure 2

501-723

Rev A 3 of 6

2. SUMMARY OF TESTING

2.1. Initial Examination of Product - All Test Groups

A Certification of Conformance (C of C) was issued stating that all specimens in this test package were

produced, inspected, and accepted as conforming to product drawing requirements, and manufactured

using the same core manufacturing processes and technologies as production parts. Where specified,

specimens were visually examined and no evidence of physical damage detrimental to product

performance was observed.

2.2. LLCR - Test Groups 1, 2 and 4

All LLCR measurements taken at 100 milliamperes maximum and 20 millivolts maximum open circuit

voltage were less than 20% increase from Initial measurements.

Condition

Test Group 1

18 AWG Magnet Wire With

18 AWG Stranded Wire 34 AWG Magnet Wire With

22 AWG Stranded Wire

Initial Final Initial Final

N 15151515

Minimum 8.39 8.13 187.71 188.84

Maximum 9.35 8.92 189.06 193.79

Mean 8.71 8.44 188.19 190.29

Standard Deviation 0.27 0.24 0.41 1.25

Test Group 2

N 15151515

Minimum 8.57 8.43 189.16 188.80

Maximum 11.05 9.95 191.96 193.74

Mean 9.10 9.01 190.70 190.08

Standard Deviation 0.63 0.47 0.73 1.18

Test Group 4

N 15151515

Minimum 6.54 6.48 183.11 184.80

Maximum 6.91 7.39 185.11 191.97

Mean 6.72 6.83 184.33 186.16

Standard Deviation 0.10 0.28 0.55 1.72

All values in milliohms.

NOTE

Figure 3

2.3. Current Cycling - Test Group 2

No evidence of physical damage detrimental to product performance was observed as a result of

current cycling.

501-723

Rev A 4 of 6

2.4. Retention Force - Test Group 3

All retention force measurements were greater than 45 N [10 lbf] minimum for single barb, 90 N [20 lbf]

minimum for multiple barb and 65 N [15 lbf] minimum for stranded lead wire with Lead Lok (Figure 4).

Condition 18 AWG Magnet Wire

18 AWG Stranded Wire 34 AWG Magnet Wire

22 AWG Stranded Wire 18 AWG Magnet Wire 34 AWG Magnet Wire

Wire-to-Wire Wire-to-Wire Single Barb Single Barb

N 30303030

Minimum 79.04 [17.77] 87.94 [19.77] 86.52 [19.45] 82.20 [18.48]

Maximum 113.07 [25.42] 112.14 [25.21] 116.32 [26.15] 100.57 [22.61]

Mean 94.26 [21.19] 99.20 [22.30] 98.08 [22.05] 89.99 [20.23]

Standard Deviation 8.85 [1.99] 7.03 [1.58] 5.96 [1.34] 3.96 [0.89]

Condition 18 AWG Magnet Wire 34 AWG Magnet Wire 18 AWG Magnet Wire 34 AWG Magnet Wire

Triple Barb Triple Barb Double Barb Double Barb

N 30303030

Minimum 110.76 [24.90] 109.43 [24.60] 124.51 [27.99] 116.90 [26.28]

Maximum 145.72 [32.76] 155.11 [34.87] 142.65 [32.07] 146.52 [32.94]

Mean 128.46 [28.88] 135.27 [30.41] 134.47 [30.23] 125.75 [28.27]

Standard Deviation 10.90 [2.45] 13.97 [3.14] 4.27 [0.96] 6.23 [1.40]

All values in N [lbf].

NOTE

Figure 4

2.5. Thermal Shock - Test Group 1

No evidence of physical damage was visible as a result of thermal shock testing.

2.6. Humidity/temperature Cycling - Test Group 1

No evidence of physical damage was visible as a result of humidity/temperature cycling.

2.7. Temperature Life - Test Group 4

No evidence of physical damage was visible as a result of temperature life testing.

2.8. Final Examination of Product - All Test Groups

Specimens were visually examined and no evidence of physical damage detrimental to product

performance was observed.

501-723

Rev A 5 of 6

3. TEST METHODS

3.1. Initial Examination of Product

Where specified, specimens were visually examined for evidence of physical damage detrimental to

product performance.

3.2. LLCR

LLCR measurements were made using a 4 terminal measuring technique. The test current was

maintained at 100 milliamperes with a 20 millivolt maximum open circuit voltage (Figure 5).

Figure 5

LLCR Test Configuration

3.3. Current Cycling

Specimens connected in a series circuit were subjected to 100% of rated current for 250 cycles

consisting of current ON for 15 minutes and current OFF for 15 minutes.

3.4. Contact Retention

The force necessary to dislodge the terminal was measured using a tensile/compression device with a

free floating fixture and a rate of travel of 25.4 mm [1 in] per minute.

3.5. Thermal Shock

Specimens were subjected to 25 cycles of thermal shock with each cycle consisting of 30 minute dwells

at -40 and 125°C with 1 minute transition between temperatures.

501-723

Rev A 6 of 6

3.6. Humidity/temperature Cycling

Specimens were exposed to 10 cycles of humidity/temperature cycling. Each cycle lasted 24 hours and

consisted of cycling the temperature between 25 and 65°C twice while maintaining high humidity.

3.7. Temperature Life

Specimens were subjected to a temperature of 118°C for 33 days (792 hours).

3.8. Final Examination of Product

Specimens were visually examined for evidence of physical damage detrimental to product

performance.