501-723 Qualification Test Report 15Dec09 Rev A Standard Range SIAMEZE* Insulation Displacement Terminals 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 4-1601000-1 Wire to Wire Description 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 2, 4-1601009-4 terminals with single barbs in a bobbin connecting 18 AWG copper magnet wire 4-1601009-4 PC Tab Single Barb Terminal 2, 4-1601009-4 terminals with single barbs in a bobbin connecting 34 AWG copper magnet wire 2, 4-1601039-2 terminals with triple barbs in a bobbin connecting 18 AWG copper magnet wire 4-1601039-2 .110 Tab Triple Barb Terminal 2, 4-1601039-2 terminals with triple barbs in a bobbin connecting 34 AWG copper magnet wire 2, 1601058-2 terminals with double barbs in a bobbin connecting 18 AWG copper magnet wire 1601058-2 .187 Tab Double Barb Terminal 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 35C Relative Humidity: 25 to 75% (c)2009 Tyco Electronics Corporation Harrisburg, PA All International Rights Reserved * Trademark | Indicates change 1 of 6 LOC B 501-723 1.6. Test Sequence Test Group (a) Test or Examination 1 2 3 4 Test Sequence (b) Initial examination of product Low Level Contact Resistance (LLCR) 1 1 2,5 2,4 Current cycling 1 2,4 3 Retention force 2 Thermal shock 4 Humidity/temperature cycling 3 Temperature life 3 Final examination of product NOTE (a) (b) 1 6 5 3 5 See paragraph 1.4. Numbers indicate sequence in which tests are performed. Figure 2 Rev A 2 of 6 501-723 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. Test Group 1 18 AWG Magnet Wire With 18 AWG Stranded Wire Condition Initial N Final 34 AWG Magnet Wire With 22 AWG Stranded Wire Initial Final 15 15 15 15 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 15 15 15 15 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 15 15 15 15 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 Test Group 4 N NOTE All values in milliohms. 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. Rev A 3 of 6 501-723 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 N 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 30 30 30 30 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] 8.85 [1.99] 7.03 [1.58] 5.96 [1.34] 3.96 [0.89] 18 AWG Magnet Wire 34 AWG Magnet Wire 18 AWG Magnet Wire 34 AWG Magnet Wire Triple Barb Triple Barb Double Barb Double Barb 30 30 30 30 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] 10.90 [2.45] 13.97 [3.14] 4.27 [0.96] 6.23 [1.40] Standard Deviation Condition N Standard Deviation NOTE All values in N [lbf]. 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. Rev A 4 of 6 501-723 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 125C with 1 minute transition between temperatures. Rev A 5 of 6 501-723 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 65C twice while maintaining high humidity. 3.7. Temperature Life Specimens were subjected to a temperature of 118C for 33 days (792 hours). 3.8. Final Examination of Product Specimens were visually examined for evidence of physical damage detrimental to product performance. Rev A 6 of 6