Electric Technologies Panel Meeting Charleston, SC Low Voltage Quick Connector Evaluation Final Outbrief

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1 Electric Technologies Panel Meeting Charleston, SC Low Voltage Quick Connector Evaluation Final Outbrief Presented by: Gregory D. Stevens General Dynamics, Bath Iron Works March 12, 2015 Approved for public release; distribution is unlimited.

2 Project Mission and Objectives Currently, using lugged terminal connectors are traditional methods for electrical connection for shock qualified applications Looking for methods and hardware that support expedited installation, while maintaining high reliability Ease of use with good electrical characteristics and performance characteristics Repeatable if mechanism is engaged several times (i.e., during troubleshooting and activation activities) 2

3 Project Participants BIW Lead Bollinger Shipyards Raytheon Dayton T. Brown Laboratories Test Specimen Vendors and Distributors WAGO Corp. Tyco Electronics Newark Weidmuller Cooper Bussmann Horizon Solutions Grainger Eaton Phoenix Contact Rockwell Automation 3

4 Low Voltage Quick Connector Evaluation Project Goals Research Available Products Evaluate Requirements Generate Evaluation Guide Evaluate Product Information Develop Test Procedure Manufacture Demonstrator Conduct Testing Evaluate Results Generate Report and Recommendations 4

5 Research Available Products Several products were researched and chosen as candidates in four basic configurations Standard lugged terminal (baseline) Screw down wire interface Releasable locking mechanism interface Non releasing locking mechanism interface Using terminal blocks, in-line splices 5

6 Evaluate Requirements Several standards and Mil-Specs were reviewed Much of the 1 MIL-C-55243: Connectors, Plugs, and Not listed (A - Receptacles, Electrical, Quick Connect and Public requirement Disconnect, 12 Contacts, Medum Power Release) (see 4.7) (NOTE - Listed as not for new design) review based on of one minute (see 4.10). shall be not less than 100 megohms (see 4.11). types of tests that applied abruptly (see 4.18) qualify a Method 201 of Standard MIL-STD MIL-DTL-22992: Connectors, Plugs, and Not listed (A - Receptacles, Electrical, Waterproof, Quick Public Disconnect, Heavy Duty Type, General Release) particular product Specification for specified. Performance and characteristics testing reviewed References and Standards for Cable Terminations and Connectors Item Reference Distribution Section Section Language Remarks 3.8 Contact retention. Individual contacts shall be capable of withstanding an axial load of 10 pounds minimum uniformly applied at a rate of 1 pound per second. Each Contact shall witstand a load of 10 pounds 3.1 Contact resistance. The voltage drop across mating contact terminals shall not Resistance between two connected exceed 20 millivolts when a current of 7.5 amperes is applied (see 4.9). terminals will be 2.67mΩ or less 3.11 Dielectric strength. The connectors shall show no evidence of breakdown when Adjacent terminals will be able to handle a subjected to a potential of 1500 volts rms, 60 cycles per second, for a minimum 1500V difference without arcing 3.12 Insulation resistance. The insulation resistance shall be not less than MΩ minimum insulation resistance megohms except for unmated connectors following the immersion test when it between separate terminals Pull. Mated connectors shall withstand an axial pull of not less than 40 pounds Mated connectors shall withstand 25lbs applied to the shell and 25 pounds applied to the cable. The force shall be applied to the cable Temperature cycling. At the extreme temperatures during the test specified in paragraph 4.20, the connectors shall be capable of being mated and unmated. Connectors shall function during Method 102A test condition D of MIL-STD Vibration (see 3.22). Mated connectors shall be tested in accordance with Connectors shall function during vibration test. 3.7 Contact resistance. When connectors are tested as specified in 4.6.4, the Contact resistance depends on Contact resistance of mated pin and socket contacts shall be such that the potential size. (EX: Size 16, 20A current, 25mV drop at the test current specified in table I shall not be greater than the values maximum drop, 1.25mΩ. Increases as Contact size increases) 3.8 Dielectric withstanding voltage. When connectors are tested as specified in Maximum voltages at sea level range from 4.6.5, connectors shall be capable of withstanding the applicable voltages shown 1000VAC to 7000VAC based on rating. in table II without flashover or breakdown Contact retention. When contacts are tested as specified in 4.6.8, they shall Contact retention depends on size. be capable of withstanding the axial loads shown in table III. Withstand axial loads ranging from 10lbs to 3.13 Insulation resistance. When connectors are tested as specified in , the insulation resistance (prior to conditioning) shall not be less than 5,000 megohms 3.17 Cable pull-out. When connectors are tested as specified in , test cables (see 4.4.3) shall not pull-out when the loads given in table V are applied, nor shall slippage exceed.125 inches (3.18 mm) Thermal shock (temperature cycling). Unmated connectors shall be tested in accordance with test procedure EIA , condition I, 5 cycles, except that the high temperature shall be 125 C, +3 C - 0 C (see 3.9). MIL-C-55243, MIL-DTL-22992, MIL-DTL-24558, MIL-T F, A-A-59125, SAE AS lbs between size 16 and 4/0 Insulation resistance minimum of 5000MΩ Cables shall withstand loads from lbs of fource (based on weight of cable) without slipping more than 0.125" Connectors shall withstand temperatures detailed in EIA

7 Generate Evaluation Guide Certain criteria for product comparison being considered, including but not limited to Ease of use (design, installation) Reliability Compatibility Commonality Electrical and physical attributes Testing performance Chose the ones indicated mainly due to availability, functionality and applicability 7

8 Evaluate Product Information The previous evaluation guide templates were filled in with vendor data This enables a consistent comparison across samples and attributes Allows for a down select to build unit demonstrators with sample materials NSRP ETP Project: Low Voltage Quick Connectors, Vendor and Product Information Evaluation Dimensions Mounting Item Name Model/PN Product Description Length Width Heighth No. Connections Conductor Size Rated Voltage Rated Surge Voltage Rated Current Rated SSC Metal Plastic DIN Rail Tensile Pull Resistance Mechanism Type (Nm) Housing Material Contact and Mechanism Material Certification, Qualifications Fire Rating Temp Rating C Interface Type Remarks 11 Tyco Position Fused Terminal Block Ideal Model 39/ J 3 Port Push-In Connector Polycarbonate 13 Power First 22EW70 Through Insulation Splice Connector UL E62622,CSA M 72M NBL Male Crimp Connector Tin Plated Copper Cooper Bussmann BNQ21 Gangable Connector Block Tin Plated Aluminum UL

9 Develop Test Procedure The current list of tests are part of the test procedure, incl. shock, vibration, thermal stress Decision on which tests to conduct were based primarily on estimated costs and value added to decision making processes Order of Test Test Standard Called Out By Section or Method 3 Voltage Drop Mil-T-16366F Dielectric Withstand Mil-Std-202G Shock Mil-Std-202G Mil-C Mil-Std-901D 6 Vibration Mil-Std-167-1A Mil-C Demonstrator Unit Testing 7 Temperature Cycling Mil-Std-202G Mil-C Cond D Reference Test Values Remarks 6-25mV at rated voltage -2x rated voltage V for 60 sec -leakage current less than 0.1% rated load - used for 4-30 A units operating at rated current - raise voltage 500 V/sec - Mil-C uses 1500 V for 60 sec - continuity maintained better than 10% of - inspect for damage to contact resistance value mounts, contacts, (drop no less than springs, etc. m in, 0-34 Hz in approx. 6 hrs to -5 C 15 min 25 to -5 C 5 min 350 to 0 C 15 min 25 to -5 C 5 min 1, 8 Contact Retention/Pull Resistance Mil-C , lb/min 2 Insulation Resistance Mil-C M Contact Resistance (TDR) Mil-C A 2.67 m - inspect for damage to mounts, contacts, springs, etc. - inspect for damage, maybe conduct pull test is for mated connectors (40 lbs) This will be done during shock and vib testing, instrumenting the demonstrator 9

10 Design Demonstrator 2 plates, 19.5 wide by 16.5 tall surface for test specimens Plates are crimped and flanged to increase strength Made from 0.1 Al stock similar to what is used for various types of boxes in various ship designs 10

11 Design Demonstrator (cont.) Plates mounted to test anvil plate at 8 points Plexiglass and stand-off units can be used to maintain safe testing environment when units are instrumented and energized Standard Shock 901D and Vib 167 tests were done on lightweight machines, 3 dimensions 11

12 Design Demonstrator (cont.) Product list includes terminal blocks and inline connectors, most mounted on DIN rail Wago Tyco Cooper Bussman Ideal Eaton Cutler 3M Hammer Weidmuller Rockwell Automation Phoenix Contact 12

13 Manufacture Demonstrator Pre cable installation Test Plate #1 Test Plate #2 13

14 Manufacture Demonstrator Pre cable installation (cont.) 14

15 Manufacture Demonstrator Post cable installation Test Plate #1 Test Plate #2 15

16 Manufacture Demonstrator Post cable installation (cont.) 16

17 Test Demonstrator Electrical and physical characteristic testing All units passed electrical testing A couple units failed pull test (only resisted 8 lbs force) for the smallest conductor in the range of applicable conductors NSRP ETP Project: Low Voltage Quick Connectors, Vendor and Product Information Evaluation: Final Listing Mechanism Type Worksheet Number Unit Number per Dwg Name Model/PN Product Description Conductor Size Rated Voltage (V) Rated Power Power Current Capacity Density (A) (kw) (kw/cu in) General Inspection Comments Tensile Pull Resistance Pass/Fail Durability Repeatability Any Failure Experienced Dielectric Test Pass/Fail Insulation Voltage Drop Thermal Shock Test Vibration Resistance Test Cycling Pass/Fail Test Pass/Fail (ohms) Pass/Fail Pass/Fail Ease of Use (conductor and unit installation) Ease of Inspection Holding Mechanism Durability Overall Applicability Score Rating Remarks 1 2 MIL qualified terminal block Term Block A-A-59125/24 for lugged terminations, for Baseline 16TB-12 Baseline Pass 10 G Pass Satisfactory Satisfactory M 314-BOX Insulation Displacement, 3- wire splicing connector, flame retardant and moisture resistant Pass/Pass / Pass/Pass Satisfactory Satisfactory 3 11 Wago splicing connector Push wire 4-conductor Pass/Pass / Pass/Pass Satisfactory Satisfactory 4 13 Wago Splicing Connector Pass/Pass / Pass/Pass Satisfactory Satisfactory 5 14 Ideal Model 39/ J 3 Port Push-In Connector Pass / Pass/Pass Satisfactory Satisfactory 6 35 Tyco 925 Flat bottom Miniature Terminal Block, Tubular Screw Clamp Pass 6 G Pass Satisfactory Satisfactory 7 6 Tyco Position Terminal Block Pass 4 G Pass Satisfactory Satisfactory 8 15 Phoenix Contact PT 1,5/S DIN Raol mounted, quick connecting terminal block; spring Pass 4 G Satisfactory Satisfactory 9 16 Phoenix Contact PT 2,5 DIN Rail mounted, quick connecting terminal block; spring cage Pass 4 G Satisfactory Satisfactory Cooper Bussman Gangable Connector Block 2/0-8 PDBFS 220 Distribution Block (1 in to 4 Source, 4-14 out) Load Pass 5 G Pass Satisfactory Satisfactory Tyco N/A Bus Bar Assembled with 2 3/8" power Posts, connectors, cables supplied Pass/Pass 3 G Pass Satisfactory Satisfactory 17

18 Testing References 18

19 Testing Requirements Order of Test Test Standard Called Out By Section or Method 3 Voltage Drop Mil-T-16366F Dielectric Withstand Mil-Std-202G Shock Mil-Std-202G Mil-C Mil-Std-901D 6 Vibration Mil-Std-167-1A Mil-C Demonstrator Unit Testing 7 Temperature Cycling Mil-Std-202G Mil-C Cond D Reference Test Values Remarks 6-25mV at rated voltage -2x rated voltage V for 60 sec -leakage current less than 0.1% rated load - continuity maintained better than 10% of contact resistance value (drop no less than m in, 0-34 Hz in approx. 6 hrs to -5 C 15 min 25 to -5 C 5 min 350 to 0 C 15 min 25 to -5 C 5 min 1, 8 Contact Retention/Pull Resistance Mil-C , lb/min 2 Insulation Resistance Mil-C M Contact Resistance (TDR) Mil-C A 2.67 m - used for 4-30 A units operating at rated current - raise voltage 500 V/sec - Mil-C uses 1500 V for 60 sec - inspect for damage to mounts, contacts, springs, etc. - inspect for damage to mounts, contacts, springs, etc. - inspect for damage, maybe conduct pull test is for mated connectors (40 lbs) This will be done during shock and vib testing, instrumenting the demonstrator 19

20 Testing Results Worksheet Number Unit Number per Dwg Tensile Pull Resistance Pass/Fail 1 Insulation Resistance (ohms) 2 Voltage Drop Test Pass/Fail 3 Shock Test Pass/Fail Vibration Test Pass/Fail Thermal Cycling Pass/Fail Post-Test Contact/Pull Resistance Test Ease of Use (conductor and unit installation) Holding Mechanism Durability 1 2 Pass 10 G Pass Pass Pass Pass Pass Satisfactory Satisfactory 2 27 Pass/Pass / Pass/Pass Pass 4 Pass Pass Pass Satisfactory Satisfactory 3 11 Pass/Pass / Pass/Pass Pass Pass Pass Pass Satisfactory Satisfactory 4 13 Pass/Pass / Pass/Pass Pass 4 Pass Pass Pass Satisfactory Satisfactory 5 14 Pass / Pass/Pass Pass 4 Pass Pass Fail Satisfactory Satisfactory 6 35 Pass 6 G Pass Fail 7 Pass Pass Pass Satisfactory Satisfactory 7 6 Pass 4 G Pass Pass Pass Pass Pass Satisfactory Satisfactory 8 15 Pass 4 G Pass Fail 5 Pass Pass Pass Satisfactory Satisfactory 9 16 Pass 5 G Pass Fail 5 Pass Pass Pass Satisfactory Satisfactory Pass 3 G Pass Pass Pass Pass Pass Satisfactory Satisfactory Pass/Pass 4 G Pass Pass Pass Pass Pass Satisfactory Satisfactory 12 9 Pass/Pass 5 G Pass Pass Pass Pass Pass Satisfactory Satisfactory Pass/Pass 10 G Pass Fail 5 Pass Pass Pass Satisfactory Satisfactory Pass/Pass 2.6 G Pass Fail 5 Pass Pass Pass Satisfactory Satisfactory Pass 2 G Pass Fail 5,6 Pass Pass Pass Satisfactory Satisfactory Pass 5 G Pass Fail 5 Pass Pass Pass Satisfactory Satisfactory Pass 2.4 G Pass Fail 5 Pass Pass Pass Satisfactory Satisfactory Pass 6 G Pass Fail 6 Pass Pass Pass Satisfactory Satisfactory Pass 4 G Pass Pass Pass Pass Pass Satisfactory Satisfactory Pass 10 G Pass Pass Pass Pass Pass Satisfactory Satisfactory Fail 3 G Pass Fail 5 Pass Pass Pass Satisfactory Unsatisfactory Pass 3 G Pass Fail 5 Pass Pass Pass Satisfactory Satisfactory Pass 5 G Pass Fail 5 Pass Pass Pass Satisfactory Satisfactory Pass 7 G Pass Pass Pass Pass Pass Satisfactory Satisfactory Fail 7 G Pass Pass Pass Pass Pass Satisfactory Unsatisfactory Pass 4.5 G Pass Fail 7 Pass Pass Pass Satisfactory Satisfactory Pass 3 G Pass Pass Pass Pass Pass Satisfactory Satisfactory Notes: 1 For those cells showing Pass/Pass, 2 conductors for the connector were tested 2 For those cells showing Pass/Pass, voltage drop was measured across connector terminated port and unterminated port, for each conductor 4 No connector test failure or damage. Fastening zip tie broke while testing. 5 Disconnected from DIN rail 6 Chatter present 7 Connector Damage NSRP ETP Project: Low Voltage Quick Connectors, Testing Results 3 For those cells showing /, measurement was made from conductor to ground, for each conductor; for the other units, worst case was across 20

21 Performance Testing Shock Testing 21

22 Performance Testing Vibration Testing 22

23 Performance Testing Thermal Cycle Testing 23

24 Types of Failures End Plates came off Connectors separated from the DIN rail interface Before Testing After Testing Before Testing After Testing Fuse Holders opened Fuses did not fail, however 24

unit separations Before Testing After Testing Before Testing After

25 Types of Failures (cont.) Foot mounting interface broke Inter unit interfaces broke, causing unit separations Before Testing After Testing Before Testing After Testing Zip Ties broke (temporary constraints not part of test article design) Conductors came loose from the connector 25

26 Cost Benefit Assessment Per unit calculator was used to apply to estimated ship quantities Numbers represent nominal values Hourly rates are arbitrary for demonstration purposes Per unit savings are small Methods and values are conservative in nature Cost Differences in Traditional Connectors and Quick Connectors Item Description Base Mounting Device Mounting Wire Preparation Wire Installation Torquing Device Labor (min) Materials ($) Totals Difference from Traditional Methods Associated Hardware Base Mount Labor (hrs) 1 DIN rail 35 Mounted Quick Connector $1.00 $0.20 $ $1 (0.16) ($1) ($17) 22.7% 2 Foot Mounted Quick Connector $3.00 $0.20 $ $3 (0.13) $1 ($12) 43.5% 3 Currently used Terminal Block $2.08 $ $2 4 In-Line Splice Connetcor $0.40 $0.50 $ $1 (0.24) ($2) ($26) 12.3% 5 Lugged Splice Termination $3.00 $ $3 Notes: 1. The above information is an average of several inputs 2. The above information represents a per unit basis 3. DIN rail mounting estimates is for a strip 24" long, able to hold 40 quick connectors (and end hardware and spacers): takes 30 min. to install 40 units, or 30 sec. pu 4. Wire installation is for input and output sides of respective units 5. Existing terminal strip is divided by the number of terminal pairs (12) 6. Costs are averages across the cross section of units investigated (there is considerable difference, but value can be adjusted easily) 7. Associated hardware includes mounting screws, endplates and spacers (where applicable) 8. Differences is the quick connector method minus the traditional method 9. A positive ROI indicates a savings 10. Spreadsheet designer entry 11. Labor Hourly cost $: 100 Materials ($) Labor (hrs) Materials ($) Total ($) Simple ROI 26

27 Cost Benefit Assessment (cont.) Using estimated equipment quantities and per unit values: Savings are calculated for switching all to new quick connectors Savings are calculated for switching % of available opportunities to QC (not part of purchased equipment) Modest savings over multiple programs reported Opportunity to Switch to Quick Connectors: From Terminal Blocks and Lugged Splice Connectors to Quick Connectors DIN rail 35 Mounted Quick Connector Foot Mounted Quick Connector Currently used Terminal Block In-Line Splice Connetcor Lugged Splice Termination Total Program Average 96,188 32,063 4, ,300 Opportunity Costs to Switch to Quick Connectors from Terminal Blocks and Lugged Splice Connectors: Labor Savings (mhrs) DIN rail 35 Mounted Quick Connector Foot Mounted Quick Connector Currently used Terminal Block In-Line Splice Connetcor Lugged Splice Termination Total Program Average ($1,737) $265 ($394) ($1,865) Opportunity Costs to Switch to Quick Connectors from Terminal Blocks and Lugged Splice Connectors: Hardware Savings ($) DIN rail 35 Mounted Quick Connector Foot Mounted Quick Connector Currently used Terminal Block In-Line Splice Connetcor Lugged Splice Termination Total Program Average ($100,119) $29,391 ($9,315) ($80,044) Opportunity Costs to Switch to Quick Connectors from Terminal Blocks and Lugged Splice Connectors: Total ($) DIN rail 35 Mounted Quick Connector Foot Mounted Quick Connector Currently used Terminal Block In-Line Splice Connetcor Lugged Splice Termination Total Program Average ($101,856) $29,656 ($9,709) ($81,908) Note: Negative values indicate a savings 27

28 Cost Benefit Assessment (cont.) Using estimated quantities to replace that are not purchased with equipment Small savings shown These estimates do not include NRE to change to new design Numbers are conservative A lot are purchased with equipment Opportunity to Switch to Quick Connectors: From Terminal Blocks and Lugged Splice Connectors to Quick Connectors DIN rail 35 Mounted Quick Connector Foot Mounted Quick Connector Currently used Terminal Block In-Line Splice Connetcor Lugged Splice Termination Average 3, ,741 Opportunity Costs to Switch to Quick Connectors from Terminal Blocks and Lugged Splice Connectors: Labor Savings (mhrs) DIN rail 35 Mounted Quick Connector Foot Mounted Quick Connector Currently used Terminal Block In-Line Splice Connetcor Lugged Splice Termination Average (489) (71) (108) (595) Opportunity Costs to Switch to Quick Connectors from Terminal Blocks and Lugged Splice Connectors: Hardware Savings ($) DIN rail 35 Mounted Quick Connector Foot Mounted Quick Connector Currently used Terminal Block In-Line Splice Connetcor Lugged Splice Termination Average (3,184) 487 (1,040) (3,043) Opportunity Costs to Switch to Quick Connectors from Terminal Blocks and Lugged Splice Connectors: Total ($) DIN rail 35 Mounted Quick Connector Foot Mounted Quick Connector Currently used Terminal Block In-Line Splice Connetcor Lugged Splice Termination Average (3,672) 417 (1,148) (3,638) Note: Negative values indicate a savings Total Total Total Total 28

29 Cost Benefit Assessment (cont.) Qualified Benefits include: Troubleshooting, testing and commissioning Flexible configuration and minimal impact to adjacent circuits Reduced installation steps Fewer parts to manage COTS (Commercial Off the Shelf) equipment Qualified benefits may be more important than quantified benefits in some applications User should determine where relative benefits are generated and costs assessed 29

30 Recommendations Future Estimation Work Users should use the tools for their programs and refine as necessary; validation is good practice, but not necessary Universal Requirements Consider requirements that can be invoked on several types of marine programs Drive program specific costs out of multiple programs Qualification Program Vendors to consider ESS qualification Use most stringent requirements, as applicable Product Resilience Vendors to assess and maintain or improve product resilience for targeted markets 30

31 Implementation Identify opportunities Identify hardware and methodology availability Determine qualification status Determine qualification scope of work Estimate costs and schedule associated with qualification Determine overall cost of change Determine point of technology insertion 31

32 Project Summary and Conclusions Project investigated a good cross section of quick connector products to consider All products, for the most part, performed well Some products require re-design to meet the types of requirements used in the project Other products will likely meet stringent requirements as they are currently designed Recommend further cost benefit analysis (which would be part of user implementation plans) Vendors are encouraged to move into qualification plans for their products 32

33 Questions?? Thank you for your support and participation 33

Electric Technologies Panel Meeting Philadelphia, PA Low Voltage Quick Connector Evaluation Status Update

Electric Technologies Panel Meeting Philadelphia, PA Low Voltage Quick Connector Evaluation Status Update Presented by: Gregory D. Stevens General Dynamics, Bath Iron Works April, 3 rd, 2014 Approved for