VIRGINIA PANEL CORPORATION HIGH POWER CONTACTS AND MODULES USER’S MANUAL: APPENDIX HIGH POWER CONTACT ELECTRICAL SPECIFICATIONS 5.89 .232 11.12 .438 8.83 .348 8.83 .348 5.72 .225 12.70 .500 11.12 .438 12.70 .500 38.48 1.515 36.20 1.425 ITA Contact Part # 610 150 101 Receiver Contact Part # 610 149 101 Dimensions shown: [millimeters] inches Electrical Specifications Operating Current 150 Amp Continuous using 2 AWG wire Operating Voltage 600V Contact Resistance 0.35 mOhms T-Rise +40°C at 150 Amps +30°C at 125 Amps Mechanical Characteristics Mating Force 2.5 lb Max [1.13 Kg] Cycle Life 10,000 cycles Contact Body Material Cu Alloy Receiver Contact Body Plating 10μ" Au over 100μ" Ni ITA Contact Body Plating 30μ" Au over 100μ" Ni Operating Temperature -40°C to 125°C Material 1 of 6 For the most current information available, visit www.vpc.com. 3/31/2016 HIGH POWER CONTACTS AND MODULES USER’S MANUAL: APPENDIX VIRGINIA PANEL CORPORATION High Power Connector Product Performance Specification 1. Scope 1.1 Content This specification covers the performance, tests and quality requirements for the High Power contact and connector system. The High Power contact is a separable electrical connection device, designed and tested using 2 AWG Cooner Wire CW6044-14(UL Rated), AS 105-14(Non-UL) wire. All High Power contact types are to be used in High Power connector modules. 1.2 Qualification Testing When tests are performed on subject product line, the following procedures shall be used: • All inspections shall be performed using applicable inspection plans and product drawings. • Upon completion of qualification testing, this specification will be assigned a number and be classified, 2. Applicable Documents 2.1 Content The following documents form a part of this specification to the extent specified herein. Unless otherwise specified, the latest edition of the document applies. In the event of a conflict between requirements of this specification and product drawing, product drawing will take precedence. In the event of a conflict between requirements of this specification and referenced documents, this specification shall take precedence. 2.2 Documents A. Standards: • AMS 2422 • EIA 364-06 • EIA 364-5 • EIA 364-29 • EIA 364-21 • EIA 364-09 • EIA 364-13 • EIA 364-17B B. Product Drawings: Housings • 510104307 • 510108281 • 510160124 • 510161124 Contacts • 610149101 • 610150101 2 of 6 For the most current information available, visit www.vpc.com. 3/31/2016 HIGH POWER CONTACTS AND MODULES USER’S MANUAL: APPENDIX VIRGINIA PANEL CORPORATION 3. Requirements 3.1 Design and Construction Product shall be of design, construction and physical dimensions specified on applicable product drawings. 3.2 Materials A. B. C. 3.3 Ratings A. Female Contact • Body - Copper alloy, Internal Contact Beams - Copper alloy Silver plated • Gold over Nickel plating per MIL-DTL-45204D Male Contact • Body - Copper alloy, IP Tip - Thermoplastic • Gold over Nickel plating per MIL-DTL-45204D Housing • G10 Epoxy Glass or Black PPS Voltage • AC up to 600VAC peak • DC up to 600VDC B. Current • 2 AWG: 150 ampere maximum C. Temperature • -40°C to 125°C 3.4 Performance and Test Description Product is designed to meet electrical, mechanical, and environmental requirements specified in Figure A on pg. 4. Unless otherwise specified, all tests should be performed at free air, room temperature, and ambient environmental conditions. 3 of 6 For the most current information available, visit www.vpc.com. 3/31/2016 VIRGINIA PANEL CORPORATION HIGH POWER CONTACTS AND MODULES USER’S MANUAL: APPENDIX Test Requirements and Procedures Summary Preliminary Electrical Mechanical Test Description Requirement Procedure Examination of Product Meets requirements of product drawing Visual, dimensional, and functional examination per applicable quality inspection plan Operating Current 150 Amp at 40°C Temperature Rise EIA-364-70: 100% of pin positions populated and subjected to 150 Amp current with 2 AWG wire Contact Resistance 0.35 mΩ max. EIA-364-06: Subject mated contacts in housing to 100mA and/or Maximum current per wire gage Dielectric Withstanding Voltage 600 VAC Peak 600 VDC EIA-364-20: Test between adjacent contacts in housing, 60 sec. min., < 20mA Durability < 10000 Cycles EIA-364-09: Mate and unmate sample for 10000 cycles Insertion/retention force > 2 lbf, > 50 lbf EIA-364-05/EIA-364-29: Measure force necessary to insert and remove samples from a module Mating/unmating forces EIA-364-13: Measure force necessary 2.5 lb max. lbf per contact to engage and disengage samples at a normal rate of engagement of the ITA Figure A Current Rating Graph Figure B NOTE: Tested and designed to use with Cooner Wire CW6044-14(UL Rated), AS 105-14(Non-UL), or equivalent. NOTE: For multiple conductor correction factors please reference chart on pg. 5 or http://www.coonerwire.com/amp chart/. 4 of 6 For the most current information available, visit www.vpc.com. 3/31/2016 VIRGINIA PANEL CORPORATION HIGH POWER CONTACTS AND MODULES USER’S MANUAL: APPENDIX VPC High Power Contacts are tested and designed to use with 2 AWG Cooner Wire CW6044-14(UL Rated), AS 105-14(Non-UL), or equivalent. Multiple Conductor Correction Factors Lead Wire Current Carrying Capacity (Ampacity) Insulated Conductor Temperature Rating AWG SIZE at 80°C at 90°C at 105°C at 125°C at 150°C at 200°C 170 190 215 232 255 293 2 Multiply the ampacity rating from above by the correction factor listed below to determine the ampacity rating of a conductor in a multi-conductor cable. Multiple Conductor Correction Factors Number of Conductors Multiply ampacity by factor 4-6 0.80 7-9 0.70 10-20 0.50 Disclaimer: The information shown here has been assembled from sources believed to be reliable, but is not guaranteed by Cooner Wire Co. Cooner Wire Co. is not responsible for its accuracy or reliability. Figure C. Multiple Conductor Correction Factors for 2 AWG wire provided by Cooner Wire. 5 of 6 For the most current information available, visit www.vpc.com. 3/31/2016 VIRGINIA PANEL CORPORATION HIGH POWER CONTACTS AND MODULES USER’S MANUAL: APPENDIX 4. Quality Assurance Provisions 4.1 Qualification Testing A. Sample Selection Samples shall be prepared in accordance with applicable instruction sheets and shall be selected at random from current production. Each test group shall consist of a minimum of 5 connectors containing at least 30 contacts total each and equal posts to mate with receptacles. Test group 1 shall have both minimum and maximum position size connectors. B. Test Sequence Qualification inspection shall be verified by testing samples as specified in Figure A on pg. 4. 4.2 Requalification Testing If changes which significantly affect form, fit or function are made to product or manufacturing process, quality assurance shall coordinate requalification testing, consisting of all or part of original testing sequence as determined by development, product, quality, and reliability engineering. 4.3 Acceptance Acceptance is based on verification that product meets requirements of Figure A on pg. 4. Failures attributed to equipment, test set-up or operator deficiencies shall not disqualify product. When product failure occurs, corrective action shall be taken and samples resubmitted for qualification. Testing to confirm corrective action is required before re-submittal. 4.4 Quality Conformance Inspection A Certificate of Conformance dimensional inspection must be completed for all samples prior to qualification testing. The applicable quality inspection plan will specify sampling acceptable quality level to be used. Dimensional and functional requirements shall be in accordance with applicable product drawing and this specification. REV 6 of 6 Date Rev Change Prepared By 1 11/27/13 Original Release R. Brightwell 2 1/20/2014 Market Release R. Brightwell 3 1/22/2014 Official Market Release C. Slagle 4 3/10/2014 Updated R. Brightwell 5 5/28/2014 Update J. Harman 6 11/25/2014 Update J. Harman For the most current information available, visit www.vpc.com. 3/31/2016