Disconnects for Use in High Vibration Applications

Disconnects for Use in High
Vibration Applications (Case 1)
A P P L I CAT I O N N OT E
Applications:
Equipment that produces high vibrations or is in close proximity
to sources of high vibration such as:
• Electrical motors
• Air compressors
•Pumps
• Commercial laundry equipment
• Transportation equipment
Customer Concern:
A manufacturer of commercial vacuum cleaners for coin-operated
car washes was having problems with reliability in high vibration
environments. This vibration caused disconnects to slip off the
male tabs, which caused internal arcing that damaged their
controllers, resulting in numerous service complaints for their
customers and downtime in the field.
Standard Non-Insulated Female Disconnect on
Left with High Vibration Disconnect on Right
Panduit Solution:
Insulated and Non-Insulated Vibration Resistant
Female Disconnects
Panduit developed vibration resistant female disconnect samples
for testing in this application. The solution required a higher
disconnect withdrawal force to overcome the failures caused
by the high vibration. As seen circled in the images on the right,
the samples that passed were designed without the curl slots to
increase the retention force between the curls of the female
disconnect and the male tab. This increased retention force
directly increased the frictional force, which ultimately delivers
a higher disconnect withdrawal force. The customer evaluation
of the new design showed that none of the vibration resistant
female disconnects slipped off the male tabs. Customer downtime
as a result of disconnects vibrating off of the male tabs has been
eliminated since implementation of this product.
Application Considerations:
Additional insertion force is required to properly install the
vibration resistant female disconnect onto a male tab 12.4 pounds
force (lbf) as compared to a standard female disconnect 7.9 lbf.
Additional withdrawal force is also required to remove the vibration
resistant female disconnect from a male tab 11.3 lbf versus a
standard disconnect 9.9 lbf. Customers should determine if the
additional force is acceptable in areas where the connection may
require removal for maintenance, repair or modifications.
w w w. p a n d u it.c o m
Standard Insulated Female Disconnect on Left
with High Vibration Disconnect on Right
Commercial Automobile Vacuum Cleaner
Application That Required a Female Disconnect
with Increased Retention Force Against
High Vibration
Disconnects for Use in High
Vibration Applications
Loose Piece
Brass
Sleeve
A
Disconnect
C
Max. Wire
Insul. Dia.
B
Housing
Part Number
Tab Size
In.
(mm)
Wire
Range
AWG
(mm2)
Color
Max. Wire
Insul. Dia.
In.
(mm)
0.250 x .032
(6.4 x 0.8)
12 – 10
(4.0)
—
0.250 x .032
(6.4 x 0.8)
12 – 10
(4.0)
Yellow
Dimensions
In. (mm)
A ±0.03
B ±0.02
C ±0.02
Crimp Tools
—
0.72
(18.29)
0.30
(7.62)
0.12
(3.05)
CT-100A, CT-160, CT-200,
CT-260, CT-570, CT-1570,
CT-2500 w/CT-2570CH
0.229
(5.82)
1.04
(26.42)
0.30
(7.62)
0.12
(3.1)
CT-100A, CT-160, CT-260,
CT-460, CT-1550, CT-1551,
CT-2500 w/CT-2550CH
Non-Insulated
D10-250C-D
Vinyl Insulated
DV10-250C-D
Reel-Fed
A
Funnel Wire
Entry
Carrier Strip
Housing
Brass
Terminal
Sleeve
C
Max. Wire
Insul. Dia.
B
.03 Wall
Thickness
Part Number
DV10-250C-2K
Tab Size
In.
(mm)
Wire
Range
AWG
(mm2)
0.250 0.032
(6.4 x 0.8)
14 – 10
(4.0 – 2.5)
Color
Yellow
Notes:
1.600 V maximum voltage rating for insulated disconnects
194°F (90°C) maximum temperature rating for insulated disconnects
302°F (150°C) maximum temperature rating for non-insulated
disconnects
Stranded copper wire only
2.Material:
a. Stamping: CDA-260 brass, tin-plated
b. High withdrawal force curl design
c. Housing: Vinyl
Tool Chart –
Recommended Presses:
CP-871 (UC200)
Wire Crimp
Area
Max. Wire
Insul. Dia.
In.
(mm)
A ±0.03
B ±0.02
C ±0.02
CA-800/CA9 Applicator
Die Inserts
0.22
(5.6)
0.95
(24.1)
0.29
(7.4)
0.12
(3.1)
CD-800-3
CD9-3B
Dimensions
In. (mm)
3.UL 310 Certified
4.Dimensions in parenthesis are in mm or mm2
5.Wire strip length 9/32+1/32
5.Package qty:
-2K = 2000 pcs./reel
-D = 500 pcs.
WORLDWIDE SUBSIDIARIES AND SALES OFFICES
PANDUIT CANADA
Markham, Ontario
[email protected]
Phone: 800.777.3300
PANDUIT EUROPE LTD.
London, UK
[email protected]
Phone: 44.20.8601.7200
PANDUIT SINGAPORE PTE. LTD.
Republic of Singapore
[email protected]
Phone: 65.6305.7575
PANDUIT JAPAN
Tokyo, Japan
[email protected]
Phone: 81.3.6863.6000
PANDUIT LATIN AMERICA
Guadalajara, Mexico
[email protected]
Phone: 52.33.3777.6000
PANDUIT AUSTRALIA PTY. LTD.
Victoria, Australia
[email protected]
Phone: 61.3.9794.9020
For a copy of Panduit product warranties, log on to www.panduit.com/warranty
For more information
Visit us at www.panduit.com
Contact Customer Service by email: [email protected]
or by phone: 800.777.3300
©2015 Panduit Corp.
ALL RIGHTS RESERVED.
TMAN15--WW-ENG
replaces WW-TMAN01
10/2015
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