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