Test Report On - Trace-Safe business park • 110 groppo drive • p.o. box 626 • winsted,...
Transcript of Test Report On - Trace-Safe business park • 110 groppo drive • p.o. box 626 • winsted,...
winchester business park • 110 groppo drive • p.o. box 626 • winsted, connecticut 06098 • 860-379-8515
Test Report On:
Trace-Safe Connector (EM TS Series)
Part Number - EM TS-19, EM TS-19-IL, EM TS-12-19, EM TS-12-19-IL
January 2012
Trace Safe Connectors were evaluated to:
UL 467-2007
Grounding and Bonding Equipment
Clause 9.5 - Short-Time Current Test
UL486A-486B-2003
Standard for Wire Connectors
Clause 9.3.4 – Pullout Test
ASTM B117-09 Standard Practice for Operating Salt Spray (Fog) Apparatus
Tests Performed By: Enes Basic – Electrical Engineer
Report Written By: Enes Basic – Electrical Engineer
Trace-Safe Connectors – EM TS-19, EM TS-19-IL, EM TS-12-19, EM TS-12-19-IL
Evaluated using UL467-2007, UL486A-486B-2003, and ASTM B117-09 standards
ELECTRIC MOTION COMPANY INC. COPYRIGHTED MATERIAL -
NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM ELECTRIC
MOTION COMPANY, INC. Page - 2 - of 17
TABLE OF CONTENTS
INTRODUCTION 3 FIGURE 1 – FIGURE SERVES AS A VISUAL DESCRIPTION IDENTIFYING THE “MAIN” AND “LATERAL” CONNOTATION 3
FIGURE 2 – FIGURE SERVES AS A VISUAL DESCRIPTION IDENTIFYING AN “IN-LINE” CONNECTION 3
SAMPLE DESCRIPTION 4
TOOLS AND INSTRUMENTS 4
TEST SAMPLE PREPERATION – FOR ALL TESTS 5 FIGURE 3 – INSTALLATION INSTRUCTIONS FOR THE TRACE SAFE CONNECTORS 5
SHORT-TIME TEST CURRENT 6 FIGURE 4 – PREPARED CONNECTOR SAMPLES USED FOR TESTING 6
FIGURE 5 – TABLE 5 OF THE UL 467 STANDARD FOR GROUNDING AND BONDING EQUIPMENT 7
FIGURE 6 – GENERAL SETUP OF SHORT-TIME CURRENT TEST ON THE TRACE-SAFE CONNECTOR EM TS-19 7
PERFORMANCE REQUIREMENTS – SHORT-TIME CURRENT TEST 7
TEST RESULTS – SHORT-TIME CURRENT TEST 8
ANALYSIS AND CONCLUSION – SHORT-TIME CURRENT TEST 9
PULLOUT TEST 10 FIGURE 7 – GENERAL SETUP OF THE PULLOUT TEST ON THE TRACE-SAFE CONNECTOR EM TS-19-IL 10
FIGURE 8 – TABLE 27 OF THE UL 486A-486B STANDARD FOR WIRE CONNECTORS 11
PERFORMANCE REQUIRMENTS – PULLOUT TEST 11
TEST RESULTS – PULLOUT TEST 12
TEST RESULTS – ABOVE AND BEYOND - PULLOUT TEST 13
ANALYSIS AND CONCLUSION – PULLOUT TEST 14
SALT SPRAY (FOG) TEST 15 FIGURE 9 – PREPARED PROTOTYPE (ABS PLASTIC) CONNECTOR SAMPLES USED FOR SALT-FOG TESTING 15
TEST RESULTS – SALT-SPRAY (FOG) TEST 16
ANALYSIS AND CONCLUSION - SALT-SPRAY (FOG) TEST 17
Trace-Safe Connectors – EM TS-19, EM TS-19-IL, EM TS-12-19, EM TS-12-19-IL
Evaluated using UL467-2007, UL486A-486B-2003, and ASTM B117-09 standards
ELECTRIC MOTION COMPANY INC. COPYRIGHTED MATERIAL -
NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM ELECTRIC
MOTION COMPANY, INC. Page - 3 - of 17
INTRODUCTION
This is an evaluation of the mechanical, electrical, and environmental integrity of the Trace-Safe
connectors, part number, EM TS-19, EM TS-19-IL, EM TS-12-19, and EM TS-12-19-IL, which was
implemented at the EMC Product Testing Lab, using the Underwriters Laboratories Inc. UL 467-2007
“Standard for Grounding and Bonding Equipment”, clause 9.5, Short-Time Current Test, the UL486A-
486B-2003 “Standard for Wire Connectors”, clause 9.3.4, Pullout Test and ASTM B117-09, “Standard
Practice for Operating Salt Spray (Fog) Apparatus” specification. The tests were conducted from
November, 2011 to January, 2012. The Trace-Safe connectors were designed for the use on Neptco
Trace-Safe RT series, insulated solid 19AWG tracer wires, and insulated 12AWG solid conductor that is
used as a trace wire in the field. The following is a summary of the tests performed and the results that
were obtained. All tests were completed with successful results.
The EM TS-19 connector was designed for connecting the Trace-Safe, RT series solid insulated 19AWG
tracer wire “lateral”, to a second Trace-Safe, RT series solid insulated 19AWG tracer wire “main”.
The EM TS-19-IL connector was designed for connecting two Trace-Safe, RT series solid insulated
19AWG tracer wires in an “in-line” connection.
The EM TS-12-19 connector was designed for connecting a Trace-Safe, RT series solid 19AWG tracer
wire “lateral”, to the insulated solid 12AWG “main” conductor.
The EM TS-12-19-IL connector was designed for connecting a Trace-Safe, RT series solid insulated
19AWG tracer wire to an insulated solid 12AWG conductor in an “in-line” connection.
Figure 1 - Figure serves as a visual description identifying the "Main" and "Lateral" connotation
Figure 2 - Figure serves as a visual description identifying an "In-Line” connection
Trace-Safe Connectors – EM TS-19, EM TS-19-IL, EM TS-12-19, EM TS-12-19-IL
Evaluated using UL467-2007, UL486A-486B-2003, and ASTM B117-09 standards
ELECTRIC MOTION COMPANY INC. COPYRIGHTED MATERIAL -
NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM ELECTRIC
MOTION COMPANY, INC. Page - 4 - of 17
SAMPLE DESCRIPTION
• 8 each EM TS-19 connectors (Final Production)
• 8 each EM TS-19-IL connectors (Final Production)
• 8 each EM TS-12-19 connectors (Final Production)
• 8 each EM TS-12-19-IL connectors (Final Production)
• 2 each EM TS-19 connectors (Prototype, ABS [acrylonitrile butadiene styrene] )
• 2 each EM TS-19-IL connectors (Prototype, ABS [acrylonitrile butadiene styrene] )
• 2 each EM TS-12-19 connectors (Prototype, ABS [acrylonitrile butadiene styrene] )
• 2 each EM TS-12-19-IL connectors (Prototype, ABS [acrylonitrile butadiene styrene] )
• 19AWG Insulated Solid tracer wires - Neptco Trace-Safe RT series - RT1800W, RT1802W
• 12AWG insulated solid conductor which is used as a trace wire in the field
TOOLS AND INSTRUMENTS
• Programma, Oden AT, Primary Current Injection Test System, (Calib. Sept. 2011)
• Megger, Ducter DLRO 10, Digital Low Resistance Ohmmeter, (Calib. Sept. 2011)
• Tinius Olsen, 30,000lbf. – 1lbf/division. Electromatic Tensile Tester, (Calib. Sept. 2011)
• Fluke 2000A Ammeter NIST traceable (Calib. Sept. 2011)
• MultiPro MultiMeter MP510 (Calib. Sept. 2011)
• Singleton Corporation, Model 22, Corrosion Test Cabinet, NIST traceable
Trace-Safe Connectors – EM TS-19, EM TS-19-IL, EM TS-12-19, EM TS-12-19-IL
Evaluated using UL467-2007, UL486A-486B-2003, and ASTM B117-09 standards
ELECTRIC MOTION COMPANY INC. COPYRIGHTED MATERIAL -
NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM ELECTRIC
MOTION COMPANY, INC. Page - 5 - of 17
TEST SAMPLE PREPERATION – FOR ALL TESTS
For all testing described here-in, the test connector samples were prepared according to the
manufacturers installation instructions respectfully, see figure 3. All connector test samples consisted
of, the connectors linking together approximately 14 inches of conductor which was used as the “main”
line and approximately 12 inches of conductor which was used as the “lateral” line.
Figure 3 - Installation Instructions for the Trace Safe Connectors
Trace-Safe Connectors – EM TS-19, EM TS-19-IL, EM TS-12-19, EM TS-12-19-IL
Evaluated using UL467-2007, UL486A-486B-2003, and ASTM B117-09 standards
ELECTRIC MOTION COMPANY INC. COPYRIGHTED MATERIAL -
NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM ELECTRIC
MOTION COMPANY, INC. Page - 6 - of 17
SHORT-TIME CURRENT TEST – UL467 Clause 9.5
Short time current tests using the UL 467-2007, clause 9.5 Grounding and Bonding Equipment
specifications, were performed on five separate samples of each, Trace-Safe connectors, part number,
EM TS-19, EM TS-19-IL, EM TS-12-19, and EM TS-12-19-IL, see figure 4. All connectors passed the
short-time current test requirements.
Figure 4 - Prepared connector samples used for testing
Continuity checks were performed using the MultiPro multi-meter, before the application of the
test current, according to clause 9.5.9 of the UL 467 standard. Continuity was measured from tracer
wire to tracer wire across the connector. The multi-meter beeper would sound if continuity of the
resistance measurement was below 20Ω, according to the MultiPro MP510 multi-meter user manual.
For each evaluation, the tracer wires (conductors) were connected in series to the terminals of the
Programma, Oden AT current injector.
For, two of each connector samples and according to table 5 of the UL 467-2007 standard core
test specifications, shown in figure 5, since there was no definitive value for the test requirement of a
19AWG, a minimum test current of approximately 110 amperes for four seconds was applied. For the
following two of each connector samples, a test current of approximately 125 amperes was applied. For
the last one of each connector samples, a test current of approximately 200 amperes was applied. Three
different ampere current loads were used to establish a scenario of the limiting, Trace-Safe, RT series
solid 19AWG tracer wire, fusing open, imitating an excessive current load and mimicking a fault
current which may be caused by a lightening strike.
Trace-Safe Connectors – EM TS-19, EM TS-19-IL, EM TS-12-19, EM TS-12-19-IL
Evaluated using UL467-2007, UL486A-486B-2003, and ASTM B117-09 standards
ELECTRIC MOTION COMPANY INC. COPYRIGHTED MATERIAL -
NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM ELECTRIC
MOTION COMPANY, INC. Page - 7 - of 17
Figure 5 - Table 5 of the UL 467 Standard for Grounding and Bonding Equipment
After the current tests each sample assembly underwent a continuity check. Observations of the
connectors were made after each current test and recorded in tables 1-4 in the “Test Results” section. A
general short time fault current test setup is shown in Figure 6.
Figure 6 - General setup of Short-Time Current Test on the Trace-Safe Connector EM TS-19
PERFORMANCE REQUIREMENTS – SHORT-TIME CURRENT TEST
• UL 467 Clause 7.5.1: “Grounding or bonding device shall not crack, break, or melt when
subjected to the current and time specified. Note: Arcing and burning of a throat insulator is
acceptable.
• UL 467 Clause 7.5.2 After having carried the current specified in Table 5 of the UL 467
standard, continuity shall be maintained on the test sample assembly.
Trace-Safe Connectors – EM TS-19, EM TS-19-IL, EM TS-12-19, EM TS-12-19-IL
Evaluated using UL467-2007, UL486A-486B-2003, and ASTM B117-09 standards
ELECTRIC MOTION COMPANY INC. COPYRIGHTED MATERIAL -
NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM ELECTRIC
MOTION COMPANY, INC. Page - 8 - of 17
TEST RESULTS – SHORT-TIME CURRENT TEST
Table 1 – EM TS-19 – Short-Time Current Test Results
Sample
Continuity-
Before
Applied
Current
Applied
Current
(Amperes)
Test
Duration
(Seconds)
Continuity-
After Applied
Current
After Applied Current- Observations
1 110 4.3 Passed UL 467 Requirement - No cracks, breaks, or melting
2 110 9.8 Passed UL 467 Requirement - No cracks, breaks, or melting
Trace-Safe Conductor Fused Open
3 125 4.2 Passed UL 467 Requirement - No cracks, breaks, or melting
4 125 7.8 Passed UL 467 Requirement - No cracks, breaks, or melting
Trace-Safe Conductor Fused Open
5 200 2.9 Passed UL 467 Requirement - No cracks, breaks, or melting
Trace-Safe Conductor Fused Open
Table 2 – EM TS-19-IL – Short-Time Current Test Results
Sample
Continuity-
Before
Applied
Current
Applied
Current
(Amperes)
Test
Duration
(Seconds)
Continuity-
After Applied
Current
After Applied Current- Observations
1 110 4.1 Passed UL 467 Requirement - No cracks, breaks, or melting
2 110 11 Passed UL 467 Requirement - No cracks, breaks, or melting
Trace-Safe Conductor Fused Open
3 125 4 Passed UL 467 Requirement - No cracks, breaks, or melting
4 125 9 Passed UL 467 Requirement - No cracks, breaks, or melting
Trace-Safe Conductor Fused Open
5 200 3 Passed UL 467 Requirement - No cracks, breaks, or melting
Trace-Safe Conductor Fused Open
Table 3 – EM TS-12-19 – Short-Time Current Test Results
Sample
Continuity-
Before
Applied
Current
Applied
Current
(Amperes)
Test
Duration
(Seconds)
Continuity-
After Applied
Current
After Applied Current- Observations
1 110 4.2 Passed UL 467 Requirement - No cracks, breaks, or melting
2 110 11.3 Passed UL 467 Requirement - No cracks, breaks, or melting
Trace-Safe Conductor Fused Open
3 125 4.1 Passed UL 467 Requirement - No cracks, breaks, or melting
4 125 7.5 Passed UL 467 Requirement - No cracks, breaks, or melting
Trace-Safe Conductor Fused Open
5 200 2.5 Passed UL 467 Requirement - No cracks, breaks, or melting
Trace-Safe Conductor Fused Open
Table 4 – EM TS-12-19-IL – Short-Time Current Test Results
Sample
Continuity-
Before
Applied
Current
Applied
Current
(Amperes)
Test
Duration
(Seconds)
Continuity-
After Applied
Current
After Applied Current- Observations
1 110 4.1 Passed UL 467 Requirement - No cracks, breaks, or melting
2 110 8 Passed UL 467 Requirement - No cracks, breaks, or melting
Trace-Safe Conductor Fused Open
3 125 4 Passed UL 467 Requirement - No cracks, breaks, or melting
4 125 7 Passed UL 467 Requirement - No cracks, breaks, or melting
Trace-Safe Conductor Fused Open
5 200 3.5 Passed UL 467 Requirement - No cracks, breaks, or melting
Trace-Safe Conductor Fused Open
Trace-Safe Connectors – EM TS-19, EM TS-19-IL, EM TS-12-19, EM TS-12-19-IL
Evaluated using UL467-2007, UL486A-486B-2003, and ASTM B117-09 standards
ELECTRIC MOTION COMPANY INC. COPYRIGHTED MATERIAL -
NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM ELECTRIC
MOTION COMPANY, INC. Page - 9 - of 17
ANALYSIS AND CONCLUSION – SHORT-TIME CURRENT TEST
All recorded test samples met the set-forth testing requirements of UL467 clause 9.5, short time
current test specifications. In all cases the Trace-Safe connectors did not crack, break or melt.
Continuity existed after the short time current tests across all test sample assemblies. Results were
acceptable by the test criteria of UL467-2007 clause 9.5, current test specifications.
All test and measurement equipment used herein is in the Electric Motion Company calibration
system and is traceable to NIST. Any additional information available will be furnished upon request.
Trace-Safe Connectors – EM TS-19, EM TS-19-IL, EM TS-12-19, EM TS-12-19-IL
Evaluated using UL467-2007, UL486A-486B-2003, and ASTM B117-09 standards
ELECTRIC MOTION COMPANY INC. COPYRIGHTED MATERIAL -
NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM ELECTRIC
MOTION COMPANY, INC. Page - 10 - of 17
PULLOUT TEST – UL486A-486B Clause 9.3.4
Pullout tests using the UL 486A-486B - 2003, clause 9.3.4, Wire Connectors, specification, were
performed on three separate samples of each, Trace-Safe connectors, part number, EM TS-19, EM TS-
19-IL, EM TS-12-19, and EM TS-12-19-IL, see figure 4.
The test samples were placed into the test fixture on a Tinius-Olsen, 30,000lb Tensile Tester, and
a load was applied at a cross-head speed not exceeding ¼ inch per min per ft of the total length of the
exposed conductor between the gripping means as specified in the standard. The length of the exposed
conductor between the two gripping means was 12” per conductor therefore 24” long for each connector
sample. This load was measured to an accuracy of 5%, and the mode of failure was recorded. A general
pullout test setup is shown in Figure 7.
According to table 27 of the UL 486A-486B standard, and since there was no definitive value for
the pullout requirement, a minimum pullout force of approximately, 17lb was used for a duration of 1
minute. Table 27 of the 486A-486B standard is shown in figure 8. The pull was exerted by the tensile
tester without a sudden application of force, or jerking. Although not a requirement, continuity checks
were performed continuously using the MultiPro multi-meter, across the connection, in order to
establish a base line and determine when continuity is lost due to the exerted pull load on the test
samples. Observations and test durations of the Trace Safe connectors were made after each test, and
recorded in tables 5-8 in the test results section. All connectors passed the pullout test requirements.
Figure 7 - General setup of the Pullout Test on the Trace-Safe Connector EM TS-19-IL
Trace-Safe Connectors – EM TS-19, EM TS-19-IL, EM TS-12-19, EM TS-12-19-IL
Evaluated using UL467-2007, UL486A-486B-2003, and ASTM B117-09 standards
ELECTRIC MOTION COMPANY INC. COPYRIGHTED MATERIAL -
NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM ELECTRIC
MOTION COMPANY, INC. Page - 11 - of 17
Figure 8 - Table 27 of the UL 486A-486B Standard for Wire Connectors
PERFORMANCE REQUIREMENTS – PULLOUT TEST
UL 486A-486B Clause 7.4.2: “The joint between a connector and the wire of the specimen set
shall be intact after being subjected for 1 min to the pullout test.”
UL 486A-486B Section 7.4.3: “As a result of the tests, there shall be no breakage of the wire or
any strand of a stranded wire, stripping of threads, shearing of parts, or other damage to the connector.
Breaking of the wire or any strand of a stranded wire shall be determined by examination of the
complete connector assembly while still intact after the pullout tests. Breakage has occurred if the wire
or a strand of a stranded wire becomes visibly unattached.”
ABOVE AND BEYOND PULLOUT TEST
Above and beyond pullout tests were implemented which were not required by clause 9.3.4 of
the UL 486A-486B standard. The connector samples were evaluated to the maximum pull force that
they could sustain. After the initial duration of 1 minute utilizing the performance requirement, a pull
force was applied to the connector samples until the conductor started to pullout, or the connector
sample was damaged. Continuity checks were performed continuously using the MultiPro multi-meter,
across the connection, in order to establish a base line and determine when continuity is lost due to the
exerted pull load on the test samples. All values were recorded in table 9-12 in the results section. The
total pullout connector strength was judged to be the maximum load that was applied before continuity
was lost.
Trace-Safe Connectors – EM TS-19, EM TS-19-IL, EM TS-12-19, EM TS-12-19-IL
Evaluated using UL467-2007, UL486A-486B-2003, and ASTM B117-09 standards
ELECTRIC MOTION COMPANY INC. COPYRIGHTED MATERIAL -
NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM ELECTRIC
MOTION COMPANY, INC. Page - 12 - of 17
TEST RESULTS – PULLOUT TEST
Table 5 – EM TS-19 – Pullout Test Results
Sample Main
Conductor
Lateral
Conductor
Minimum Pullout
(lb)
Time
Duration
(min)
Pullout force at which
Continuity was lost Result – mode of failure
1P 19AWG 19AWG 17 1 N/A Passed the performance requirements
Conductor did not pull out
2P 19AWG. 19AWG 17 1 N/A Passed the performance requirements
Conductor did not pull out
3P 19AWG 19AWG 17 1 N/A Passed the performance requirements
Conductor did not pull out
Table 6 – EM TS-19-IL – Pullout Test Results
Sample In-Line
Conductor
In-Line
Conductor
Minimum Pullout
(lb)
Time
Duration
(min)
Pullout force at which
Continuity was lost Result
1P 19AWG 19AWG 17 1 N/A Passed the performance requirements
Conductor did not pull out
2P 19AWG. 19AWG 17 1 N/A Passed the performance requirements
Conductor did not pull out
3P 19AWG 19AWG 17 1 N/A Passed the performance requirements
Conductor did not pull out
Table 7 – EM TS-12-19 – Pullout Test Results
Sample Main
Conductor
Lateral
Conductor
Minimum Pullout
(lb)
Time
Duration
(min)
Pullout force at which
Continuity was lost Result
1P 12AWG 19AWG 17 1 N/A Passed the performance requirements
Conductor did not pull out
2P 12AWG. 19AWG 17 1 N/A Passed the performance requirements
Conductor did not pull out
3P 12AWG 19AWG 17 1 N/A Passed the performance requirements
Conductor did not pull out
Table 8 – EM TS-12-19-IL – Pullout Test Results
Sample In-Line
Conductor
In-Line
Conductor
Minimum Pullout
(lb)
Time
Duration
(min)
Pullout force at which
Continuity was lost Result
1P 12AWG 19AWG 17 1 N/A Passed the performance requirements
Conductor did not pull out
2P 12AWG. 19AWG 17 1 N/A Passed the performance requirements
Conductor did not pull out
3P 12AWG 19AWG 17 1 N/A Passed the performance requirements
Conductor did not pull out
Trace-Safe Connectors – EM TS-19, EM TS-19-IL, EM TS-12-19, EM TS-12-19-IL
Evaluated using UL467-2007, UL486A-486B-2003, and ASTM B117-09 standards
ELECTRIC MOTION COMPANY INC. COPYRIGHTED MATERIAL -
NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM ELECTRIC
MOTION COMPANY, INC. Page - 13 - of 17
Table 9 – EM TS-19 – Above and Beyond Pullout Test Results
Sample Main
Conductor
Lateral
Conductor
Minimum
Pullout
(lb)
Maximum
Pullout
Reached (lb)
Pullout force at which
Continuity was lost
(lb)
Result – mode of failure
1P 19AWG 19AWG 17 64 60 Passed the min pullout requirement -
Conductor started to pull out
2P 19AWG. 19AWG 17 65 60 Passed the min pullout requirement -
Conductor started to pull out
3P 19AWG 19AWG 17 65 60 Passed the min pullout requirement -
Conductor started to pull out
Table 10 – EM TS-19-IL – Above and Beyond Pullout Test Results
Sample In-Line
Conductor
In-Line
Conductor
Minimum
Pullout
(lb)
Maximum
Pullout
Reached (lb)
Pullout force at which
Continuity was lost
(lb)
Result – mode of failure
1P 19AWG 19AWG 17 95 90 Passed the min pullout requirement -
Conductor started to pull out
2P 19AWG. 19AWG 17 100 95 Passed the min pullout requirement -
Conductor started to pull out
3P 19AWG 19AWG 17 85 80 Passed the min pullout requirement -
Conductor started to pull out
Table 11 – EM TS-12-19 – Above and Beyond Pullout Test Results
Sample Main
Conductor
Lateral
Conductor
Minimum
Pullout
(lb)
Maximum
Pullout
Reached (lb)
Pullout force at which
Continuity was lost
(lb)
Result – mode of failure
1P 12AWG 19AWG 17 50 50 Passed the min pullout requirement -
12AWG Conductor started to pull out
2P 12AWG. 19AWG 17 50 50 Passed the min pullout requirement -
12AWG Conductor started to pull out
3P 12AWG 19AWG 17 65 60 Passed the min pullout requirement -
12AWG Conductor started to pull out
Table 12 – EM TS-12-19-IL – Above and Beyond Pullout Test Results
Sample In-Line
Conductor
In-Line
Conductor
Minimum
Pullout
(lb)
Maximum
Pullout
Reached (lb)
Pullout force at which
Continuity was lost
(lb)
Result – mode of failure
1P 12AWG 19AWG 17 65 60 Passed the min pullout requirement -
12AWG Conductor started to pull out
2P 12AWG. 19AWG 17 60 60 Passed the min pullout requirement -
12AWG Conductor started to pull out
3P 12AWG 19AWG 17 65 65 Passed the min pullout requirement -
12AWG Conductor started to pull out
Trace-Safe Connectors – EM TS-19, EM TS-19-IL, EM TS-12-19, EM TS-12-19-IL
Evaluated using UL467-2007, UL486A-486B-2003, and ASTM B117-09 standards
ELECTRIC MOTION COMPANY INC. COPYRIGHTED MATERIAL -
NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM ELECTRIC
MOTION COMPANY, INC. Page - 14 - of 17
ANALYSIS AND CONCLUSION – PULLOUT TEST
All Trace-Safe connectors, part number, EM TS-19, EM TS-19-IL, EM TS-12-19, and EM TS-
12-19-IL, passed the pullout tests using the UL 486A-486B - 2003, clause 9.3.4 performance
requirements. Continuity checks were performed continuously using the MultiPro multi-meter, across
the connection, in order to establish a base line and determine when continuity is lost due to the exerted
pull load on the test samples. The multi-meter beeper would sound if continuity of the resistance
measurement was below 20Ω, according to the MultiPro MP510 multi-meter user manual. The joints
between the connectors and the conductors of all samples were intact after being subjected to the tests.
There was no shearing of parts or damage to the connector.
Further, above and beyond tests were implemented which were not required by clause 9.3.4 of
the UL 486A-486B standard. The connectors were evaluated to the maximum pull force that they could
sustain. After the initial duration of 1 minute utilizing the performance requirement, a pull force was
applied to the connector samples until the conductor started to pullout, or the connector sample was
damaged. All connectors sustained a maximum pullout of approximately 50-60lb, way beyond the
required pullout minimum of 17lb. All connector samples passed the pullout test requirements.
All test and measurement equipment used herein is in the Electric Motion Company calibration
system and is traceable to NIST. Any additional information available will be furnished upon request.
Trace-Safe Connectors – EM TS-19, EM TS-19-IL, EM TS-12-19, EM TS-12-19-IL
Evaluated using UL467-2007, UL486A-486B-2003, and ASTM B117-09 standards
ELECTRIC MOTION COMPANY INC. COPYRIGHTED MATERIAL -
NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM ELECTRIC
MOTION COMPANY, INC. Page - 15 - of 17
SALT SPRAY (FOG) TEST - ASTM B117-09
A salt spray (fog) test using the Standard Practice for Operating Salt Spray (Fog) Apparatus
ASTM B-117-09 specification was performed on two separate samples of each, Trace-Safe connectors,
part number, EM TS-19, EM TS-19-IL, EM TS-12-19, and EM TS-12-19-IL, see figure 9. All parts
were placed in the Corrosion Test Cabinet, and resistance measurements were recorded periodically, to
note any change in resistance due to the corrosive effect salt spray has on metals. The salt spray test was
started on November, 11th
2011 and completed in December, 23rd
2011 after 1000 hours or 42 days of
salt spray exposure.
NOTE: The connector samples which were evaluated in this salt spray test, were the original prototype
samples which were created using a porous 3D printer ABS plastic and which did not contain any
waterproofing gel substance. This test was deliberately conducted on the prototype plastic samples in
order to witness “worst case scenario”, if there was no waterproof gel and if the plastic itself was porous
enough, to let the salt spray soak the connection and intentionally attempt to cause corrosion on the
connection. The following is a summary of the tests performed, and the results that were obtained. All
results were recorded in tables 13-16.
Figure 9 - Prepared prototype (ABS Plastic) connector samples used for salt-fog testing
Trace-Safe Connectors – EM TS-19, EM TS-19-IL, EM TS-12-19, EM TS-12-19-IL
Evaluated using UL467-2007, UL486A-486B-2003, and ASTM B117-09 standards
ELECTRIC MOTION COMPANY INC. COPYRIGHTED MATERIAL -
NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM ELECTRIC
MOTION COMPANY, INC. Page - 16 - of 17
Resistance readings were taken before the salt fog immersion, and at the recorded periodic dates.
Resistance readings were made when the test samples were taken out of the salt fog chamber and
allowed to dry from the salt fog moisture. Resistance was measured using the Megger, Ducter DLRO
10, Digital Low Resistance Ohmmeter, across the connection, from the end of each tracer wire. This
allowed for consistent measurement of resistance at the periodic dates. Continuity was checked using
the MultiPro MP510 multi-meter. The multi-meter beeper would sound if continuity of the resistance
measurement was below 20Ω, according to the MultiPro MP510 multi-meter user manual.
TEST RESULTS - SALT SPRAY (FOG) TEST
Table 13 – EM TS-19 Resistance Measurements – Salt Spray (Fog) Test
Date 11/11/11 11/18/11 11/23/11 12/2/11 12/9/11 12/16/11 12/23/11
Exposure to Salt Fog (Hours) 0 168 288 504 672 840 1008
Sample 1 – Resistance (mΩ) 26.5 24.3 22.4 18.6 18.4 18.7 19.2
Sample 1 - Continuity
Sample 2 – Resistance (mΩ) 24.3 23.4 21.1 18.1 19.1 19.2 18.5
Sample 2 - Continuity
Table 14 – EM TS-19-IL Resistance Measurements – Salt Spray (Fog) Test
Date 11/11/11 11/18/11 11/23/11 12/2/11 12/9/11 12/16/11 12/23/11
Exposure to Salt Fog (Hours) 0 168 288 504 672 840 1008
Sample 3 – Resistance (mΩ) 20.0 20.1 19.8 19.7 19.8 19.6 19.5
Sample 3 - Continuity
Sample 4 – Resistance (mΩ) 20.1 20.2 19.6 18.9 19.1 19.3 19.2
Sample 4 - Continuity
Table 15 – EM TS-12-19-IL Resistance Measurements – Salt Spray (Fog) Test
Date 11/11/11 11/18/11 11/23/11 12/2/11 12/9/11 12/16/11 12/23/11
Exposure to Salt Fog (Hours) 0 168 288 504 672 840 1008
Sample 5 – Resistance (mΩ) 12.3 12.1 12.2 11.9 12.1 12.1 12.1
Sample 5 - Continuity
Sample 6 – Resistance (mΩ) 13.4 13.2 13.1 12.9 13.1 13.2 12.9
Sample 6 - Continuity
Table 16 – EM TS-12-19 Resistance Measurements – Salt Spray (Fog) Test
Date 11/11/11 11/18/11 11/23/11 12/2/11 12/9/11 12/16/11 12/23/11
Exposure to Salt Fog (Hours) 0 168 288 504 672 840 1008
Sample 7 – Resistance (mΩ) 13.7 13.9 14.1 14.6 14.3 13.9 14.6
Sample 7 - Continuity
Sample 8 – Resistance (mΩ) 15.1 14.9 14.7 14.8 14.8 14.5 14.5
Sample 8 - Continuity
Trace-Safe Connectors – EM TS-19, EM TS-19-IL, EM TS-12-19, EM TS-12-19-IL
Evaluated using UL467-2007, UL486A-486B-2003, and ASTM B117-09 standards
ELECTRIC MOTION COMPANY INC. COPYRIGHTED MATERIAL -
NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM ELECTRIC
MOTION COMPANY, INC. Page - 17 - of 17
ANALYSIS AND CONCLUSION - SALT SPRAY (FOG) TEST
The connector samples which were evaluated in this salt spray test, were the original prototype
samples which were created using a porous 3D printer ABS plastic and which did not contain any
waterproofing gel substance. This test was deliberately conducted on the prototype plastic samples in
order to witness “worst case scenario”, if there was no waterproof gel and if the plastic itself was porous
enough, to let the salt spray soak the connection and intentionally attempt to cause corrosion on the
connection which in turn would increase the resistance across that bonding connection. The resistance
readings of all connectors ranged within a change of 5-7mΩ indicating no significant change in
resistance, throughout the duration of the salt spray (fog) test. All connectors maintained continuity
throughout all resistance measurements, since the measured resistance did not exceed 20Ω. In
conclusion, the salt spray (fog) test did not jeopardize the connection of any of the eight separate, Trace-
Safe connectors, part number, EM TS-19, EM TS-19-IL, EM TS-12-19, and EM TS-12-19-IL.
All test and measurement equipment used herein is in the Electric Motion Company calibration
system and is traceable to NIST. Any additional information available will be furnished upon request.