Success Depends on the Crimp

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Austen Norton
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1 Success Depends on the Crimp Understanding the UL-486F Standard for Bare and Covered Ferrules Vince Barone, May 12,

2 Agenda 2

strands Single Twin Non-Insulated Ferrules

Polypropylene Large Ferrules Wire Range: #1

3 What is a Ferrule? Ferrules are terminals that only have a barrel. They effectively prevent straying of wire strands Single Twin Non-Insulated Ferrules Wire Range: #2 #28 AWG Non Insulated & Polypropylene Large Ferrules Wire Range: #1 500kcmil AWG Non Insulated Polypropylene (#1 300kcmil) Ferrules Wire Range: #2 #28 AWG Non Insulated & Polypropylene Expanded 3

Contains wire strands Terminal Block Applications Terminal Block

4 What is the difference between a Pin and a Ferrule? Pin Terminals Ferrule Terminals Used to contain wire strands Used to Contains wire strands Terminal Block Applications Terminal Block Applications Wire stops at barrel Wire runs length of barrel Smaller cross section, higher density 4

5 Best for terminating wire in mechanical connectors Modifies stripped end of high strand wire to the performance of a solid wire Stranded and Flex Cable Similar to shoelace aglets Unit Substation Motor Control Transformers Centers Switchgear Circuit Breaker Power Distribution Terminal Blocks 5

6 No Ferrule Flex cable on its own is not UL approved When installed using a Ferrule

7 Evolution of Ferrule Standards: DIN DIN & IEC Specifies Design Dimensions color Provides a reference to: Wire pullout Crimped profile Refers to IEC for additional specification requirements 7

8 DIN Pull-Force Recommendations Relationship between pull force, maximum cross-sectional area and wire size Standards: DIN Part 4 & IEC English Units Cross-Sectional Area AWG Pull Force lbf Form of Test Pin Fig. 1 A A A A A A A B B B B Size a in Size b in Metric Units Cross-Sectional Area mm^2 0,2 0,34 0,5 0,75 1,0 1,5 2, Pull Force N Form of Test Pin Fig. 1 A A A A A A A B B B B Size a mm Size b mm Fig. 1; Cross Sectional Profile Diagrams for Crimped Ferrules

9 Evolution of Ferrule Standards: CSA C22.2 No (R2004) Adopted DIN 9

10 Panduit CSA File Number

11 Evolution of Ferrule Standards: UL-508A UL 508a Approved method for terminating ferrules within a control panel Ferrule must be crimped: Prior to insertion into the end device Using Manufactures Recommended Tool If a tool is not available it will not meet UL 508A 11

12 Evolution of Ferrule Standards: CSA C22.2 & UL-486F UL 486F & CSA C22.2 No 291 Released in March of 2014 Harmonized CSA Group and UL standard For Bare and Covered Ferrules For Wire Ranges from 20AWG 1AWG Panduit and NEMA council working with UL and CSA to expand the wire range Addendum will be made upon completion 12

factory wiring In accordance with NEC, ANSI/NFPA-70

1 Facilitate connection of stranded wire to a

wire Terminated in wire connection devices rated

13 UL-486F & CSA C22.2 No 291 General Scope Intended for field and factory wiring In accordance with NEC, ANSI/NFPA-70 and CSA C22.1 Facilitate connection of stranded wire to a device Suitable for use with 1/0 20 AWG stranded wire Terminated in wire connection devices rated for solid conductors Not intended for use in IDC (Insulation Displacement Connections) Does not apply to pin adapters covered by UL 486A- 486B

14 UL-486F & CSA C22.2 No 291 Construction Materials Copper & Tin Plated Flammability Covering shall have minimum classification of UL94 HB Thermal properties Covering shall have minimum relative thermal index of 80 C (176 F) Test Requirements Tensile test shall not visible move within the ferrule or be pulled out Mold stress relief - no warpage, shrinkage, or other distortion Dielectric voltage-withstand plastic sleeve shall withstand the applied potential without breakdown Sampling Requirements Three samples of each assembly requirement Four assembly requirements Conducted for each wire class Conducted for each tool being listed

15 UL-486F & CSA C22.2 No 291 Test Methods Assembly using identified tooling and strip length Largest size conductor with highest stranding count Largest size conductor with lowest stranding count Smallest size conductor with highest stranding count Smallest size conductor with lowest stranding count Tensile Test Minimum described force applied at rate not to exceed 25.4 mm per min (1 inch per minute) and applied for 1 minute Mold Stress Seven hour oven test Assembled ferrules at uniform temperature Not less than 90 C

16 UL-486F & CSA C22.2 No 291 Dielectric voltage withstand test After completion of mold stress test Subjected to an ac test potential of 1000 V for 1 minute Marking, Labeling and Packaging Manufacturers Name & Trademark Catalog number Wire Size Installation tool and catalog number Wire strip length

17 UL-486F & CSA C22.2 No 291 Conductor Cross Section mm 2 (AWG) Force Newton (N) Force Pounds (Lbs.) 0.5 (20 AWG) (18 AWG) (16 AWG) (14 AWG) (12 AWG) (10 AWG) (8 AWG) (6AWG) (4 AWG) (2 AWG)

18 Ferrule Offerings Standard Ferrules Expanded sleeves Short circuit sleeves Twin Ferrules Large wire ferrules up to 500 kcmil With and without sleeves Ferrules on Reel and Mini-reels Tools: Hand Tools Battery powered Automated wire stripped / crimper

19 Focused Crimp Training Success Depends on the Crimp

20 Why the Training was Developed

Did You Know That: The leading reason for warranty

first minutes literally the cost is a new terminal and

In the first days as the product may be in process or

21 Did You Know That: The leading reason for warranty claims on electrical assemblies is due to poor electrical connections. The cost to repair a poor electrical connection: In the first minutes literally the cost is a new terminal and the 20 seconds of labor to install. In the first days as the product may be in process or final test and the problem will have to be investigated, found and repaired. In a few weeks possibly thousands of dollars, as the product may be in the field or production requiring field service repair, or line down situations.

22 Issues Affecting Quality Crimps Did You Know That Most Installers: Have never received formal crimp training, it has been passed down Do not understand terminal selection criteria Do not know when to spec a ring vs. fork terminal Do not know the difference between material characteristics of nylon and vinyl and where to use Do not understand the value or purpose of an insulation crimp Do not understand the consequences of a bad termination

23 What is this Training? What it is: A highly detailed crimp educational experience that covers application, wire selection, product selection and physical crimping A tool to help educate electricians This training is a powerful tool available by presentation from a Panduit Sales Representative. What it isn t: A Commercial A replacement for a customer s in-house crimp training program A formal, legal certification A Public Service Message Our goal is to ultimately show the value added services we can supply!

24 What is the Value to the Customer? Everybody is on the Same Page When all employees doing crimping attend this program they receive a consistent message. They all understand the dynamics of a crimp as well as selection criteria of wire and components. A consistent message results in consistent performance. Significant Education Based on our research, a consultant company providing the same training to your customer would charge between $850, and $1,500 per student. If a customer is looking for a cost savings / cost avoidance, and we train 15 of their electricians, using the lowest value, we have provided a service that is valued between $12,750 and $22,500.

No Insulation Crimp Crimp through insulation Fork stud size too large

25 Why did We Develop This Training? Because we don t want your electricians to do this. EVER! No Insulation Crimp Crimp through insulation Fork stud size too large for terminal strip Strip length too long Fork Terminal for grounding Crimped with hand tool for non-insulated terminal

26 Thank You Please stop by the Panduit Booth for additional information and product demonstration 26

The Spec-Kon. Example: KV18-6R-M (18) AWG (14) AWG (10) AWG (8) 8 AWG (6) 6 AWG (4) 4 AWG (2) 2 AWG

The Spec-Kon. Example: KV18-6R-M (18) AWG (14) AWG (10) AWG (8) 8 AWG (6) 6 AWG (4) 4 AWG (2) 2 AWG Overview Crimp, Disconnects, and Splices Thomas & Betts is pleased to introduce crimp terminals, disconnects, and splices. Ideal for OE applications, the line can be used anywhere a high number of terminations