test report on

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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






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






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






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






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.






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.






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


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



2 110 11 Passed UL 467 Requirement - No cracks, breaks, or melting







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










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















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.






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






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.






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




Table 6 – EM TS-19-IL – Pullout Test Results

Sample In-Line

Conductor

In-Line

Conductor

Minimum Pullout

(lb)

Time

Duration

(min)


Continuity was lost Result







Table 7 – EM TS-12-19 – Pullout Test Results

Sample Main

Conductor

Lateral

Conductor

Minimum Pullout

(lb)

Time

Duration

(min)









Table 8 – EM TS-12-19-IL – Pullout Test Results

Sample In-Line

Conductor

In-Line

Conductor

Minimum Pullout

(lb)

Time

Duration

(min)














Table 9 – EM TS-19 – Above and Beyond Pullout Test Results

Sample Main

Conductor

Lateral

Conductor

Minimum

Pullout

(lb)

Maximum

Pullout

Reached (lb)


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 -




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)


Continuity was lost

(lb)








Table 11 – EM TS-12-19 – Above and Beyond Pullout Test Results

Sample Main

Conductor

Lateral

Conductor

Minimum

Pullout

(lb)

Maximum

Pullout

Reached (lb)


Continuity was lost

(lb)



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)


Continuity was lost

(lb)













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.








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






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



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






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






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











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.



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