ML20132F314
| ML20132F314 | |
| Person / Time | |
|---|---|
| Site: | 05000000, Waterford |
| Issue date: | 10/24/1983 |
| From: | LOUISIANA POWER & LIGHT CO. |
| To: | |
| Shared Package | |
| ML082320156 | List:
|
| References | |
| FOIA-84-206 MI-5-118, NUDOCS 8510010297 | |
| Download: ML20132F314 (132) | |
Text
'
l' TITiI
? AGE DEPAs _ CAI. PRCCURI MI-5-118 gg7:gIc3 2
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m c m ;A g 10-24-83 CALIBRATION PROCEDURE gf h 3 U',NCONTROLLEQb91.
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APPROVED:
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gR# _ s.e.1...>em mE 8510010297 850227 PDR FOIA BERNABE84-206 PDR
(.1 of 1) [d/A'/6 MD-1-011 Revision 2 30 A::act=nenc 6.7
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DITA 3~MI:-"AL PRO ZDU?2 C?iliOI/?IVISION/Dr.2 ION FlQUIS-Procedure No. N I "
O h Title h fNM
.Iffac:1ve Date (if differen f rc= Group Head approval date)
Censlete A,
- 3. er C A.
Change No.
h)/A 0
3.
Favision No. A C.
Deletion A/[4.
t' RIASON FOR CHANOE.
?_".7 SION, OR DCi !ON bat %P!d' Aff' M W W )/d/h 1 44/
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/M"N Technical Review Y /c /M u Date %/,P-/3
! " *SA?!*? ETALUATION
( d Does this' change, revision,-or dale:1on:
TIS NO 1.
Change the facility as described in :he FSAR?
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0.
Change :he procedures as described in the FEAR?
g 3.
Condue: :ssts/experi=an:s not described in the FS.;17 4
4 Create a condition or conduct an operation which exceeds or could result in exceeding, the 1*-*:s in Technical Specifica:1on?
x If the answer to any of the above is yes, cc=plete and a::ach a 10 C77. 50.f9 Safe:y Ivalua: ion. checklist.
Safa:7 Ivaluation Date 7 / 8 # J s _m m Temporary Approval
- Date Temporary Approval
- Date GC Review A W Y k
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.Date
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- Te=porary approval nus; be follove Q Review and Group /Depar:=en: Head approval N'd:hin 14 days.
MD-1-011 Revisien 1 29 A::achmen: 6. 8
(,1 of 1) i
e MI-5-116 Calibration Procedure Revision 2 Calibration of Crimpers TABLE OF CCNTENTS 1.0 PURPOSE
2.0 REFERENCES
30 PREREQUISITES 4.0 PRECAUTIONS AND LIMITATIONS 50 INITIAL CONDITIONS 6.0 MATERIAL AND TEST EQUIPMENT 70 ACCEPTANCE CRITERIA 8.0 PROCEDURE 8.1 Precalibration 8.2 Calibration 8.3 Postcalibration 90 SETPOINTS 10.0 ATTACHMENTS 10.1 G12.21, Measuring and Test Equipment Record of Calibration (2 pages) 11.0 COMMITMENTS AND' REFERENCES LIST OF EFFECTIVE PAGES Title Revision 2 l
1-6 Revision 2 l
1
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MI-5-118 Calibration Procedure Revision 2 Calibration of Crimpers n
e
- - mm, _,
1.0 PURPOSE This measuring and test equipment (M&TE) procedure provides instructions for verifying the accuracy of cricpers.
f
2.0 REFERENCES
2.1 MI-1-002, Administrative Control of Measuring and Test Equipment AmpInstruction/ Maintenance /InspectionSheetIb1559h(457000736) 2.2 dEAiiiEE5fr, 30
?REREOUISITES No8 F05-100bS 31 Ambient temperature, 70 2 3 degrees Fahrenheit ffecsFICD ItJ 32 Relative humidity, 20 to 55%
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4.0 PRECAUTIONS AND LIMITATIONS 4.1 "As Found" readings shall be taken prior to any repairs or adjustments being made.
4.2 If any "As Found" readings are out of tolerance, refer to MI-1-002 for disposition.
43 Visually inspect the tool for missing parts.
Operate-the tool and ensure that the return action of the spring-loaded handles is operating correctly.
4.4 Visually inspect the die closure surfaces for flattened, broken, pitted or chipped conditions.
45 The ratchet should be checked to ensure that 'it is not releasing prematurely, allowing dies to open before they have fully closed.
5.0 INITIAL CONDITIONS N/A 6.0 MATERIAL AND TEST EQUIPMENT 6.1 GO and NO-GO plug gages 6.2 Outside Micrometer, 0-1" 2 0.0001" accuracy, or equivalent 2
Calibraticn Procedure MI-5-118 Calibration of Crimpers Revision 2 70 AccEPTAEIE CRITERIA The crimper must meet the accuracy requirements specified in the M&TE Index or the applicable manufacturei
- 7 mended tolerance.
8.0 PEOCEDURE 8.1 PRECALIBRATION 8.1.1 Record the Metrology Laboratory a=bient temperature and relative humidity on Attachment 10.1.
C.2 CALIBRATION 8.2.1 Performance Test for Crimpers Using Plug' Gages 8.2.1.1 Close handles of the tool until the wire barrel dies are closed.
Do not apply additional pressure to tool handles.
8.2.1.2 Hold the barrel crimp GO plug gage in straight alignment with the die closure and carefully try to insert without forcing.
The GO gage must pass completely through the barrel crimp die closure.
Record reading as " SAT" or "UNSAT" (satisfactory or unsatisfactory) in the "As Found" column of Attachment 10.1.
8.2.1 3 Hold the. barrel crimp NO-GO plug gage in straight alignment witn the die closure and carefully try to insert without forcing.
The NC-GO gage must not pass through the barrel crimp die closure.
Record reading as " SAT" or "UNSAT" in the "As Found" column of Attachment 10.1.
8.2.1.4 Hold the insulating crimp GO plug gage in straight alignment with the die closure and carefully try to insert without forcing.
The GO gage must pass completely through the insula-tion crimp die closure.
Record reading as "S AT" or "UNSAT" in the "As Found" column of Attachment 10.1.
8.2.1.5 Hold the insulation crimp NO-GO plug gage in straight alignment with the die closu: e and carefully try to insert without forcing.
The NO-00 gage must not pass through the insulation 3
r Calibration Procedure MI-5-118 Calibration of Crimpers Revision 2 cricp die closure.
Record reading as " SAT" or "Ul! SAT" in the "As Found" column of Attachment 10.1.
8.2.2 Performance Test for Crimpers Using Outside Micro =eters 8.2.2.1 Insert wire slug in cri=pers and squeeze handles.
8.2.2.2 Remove slug from crimper and use outside micrometer to check thickness of crimped slug.
Record reading in "As Found" column of Attachment 10.1.
83 POSTCALIBRATION 8.3 1 If all "As Found" readings are within tolerance and no adjustments were made to improve accuracy, recording of "As Left" data on At-tachment 10.1 is not applicable.
Attach a completed calibration sticker to the instrument in accordance with MI-1-002.
8.3 2 If any "As Found" or "As Left" readings are out or tolerance, refer to MI-1-002 for disposition.
9.0 SETPOINTS H/A 10.0 ATTACHMENTS 10.1 G12.21, Measuring and Test Equipment Record of Calibration 11.0 COMMITMENTS AND REFERENCES 4
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CALI3Rt.IION PROCEDURE
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INCRU': TION / MAINTENANCE / INSPECTION SHEET l$ 1261
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INTRODUCTION
. MG Aac ation Fe:istant terminais anc s=hCes on Tnis cueli:ation crovices "instn.ctions" en er:cu:t wire sees t 2 arc 10.
acotication and a " Maintenance and inspe::;cn
. ptA37i.apipw terminais :n.vire sizes 1210 and i
Precedure" f or:
M-14 H D.
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CRIMPING TOOL NOS.
3 yI 53239-4 59237 2 69153-1 69634-1 Basi: instructions en tne use of tnese tools. Wire js preparation, tool aciustments, et:. are proviced in Section 2.
" Instructions." Sect:cn 3 features a M
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terminal and splice "Onma insce: tion" procedure.
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Section 4 contains a " Maintenance and inscection yj Procedure' wnien wiit enacle you to estaclism anc 33 These tools are usec to enmp:
rnair.tain a tool certification program.
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- PIDG* terminals and sollees en wire sizes 12-10 These instructions may be usec for tools not listed l3 and 16-14 HD.
in Figure 1 Out a:: mpaniec by this IS. For unlisted p
. PIDG STRATO-THERM
- terminals en wire size =
tools, use the wire stnp dimensions given in Figure 1 l
12-10.
for an identical size tool.
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- PIDG insulation restneting nylon terminals en wire Tools are coated with preservative to prevent rust and j}
sizes 12 and 10.
PIDG insulation restricting TEFLONt terminals on corrosien. Wice this preservative frem toci, partic-Li e
jf wire sizes 12 and 10.
ularly from enmoing area.
5i N5 sP ARE W1RE CAP PLAST 1-Grip PtOG TrPE p,0G BUTT SPLICE TER MiNAL TERMINALS ig$gtArics yv CC " smin E
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TOOL NANQLE INsutATION INsuLAftON
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DOT :CDE RANGE wi.
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PLASTbGRip I!1I
'EnviMALS 12-tc YELLOW SS23S4 3 250 lIIsl 5~2i atDGv?NvL YELLOW
,,12,,-10 H2SL2 h 300
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ANO NYLON ONECCT
, gg 5116-1113r T113r sis-g,"g" 69150 1 230 CNLY
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E sTRATo TkERM 69014 1 12-10 214 CNLY BLACK S r t 6' 11 t 3r NEDOT 4$ 5 TERMINALS i--
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t 3i37 i.5 s ONE007 69150-1 NYLON 10 119-200 YEl.,0W iNsuL. WISROWN BAND i 3' ~?.3
'E AMIN ALS h3 8?OG 2*I INSULATION 12 085 203 YELLCW
! '"~ i o RESTRICTING BLACX 6900a-1 1513r
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sTRATo-TNERM to 119.200 BROWN J y, 2
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PAGE1OF8
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e p Pi INSTR ucTi o N/ M AINT E N A NCEnNsp g: son g, EEP 2.
INSTRUCTIONS 2.2.2 Suit Splicts (R:f:r to Figure 3)
NOTE: Pe'er to paragraan 2.2 tcr insulation onma tal Be sure s li:e Insulation :alor coce matches tect ac!ustment.
nandle color. See Figure 1
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(b) Oe ress ic:ator. Position s lice in 195 so that 2.1 WIRE STRiDPING ic:ater seats in wincow mcent cf sol; c.
E Stnc wire to c:mensions !isted in Figure 1 (c) C:ose tool nancles to that splice is neic firmly in C'*C
NOTE: Do raot use wtre with nicked or
- stssing conductor strancs.
(c) Insert stricoec wire until ene of concueter butts against splice wtre stco.
2.2 CRIMPING PROCEDURES (e) Close tool handles until rat: net releases.
U) To enmp other han of schee, tum spHce or tool Open enmping dies by !osing nancies until CERTI.
CRIMP
- ratchet, see Figure 5. releases. N0te that around. Posnien unenmoed had in des anc fcuow once ratchet is engaged, hanotec cannot ce openec same are ecure used to enmo first nad of schee.
until they are first f ully closed.
(g) Observe det coce on finished enmo to insure that correct slHice and tool Ocmoination was used. See 2.2.1 Terminals (Refer to Figure 2)
Figu re 1.
(h) Refer to paragra:M 3 and Figure 6 'or soilee enmp (a) Se sure terminal insulation ccior coce matches tool inspection precedure.
handle color.
(c) Place terminals in dies so tnat wire barrei butts against !ccator.
PIDG BUTT SPLICE (c) Close tool handles until terminal is held firmly in place.
-C" WWCC* *0ENT fc) insert stnoced wire untti end of conouctor butts
-s EcWALs wtAE SA AREL against locator.
1
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-0 Ect.ALs WSulATloN (s) Close tool hancies until ratenet retsases.
sAa EL
- "**nh.
(f) Oeserve cot coce on finished enmp to insure that correct terminal and tool combination was used. See e*--
Figure 1.
ENo or coNoucToR (g) Refer to paragraph 3 and Figure 6 or 7 for terminal auTTs AGAWsT spues enmp inspection procedure.
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(a) Strio wire to dimensions listed in Figure 1 I
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wtRE BARREL 8uTTs LOCATOR (C) Close tool handles until CnmCing dies Dartially Close.
'G^*87'OC#70" but leave enough space for cap to be inserted between dies.
STR ATO. THERM TERMIN ALS (c) Decress locator so that end of Cao rests against the m
recessed surface of the locator as shown in Figure 4 i
?
(e) Close nancies until cao is held firmly in place. Do not M q
'j LOCAfoM deform cap wire carrel.
- 4 } j (g) Hold wire in position anc complete enmp by closing
( l (f) Insert stricced wire into cao until concuctor cottoms.
4 f@, !
i nancies until CERTI CRIMP ratchet releases. Handles (f
}\\
will open automatically and enmoed cao may De g,7_;
I m,
TEaumAL Aint sAnnEL ANo removec.
ENo cr 00Neuc ca sur-(h) Refer to Section 3 and Figure 7 for spare wire cao c t'L"?. l AGAms;.ocATom enmp inspection procedure.
Figure 2 PAGE2OP8 IS 1251
hJ; N TwcTicN;MAINTE*. ANcE ins *E:7.aN 3aEET (Os Csition No.1 is f 0r wi'a navin; a sma'l insuse: -
r-.
- ^
- ameter.
m
\\
_ierminai insuistien sncu;: iceatly =e in contact ve.t-wi e inseat::n atter :r r :.n;.
win : Nouc'on soTTeusis 3.
CRIM P INSPECTION C^*
Inspect :nmeed terminais, s::nces and s are wire
__h
[,_,, _
/
caos by enecking the features cesented.n Figures 6 L
n r-g and 7.
8 0
A so Use only the terminale solices and caos that rr, ret
=
oEyE 0,fA i
l[
the conditions shown in the " ACCEPT" column.
atsT:ACMNsT ai-
"REJEO*" terminals, solices and Oaos can be avo, cad
$5], sun *4cso" tnrough careful use of instructons in Se: tion 2, and by performmg regular tool maintenance as instre ted msuunos roausTueNT
., ql ammNoaaosmos
,n Section 4 F6gure 4 4.
MAINTENANCE / INSPECTION PROCEDURE AMP rec mmencs that a maintenancerinspection 2.3 INSULATION CRIMPING ADJUSTMENT program be performed oenedically to ensure ~~
2.3.1 PIDG Terminals and Splices pendaele and uniform terminations. Tools snoulc : e NOTE: PIDG terminals and splices feature an insula.
enspected at least once a montn. Frequency of tion grip.
inspection may be ac}usted.to suit your require-The insult. tion crimping section of the hand tool has ments througn expenence. Frequency of inspection tnree positions: 1 - Tignt,2 - Medium,3 - Loose.
is dependent upon:
(a) Insert insulation adjustment pin in No. 3 position.
See Figure S.
- 1. The care, amount of use, and nandling of the tv.'
(b) Pla:e terminal or splice in enmping dies as shown in
- 2. The type and size of the Arcoucts crimped.
Figure 2 or 3.
- 3. The degree of operator skill.
9 (c) Insert UNSTRIPPED wire into ONLY the insulation
- 4. The presence of acnormal amounts of dust v.-
barrel (see Figure 2 or 3) of the terminal or splice.
dirt.
j (d) Make a test crimp (Paragrapn 2.2). Remove enmped
- 5. Your own established stan s.
terminal or splice and check insulation support as follows: Bend the wire back and forth once Terminal All tools are inspected before agmg. Since the.
or splice should retam grip on wire insuldon.
is a possibility of tool damage in shipment, new tom (e) If wire oulls out, set insulation adjustment pin in snould be inspected in accordance with Section -
next tignter position (No. 2).
when received in your plant. Due to the precis *.
(f) Mane test enmo and repeat adjustment as ne:essary cesign, itis important that no parts of these tools r+
until desired insulation gno is obtained. Do not use a interchanged exceof those replacement parts lisferd tighter setting than required.
in Figure 12.
4.1 CLEANING 2
The tool should be immersed (nandles part:Miy 7dT closed) in degreasing compound to remove s.c;.u-p*O ? Qie,
N mutated dirt, grease and foreign matter. Make etertain i
N y ["' g the degreasing compound does not attack paint.sr plastic matenals.
g NsuuMoM CRiMMNC k
'M' acausTMENT AN m No.
Remove remaining degreasing compound with a imt ET sacsmoN free cloth. Wnen degreasing compounds are not Figure 5 availacle. tool may be wiDed clean with a lint free clotn. Relubncate tool, as instructed in paragraon 2.3.2 PLASTI-GRIP Terminals 4.2 VISU AL INSPECTION NOTE. PLA S TI-GRIP terminals feature a were insulation support only.
(a) Visually inspect the tool for missmg pins or retainirg rings. If parts are missmg or cefective, refer to E gt6e t
A The insulation cnmping section of the nand tool nas 12 for Customer reolaceable parts.
/
I
)
tnree oositions: 1 - Tignt, 2 - Medium. 3 - Locse. (b) Visually inspect tne die closure surtads for flat-See Figure 5.
tened. Orc <en or cnioce(conattto%s. Altnougn dias (al Position No. 3 is for wire havmg a large insulation may gage witnm permisafbie timits, wom or damaind diameter.
die closure surfaces are oclectionacle anc can affuct (b) Position No. 2 is fcr were naving a medium insulation the quality of tne enmo. Exsmales of =cssible diameter.
damaged die closure surfaces are snown in Figure 8.
IS 1261 PAGE 3 0F 8 w-
- IN5? AI.!CT)O% M As NT E N A N ea
- N5*EC?: N S E E?
9 A 007 OCCE n OA 2 COTSi MUST AcoE/. A l R E.!EOT j
[ACCEPTj CN ALL CAIMDEOiTEMS f
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l e
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I
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g3 5' - -
O
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~= m O@}
l[,' -
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/
m
" db %.
wimE RANGE plDG &
- ~'E
^
ST AusE3 MERE PLASTI-GRIP TEr1MINALS
~-
s wtaE RANGE st-so <AE
.s s
%~-
-x s x x s s m g.
_ =m4 g-t Wl/ /
x,..
, y /,
p p/
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_Q W Y/ O r
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s x
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s x x.x m
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r #"M:!M L_ x"s~m~m c
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I WiAERANCE Sf a uPED HERE 5
PibG A-h
\\
'E' 1
s 8UTT SPLICE 8
6
$4tf W
=
h Wire insulation extruced. (Insulation crimo too tignt on PlOG terminals ano sctices) See Paragracn 2.3.1.
Insulation carrei is in firm contact with wire insula-Wrong cet code anc color coce comoination. See
- gion, Figure 1.
,n
, 7,n O2 Correct color code, cot coce, anc tool comoination, minal tongue or schce.
@ Wire size is witnin wire range stamped uncer terminal Como not centered on wire carret. (Terminal was not tongue or on center of solice.
muttee against locator. See i:igure 2).
@ Onmo centerec on were carrel.
h Enc of concuctor is not flusn witn or Sxtending
@ Enc of concuctor is flusn with. or extencs oeyone ceyonc ene of wire carrer. iChecx for cc rect sino enc of terminal wire carret.
h End of concuctor against wire stoo of solice or at h Excessive flasn or extruced insulation. (arong tooi, p
least flusn witn. or extenceo stigntly ceyond were terminai. or solice ecmcination, or camageo cies.;
7 wire insu.ation enterec wire carret.
carrel.
h Wire insulation coes not enter wire carret.
Nacxed or missing cor.cuctor strancs.
8 h No nicuec or missinq conductor strancs.
IS 1261 DAGE4CF3 w
.r,;- s y : i:....w s'I st-sci iN58107 3 3-E ET l
fACCEPT l 0
s Pt0G
'/
-,f STR ATO.TH ER M
",^-
.g TERMIN ALS f dQ' '..
ANCE
$74ygggg(CEA s? AuPEO UN DE A D GUI TONGUE h
PtDG 10
.w..,__ h INSULATION m,
RESTRICTING we 4'qg TERMIN ALS y -
r SP ARE WIRE CAPS QS wi AE B ARREd
.,s 1
O :.;;y V, '
w.'
1
.,, ?.?
~
4
~ ~ 2 01
,/
. /;'
h
/<g
=....,
c.n.t
~
wh.
8 mij i
Qh e---
h Correct color cooe. cet coce, and tool comennation.
h wrong cot code and color code combination. See enart. Figure 1.
h insuiation carrel is in firm contact witn were ensula.@ Terminalinsulation carrelis not :n contact witn wire tion insulation. See Paragraon 2.3.1.
h Eac of conouctor is flus 9 witn end of were carrel onh Enc of conductor is not flusn or extencoc Deyonc S* Ar TO.THE AM terminat. Concuctors may extend end of wire parret. Check 1or cotrect stna lengtn.
siicntiy ceyonc wire carrets on otner terminals.
h Crimo centered on wire carrel.
h Cnmo not centered on wire carrel. (Terminal was no cuttec against locator. See Figure 2.)
@ N: t'ase ce estruced insuistion-
@ Excessive flasn or extruced insutation. (Cnmoed in wrong tool or camaged dies.)
@ v...
s.:e is. inin were range stamoec on terminal h were size is not witnin wire range stamoec on ter-
- -.,e minal tongue.
Q /.s...-,uatioa coes net enter were carrei of terminal h wire insulation enterec wire carrel of terminat er cao
- :4
.h Enc e concu:ter cottornec in cao
@ Enc of concuctor not Octtomed in cao.
h z.,
..ctn o' crimo is over were carrei et cao.
h Part of crimo off ene et wire carrel of cas. (Cao wa no: ottomec in recess of locator). See Figure 4.
f.
h re a.:.ec cr missing c:ncuctor strancs.
h Correct aire size usec.
hicnec or missing concuctor strancs.
h incorrect wire sizes used.
Figure 7 i
DAGE5OFS IS 1261 i3 AGE 7 0 F 8
la.wt DI -
INSTAWCT.cs Ya:NTENAtdCE/INsPEc9eN Sc'EET NOTE: On me PtDG S TRA TO-THERM ter :gr'ai
,,anc m crimcong :oct. It woII ce necessarv to remove the
- "E' 4
- ocator to :nsert gcge in wre cartes c e closure.
//
['
7 Carefully try to insert, witncut fore:ng, the GO memoer. See ~igure 11. Detail A. The GO memeer must pass ccmpletely througn the die closure.
/
(c) Try to insert the NO-GO memcer. The NC-GO
, % Mp c
member may enter partially, but must not pass g g
- g ' q-comcletely tnrcugn the die closure.
- ,,y
)
(e) Insert insulation enmp adjustment ein in the No.1
%'W* % M Oi'!
6 i
position.
ff) Inscect the insulation enmo die closure using the proper plug gage in tne same manner as steps (c) and q -
- /G (c). See cigure 11, Detail B.
(g) Reinstall locator on the PIDG STR A TO-T'-iER M
[c"s
(-)
terminal enmoing tool.
I eu ENEo (h) If both wire barrel and insulation enmo ' tie closures t
AnEA meet the GO NO-GO gage concittons, the cie b
closures may te consicered dimensionalty correct.
g Aguro a (i) If you find that the die closures do not conform with r
tne GO NO-GO gage condi'9ns, contact your local i
AMP field representative.
C, 4.3 LUBRICATION Lubncate all pins, pivot points and bearing surfaces with 1 good grade S. A.E. #20 motor oil as followe 7
SUGGESTED PLUG G AGE DESIGN-WIRE D ARREL CRIMP Tools used in daily production - Lubncate daily oiscLosuas ao e,u, NQo Tects used daily (occasional) - Lubncate weekly ccNaicunarioN - -s cia.
-s cia -
,4 I,
wr, Tools used weekly - Luencate monthly A~
(,8, ciu. r(~i,~
i t_.__._.. o-4 ai ;
w
- a Wipe excess oil from toct, particularfy from crimping
+24N -
area. Oil transferred from the enmoing area ento oiscLosuas cAce wemsen te c;rtain terminations may affect tne electrical charac-root osu s -a* t o w's.-s-cia.
tIristics of an acclication.
GO NMO GO 8
NMO sers.4 59287 2
.t633
.175o
.teso..i.es
.ir..ir5a 6915o.1 4,4 DIE CLOSUREINSPECTION mu.i
,,so i
,$ o i
,,so.. ion i i n seo Each tool is inspected for proper die closure before Figure e pickaging. An :nsoection should be performed penodically to enecx the tool die closure for Excessive wear.
The die closure inspection is accomplisned using GO SUGGESTED PLUG G AGE DESIGN-INSULATION CRIMP l NO-GO plug gages. AMP neither manufactures nor
-G-rem s;its plug gages. Suggested designs and GO NO-GO c,NF
,_t dimensions for the plug gage members are listed in ciu. f
- ~'~ 2
[~-~7.w
\\
Figures 9 and 10. The following procedure is h/
~*"
recommended for inscecting the die closures.
root.
orars s tises cAct utusen tt
- 'ON (O Clran oil or dirt from :ne die closures and plug gage No.
insunnen Astusement oius.-c-mImbers.
" No.1 Punen
' un.)
(b) Close handles of too: until wire barrel dies are bot-GO 3 "040 8 GO I
"0-GU tomed. Do not accly additional pressure to tool hindles.
M M
NM NM
' 7' 59150.t (c) With wire barrei dies bottomed, insoect the wire m S'a ecrrei enmp die closure using the procer plug gage.
]ll oc4Q'Z",C",8,*c3lg,*"* 3*" 3*s
~ uavai-nosin.
o ;ss the scring-loaced locator down and notd gage r
Fiqure to i straignt alignment witn the ole closure.
P AGE G OF 8 iS t261
[A=/Mj it.sTru:ncWM AWTEN ANOUiNsPECTinN SWEET 4.5 CERTi-CRIMP RATCHETINSPECTION 4.6 REPLACEMENT PARTS Tne CERT;-CAIMo ratenet feature on hand too:s it may be a:vanta;e:us to trecx ce-ain reciteear:e snowc be :neexed te maxe cer:ain that the rat: net parts to creent loss Of cr:ce:tien time. cigure :2 i sts tne cu:temee re::a:ea:ie :a-t: tnat can roe cce. not release prernaturely allow:ng dies to c;en i
tetore tney nave fully :ttamec.
zurenased frem AMP in:or; rated. marts ciner inen ta) incrou;;nly clean the bottemmg surf aces of tne dies.
tnose liste: on Figure 12 snouic ce recia:ec by AMP (b) Maxe a test crimo using tne maximum were load, i.e.,
in crocratec : insure arcoer CERTI-CRIMP ratenet a No.10 AWG wire in a 12-10 terminal. When this acjustments.
cnmo is made, scueeze handles until the ratchet is tree, however, 00 NOT RELAX PRESSURE ON For major tool repair servi:e or acjustment. contact your local AMP fiele representative or return the tuni TOOL HANDLES.
to AMP incorporated, Tool Recair Ser'nce,1523 h (c) Bottoming is satisfactory if bottoming surfaces of Fourtn Street. Harnscurg, Pennsylvania 17105, er a the wire barrel enmp dies mane contact with eacn other or if the clearance between the bottoming wholly owned su0siciary ot AMP incorporated.
surraces is.001" or less.
(d) If the.001" snim stock can be inserted completely between the bottoming surfaces of the wire Cartel CrimQ dies. the cies are Considered as not bottoming.
Contact your local AMP fiete representative.
DETAll A DETAIL B INSPECTION OF WIRE BARREL INSPECTION OF INSULATION CRIMPlNG CIES CRIMPtNG DIES I
NoE REMOVE I'*%^
NToR oN g
wine BARREL cEsaoTToMEo 0
0 N
ERW EuTNoTuMQER c
WIRE BAAAEL PRESSURE.
AoJusTMENT PIN cig3 30TTQ4g3 iN No.1 Posmeg.
a "y d lBuT NoTuN:ER g
s 4 e 3.
PREssuAE ll l
.i 805E0 unal "GO" gage tws: pas comoseteev "GO" goes must nous comosessey througn the die clamare tnrough ttie des doeure
!I l
)
edr, - -
"No GO" goes mov enter pertusly, but "NO GO*' gage may enter certieuy, but must not omas comp 6eteey ttwougn the must not pass cornpietety tnrough the che caosure.
ee closure.
C Figure 11 PAGE 7 OF c IS 1251
4 M
INSTR UO"!ONW AINTEP4 AN OE/ INSPECTION Sr4 E ET P
- h. -
l l
~%
\\"
1 x. / /,- D n 3
=
3
, 'R;cx-y
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. IVQ r m //
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g W 'l%>k. '
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ew
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I s
TOOL NUMBERS AND COMPONENT PART NUMBEh5 l
nu oss==R =
orv-3.z3u i
..m.2 i
, so.,
i DE* AIL A I
DETA!' A I
CETAIL A l
CETAll8 1
P'N RETA!NING 2
l 300380 1
300388 1
300358 4
30C386 2
AiNG. RETAIN 6NG 4
l 2104 S 3 1
21045 3 l
21045-3 i
21045 3 l 3 ptN. RETAINING 1
}
3003AS 6
30G389 1
30C389 3X3380 t
4 RING. RETAtNING l2 21045 4 1
21046 4 j
2104S 4 21045 4
+
PIN ASSY.. ADJ.
1 N
303848-2 1
303648-2 l
333848-2 I
LOCATOR. STOP 1
308110 4 306110 4 1
334113 1
3C70* *-1
/
INN 1
5 21C29-7 5-21C28-7 i
5 21C28 7 l
8 ~ 4 SPRfMG 1
7-900E}4 l
7-90083 4 3C3013 l
)
9 SCREW 2*
6008131-4 6
6 008131-4 6-306131-4 1
2 21CO2-5 l
l 3 21924-5 1
10 SCREW 1
=
11 STATICNARY CiE -INSUL 1
306105 2 l
4ss914 1
305539 t
45a714 12 MOVING DIE -INSUL 1
318107 2 i
45888 7 i
305535 l
45886 4 93 l 81N 1
21C28-4 l
21C28-5 1
55433 1
21C2M
- Detzt 8 - Quarittty 1 Rgum 12 l
I t
lk AEL DATE l
REV.DATE l
APPROVALS
]-
pqg QQg
" a.
to-s-sa s o-5 7_ n v
v IS 1261 PAGE 8 OF 8 w
lad INSTRUCTION /M AINTENANCE/ INSPECTION SHEET l$ 1559 E -
N C E : 5 * ' * ' * * ' '* * *' ' ' = * ' O' * * * * * * * * !' 0 "
1.
INTRODUCTION T9s mstruction sneet provices " Instructions" en Fqure 5 lists the numoer of ccts tnat accea
$h c ccuct acphcation and'a "Ma:ntenance anc insce -
emc0ssec en a c ime terminal solice c cac Cosev tne cot coce Cn 'inisnec Crimo 'o insure tha' correr
[3 t:en a ccecure" for; 4y precuct and tool combination was used.
ll NOTE: Dot coce will :rsaccear after neat sealm; j
- H AND CRIMPING TOOL NOS, etnwronmental sealed splices.
?jE E O 46121 MOD. M 47367 MOD. P 48518 MO D. V 75 47304 MOD. L 47387-2 MOD. R 63343 1 w'mE s'ZE RANGE i5 47386 M O D. R 47907 MOD. L 69151 1 MOD. F smoEc. E AE fj 35 47386-2 MOD. T 47907 1 69152-1 MOD. F d
/
n col 0a cccE =ca acc 'No 7 f:: 'o rO
- 2 69163
/
c' -
usTi.onio cacoucis jj ko f,
- n= =ce) P h o W- -...
=t
\\
J i
ji These tools are used to crimp:
- g
\\
- 5 !
+ PIDG* Terminals and Splices on stranded copper msutATioN epwp
/
L'BE' CAO"COOE wire sizes 30 thru 14.
A cJUSTMENT Dins tN CERTI. CRIMP rOmSEALED 9
No 3 8cslT oN I:
+ PIDG Insulation Restncting Nylon Terminals ori mater.ET sauces S, ! y strandec copper wire sizes 26 thru 14 j i, :,
= PIDG Raciation Resistant Terminals and Splices Figure 1 m
on stranded cepper wire si:es 26 thru 14 iii
- PLASTI-GRIP
- Terminals on solid or stranded 2.2 WIRE STRIPPING & CRIMPlNG PROCEDURES copper wire sizes 22 thru 14.
- PLASTI-GRIP Sutt Splices on solid or stranded NOTE: Refer to paragraph 2.3 for insulation crimg cepper were sizes 26 thru 22.
aclustment.
/%
- Pre-Insulated Environmental Sealed Solices on Q
solid or stranded copper wire sizes 24 thru 12.
2.2.1 PIDG & PLASTI-GRIP Terminals and Splices
. Spare Wire Caps on were si:es 22 thru 14 (a) Strip wire to dimension listed in Figure 5.
Do not use wire w@ nicW or missMg 3!E Basic instructions on the use of these tools, wire
<'n conductor strancs.
3 i i, preparation. tool adjustments, etc. are proviced in IIil Section 2, " Instructions" Section 3 features a ter-(b) Open tool crimping jaws by closing the handlas anti j $ 3!
minal, splice ano cao " Crimp inspection" procedure.
CERTI-CRIMP
- ratchet releases. See Figure 1. Note g2l Section 4 contains a " Maintenance and inspection that once ratchet is engaged, handles cannot o-Procedure" which will enaDie you to establish and openec until they are first fully closed.
< 5l 3j maintain a tool certification program.
(c) Place terminal or splice in dies as shown in Figure
- 1 or3.
!hf These instructions may be used for tools not listed in
,=jj Figure 5 but accompanied by this IS. For unlisted NOTE: Apply and maintam pressure against end o-y 5%>
tools. use tne wire strio dimensions given in Figure 5 pre-insulated enwronmental seated solices until step '
llfl for an identical stze tool.
(d)is completed. See Figure 3.
d j[i Toots are coated with preservative to prevent rust and (d) Close handles until terminal or splice is held firmly i r-j
- 2. i ? j corrosion. Wipe this preservative from tools. partic-place. Do not deform terminal or splice wire barrel.
j j]l ularly from crimping areas.
(e) Insert stripped wire into terminal or splice wire barre po as snown in Figure 2 or 3.
INSTRUCTIONS NOTE: Do not allow wire insulation to en*er termina s
d j il 2*
f, j 2.1 COLOR ANO DOT CODING or splice wire barrel.
Y;jj Note that tool label and nandles, also terminal, splice (f) To complete enmp, close nancies unti! CERTI-CRIMF and ca;: nsulation are color coced for a given wire rat; net releases. Handles will cpen automatically an.
p;
- 3;,
range as listed in rigure 5. Crimo the color coded enmped item may be removed.
q {;
terminal splice or cap m tne matening color coded To enmo ctner natt of splice, remove it anc recesltior
( )
- 00' unenmced nalf in tect as shewn in rigure 3. :oilos For exam::le. Onmo yellow coced PIDG terminals and same crocecure used to enmp first natf cf scisce. t solices and red cocec pre-insuiated sealec splices in splice cannot be turned. turn tool around.
'~
tool No. 46121 Mod. M (Handles color coced red and in) Refer to Section 3 and Figures 6 anc 7 for terminal c yellow). See Figure 5.
splice enm;: inspection procedure.
N*U AMP In::orco 'ted. Harriseurg. Pa.17105. U.S. A.
+., e, _,... 2.... :., m,. e
JAmP!
issravericNata NTENANcE.insaE:rico. s 4EET 2.2.2 Prdnsulated Environm:ntal S:alzd splices p:DG & PLASTI Grip TERMIN ALS ta) Trermal stric wire to Olmensic~s listec in Figure D.
E 9
NOTE. Inermal stricptng eilminates the pos3IbtliiY O' p1CG 1NsuL Anon nicks anC s:tatches on Insulation at:C wire strands.
~
rs=usNAL
il""'~'E'U" R E'*" ~*
thereby ensunng a reliacle mctsture croc! seat wnen
...c
_- - ~
solace is near sealec on wire.
0 E
Ibi Aefer to I.S. 375 I;:ackage: witn s::lices) for furtner i
s Ecv4Ls v.i=E s Aaar
~
ure cre::arat.cn anc neat seal ;;rceetures.
s,tAsn.c mie
- EcuA.s Nsuia-NisAmaE,.
NOTE. Set Insulation Cnmp a:iustment pins at Nc. 3 TEnMiNAL l
^'
- osition when crimping all si
- es of sealea splices
\\,
that will be heat seale:.
.n
"{BAmm Set insulation cnmp adjustment pins as directed in I b.,.
s,,
i, h._.
paragrach 2.3.1 (FIDG TERMINALS AND SFLICES) i tu 3 l
pw..'t.,.y mie
. j.n w9en enmoing sealec splices that will not be heat AGAiNs*
e L::Arca g
1, g y.
i, sealed.
1 a
(c) Cnmo solices as instructec in steps (bl tnru (g) in
/
yj
/
1 E* 3 08 %iaE CON:uC? 2
'//
paragrach 2.7.1.
5 (d) Refer to Section 3 and Figure 7 for splice enmp
,'jc c inspection procedure.
'N Figure 2 2.2.3 Spare Wire Caps (a) Stno wire 'o dimensions listec in Figure 5.
- #'# 3'#E BUTT SPLICES s t uA sunE 3 Ann!.
conductor strands.
wtN
'N IN:ENT
-C' i_ _"3;,
g g
g
- msutarct, i
matening color codec tect. Refer to paragracn 2.1
'- M LL-g-?W!j_ l ar.d Figure 5.
ENvinoNutNrAL i-SEALED splice ' _.
0-
-e-wiaE'sTeo (b) Place tool insulation adjustment pins in the No. ",
- wiNccW IN ENT position.
f f' @[
(c) Close tool handies unti! cnmoing jaws partially close.
,,co L kyj. _-
,.@ =:e=
J,,
but leave enough space for cap to be inserted WimEs'c' between dies.
~C". ~8'
. wmCCW INCEN?
(c) Raise locator so that en of cap rests against the
/,
recessed curface of the lccator as shown in Figure 4
- E..r- -.?.' C'
.s. _ -
FIRST CRIM P PLA573-GP
3 SP ARE WlRE CAPS
.CCATC A sE ATs IN v.i E si p W'NOCW INCEN T CF EF' tC A inggg;7 cy
/
.AOJusIVENT
/
//
- - /
g T
==
orNS.N NO 3
. %,Y',
j
~
3 PC s;7;CN
!S
- /
f, h i
se ' '.
.a6
- jf i b_
NI I
.-4 f
g.
' h
sc.C 6;
wioE E A A*EL I
-j b t
.h)
LCCA?CD E
/
1, N n
/
AsA A-g 4
EN:c=wi=E::.:v ca
-. _,p, o:EaNsutATE l
'l1
- s. s:GA.Ns?sh c!
...:E si::
55AL E3 SPLICES ON.O A8 sty D A'S E LCCA*: A so W_I
\\
DE E S sLD E T*A?EN:CF CA8 1
SECOND CRIMP AG A6Ns? ENC EEsIs AGAlNs* #E.
CEssE su s ACECr
." : -g WI AE CONCUC*Oc a
Eo7 0MsIN L-=g g EN::F wine P.Cu T0r 1.0:Atem CA8 96-*s AGAINs?
5 8.' 1 #:Es!O2
[
/,
b 3.-. /
rei C::se nancies ;ntil:
s neid 'rm', in ;;iaca. Oc -Ot
~~(N.
i-M.y 09'Orm 03: wtre carrei M'e ".. lap
=
/
Ifl Insert striO :ec wife intO Cat untP Nire CCt! Cms.
g.
,! c., O
,/
(g) *dcid wire in 00$1 tion anc COmCiete Ofir": by ::031c;
\\
('/
K [}> -
\\
rancies urtil CE 71-CFivo eat: ret re' esses -ane:es
=E a su.4*E:
wi!! ccen automatically ar c.c :ec ca: r ay te
.0:A*C8 SEA's'N I. I ' ,I U,3,-
n, Fefer :o Se:nen 3 anc F ;ure 7 for scare W.re :a:
II rem 0vec p':' jam:EN:t
- i h 3,g AG' ' E* EN Crir insceC;10t DrCCtCure.
Figure 3
- :n
- AOE : ::-
^=
-- = =--
n-.
2.3 INSUuATION CRIMP ADJUSTMENTS 2.0.2 PLASTI-GR!P Termina!; and Spli:es 2.3.1 Pf DG Terminals and Splices NOTE: PLASTI-GR:P ter.~:inals an: solices feature i.
NOTE. P!DG terminais and sol:ces testure a were ware "onsulat:cn su:Dcr "cnly.
"insu.ation gr c" fa) Set adjustment ens in pcsition NO. 3 for wire navir; Tne nsulation enmoing section of the nand tooi nas a large insulation ciameter.
tnreE cositions:1
. Tight. 2 - Mecium,3 - Loose.
(0) Set adjustment ; ns in sosition No. 2 for wire navin; fat insert msu!ation Crimo acjustment pins in NO. 3 posi-a mecium insu ation diameter.
tien. See Figure 1 or 3.
(c) Set a:justment pins in 00siSon No.1 for wire navm:
- b) Diace terminat or s
- tice in enmping jaws as snown m a small msulation clameter.
Figure 2 or 3.
Wnen making an adjustment, make certain tnat 00t (c) insert UNSTRIPoED wire into ONLY the insuiation insulation crimp adjustment pins are in tne samt barrel (see Figure 2 or 3) portien of the terminal er position.
- splice.
Terminal or splice insulati:n should ideally be it (d) Make a test crimp (Paragraph 2.2.1). Remove enmoed contact with wire insulation.
terminal or splice and check insulation grip as
' follows: Bend the wire back anc forth once. Terrninal 3.
CRIM P INSPECTION or splice should retain gr:p on wire insulation.
Inspect crimped terminals and splices by ene: kin; (e) If wire pulls out, set insulation crimp adjustment pins the features described in Figures 6 and 7.
in next tignter position (No. 2).
Use only the terminals anc' splices that meet th4 (f) Mane test crimp and repeat adjustment as necessary conditions snown in " ACCEPT" column.
until desired insu!ation grip is catained. Do not use
" REJECT" terminals and splices can ce avoice; a tighter setting than required.
through careful use of instructions in Section 2. am Alweys make certain that both insulation crimp by performing regular tool maintenance as instructe<
adjustment pins are in the same position.
n Section 4.
PLASTI. GRIP SP ARE WIRE OAP PiDG BUTT CPUCE PRE. INSULATED ENVIRON MENT AL TERMINAL
"[-
- Q'["J - y sTAI AE oN SEALED SPUCE N'
R A Oi ATtCN mEsisTANT %QJ s
n
~
x.
TR ALS
.g
/'
RESTRC NG color C00E0 N
M.I
['
m SEAL UNERS 7
d
'?I COLCA Nj f
PLASTI-GRIP CcioA Sim8E BUTT SPUCE cro AADIATicN mEs'sTANT TOOL WIRE STRIP LENGTH
' ~
Took No. AND WlRE Color PRODUCT pro 00CT TER MtN ALs l
SPUOES DESCRIPfloN RANGE AND007 INsuLATloN CCLom CODE CODE MIN.
MAX.
MIN.
l MAX.
2fA2 PID3 63163t sHO AT M OL.
30 26 NoNE TEAMS. & sPUCES g
46121 AED gogg ggg' McD. M ANG PiOG TERMS. sPUCEs 48518 YELLOW AND PLAST 4mp YERow
$132" 3M6" 57 3M 6" sMoATMOL.
26-22 gg-* SPLIOES MCO V CNEOCT 7g,$0 sMc AT M OL.
YELLOW g3 o
479C7 BLUE AND piDG TERMINALS & SPLICES NATURAL COLOR TRANSLUOENT I'
sMcMMA W MITE P!DG AAoiATioN RESISTANT (R AOIATION RESl$7 ANT H As 3116" )
"'32" 13/64" 13/64-j Mc3 L 24 20 Two Dois TERMINALS & sPUCES wMITE STAl#E) l 47907 1 LoNG MDL.
am6 M
ggyg ggg Moc. A AED Slog
( A ACIATioN RESISTANT -
am62 AE, TEAMS & SPLIOES NATuPAL CoLoA TRANSLUCENT VCU T swo AT M *"'-
- -16 oNE-T g oLASTi-G Ai' Ws RED sTAtPO 694 M T gogg,gg.
pg3
2016 MO BLUE 13,64' 15 v
'na" 3 32-
'?387-2
'6-14 BLUE AND PIOo A A DI A* ION (P ADIATION AEsiSTANT -
5,3p7 wgg' MO3 A 20 *$ M3 GAEEN DESIST ANT TE DVIN ALs NATURAL COLop TR ANsiuCENT N S UOES g,g;;g $7,iop 5['/ LONG Mot.
Two Octs I
- s3d r Ga
?s-14 BLut
{,n g pp t T.;* es#ai.on s,.::c ter ones witn ta n *ainnseatien a
Figure 5 [ Cont]
- S*sgo D t-3 E 3 0 '
b INST R u CTIO N/ M AI NT E N A NC Eil NSP E CTI C N sn E E 7 (Crnt. Figure 5)
TOOL wims STRIP LENGTH INsUL TOOL No. AND WIR E COLom pRoCUCT PRC M DESCRIPTION slZE AN0 00T INSULATION COLOR CoCE R
E MIN.
MAX.
M OM
- # #0*NO 26
.C26-CS$
a s-C RT HOL MCO V ygg;gw 3f;g-7,37 47:04*
24
.C31..Cs3 CNE007 YELLOW WiBLUE SANC SMcRTMOL MCO:.
YE W
6, 4
LCNG MOL 22
.038 110 REDWsGREEN SANO g
y sMORT HOL 2C
.046.110 OWs E08AND y
oNE T E R NG 69151 1f (ToCL No. 69151-1 MCO P NYLCN LoNG MOL.
18
.0561 t 0 Rht'AW SW Moo. P is CCOED R EO ONLY)
TERMINALS
,f, 973 7 7
LONG MCL 16
.C63.130 BWE WIRuE BAND 4 72 sHORT HCL g
GREE 69153 17 14
.075.130
^"
LONG MCL TWO OCTs WC0 F f Tignt msweation sucocri for aire witn tnin wall moulation.
TCol WIRE STRIP LENGTH Tu!L No. AND W:RE COLOR SEAL UNER PRODUCT PO DEsCRIPT1CN MANGE AND 007 CoLCR CoOE INsuLATt0N COLCR CCCE MIN.
MAX.
CCOE M
M REDANC RED 262o istu-13r54-YEtteW
~
s CRT MOL oNEOCT 9cg y
'N7 8LUE AND PRE-INsutATED sMORT MCL~
MCC L WHITE BLUE ENVIRCNMENTAL BLUE 15164*
17i64*
, ' ~
20 16 s!ALED SPUCEs 47207-1 LONG MOL '
TWO 00Ts
[C LCNG MOL.
YELLCW AN0' gg AIU 114" 9,3r 14-12 sHO RT HCL oNECCT l
ne,
TOOL wire STRIP LENGTH TCCL NO. AND vnRE COLOR PROCUCT PRODUCT DEsORIPTioN RANGE AND 00f IMOULATioN CCLoA Co0E 4726 YELLOW
'ONO "c
MCC R.
ANO SPARE WtRE CAP 47326 2 EO No. 3M sHCRT MC,*
MOS T oNE007
$ fi g-93f3--
4737 BLUE LCNG %..
MCO P ANO SPARE WIRE CAP BLUE 47M?-2 GREEN No. M s*0RT MOL-V00 a 2 OC's Figure 5 4.
MAINTENANCE / INSPECTION PROCEDURE All tools are inscected before packaging. Since there AMP reCammends that a maintenancelinspection is a possibility of tool damage in snipment, new tools program be performed periodically to ensure depend.
should be inspected in accordance witn Section 4 acie 'and uniform terminations. Tocis should be when received in your plant. Due to tne precision inscected at least once a month. Frequency of design. itis imacetant that no parts c/ these tools ce inscectiCn may be adjusted to suit your recuire.
Interchangec excoat those rectacement carts listed ments tnr ugn ex:errence. Frequency of inspect;:n in Figure 72.
is decencent u=Cn:
- 1. Tne Cara, amount of use, acc hano'ing of the teol.
4.1 CLEANING
- 2. The ty e and si:e of trae prCcucts crimped.
The too! snould Oe immersed inancies pa~ially
- 3. The degree of oceratCr skill.
Closed) in cegreasing Comocund t0 remove acc.,-
.t. The presence of acnormal amounts of cust and mulatec cart, grease and fcreign matter, a t rt.
NOTE: Make certain the cegressing compound coes
- 5. Ycur cW~ establisned standards, not attack pasi't or a:astic materrats.
.;:. s = :-
g, A OCT OCCE d 03. 2 OC'Ss MUST AP3EA A RIJECI
- ,~~'
I
- ON A'.L CP!MPEO l'" EMS 7
M m
W
.T.m Il p,f r, f
QV
,& o
~w v.
y u
}.-
W f
n k
[
4 D
4(ee l
~
\\
\\ vi N[
~
iNNk
.. L ~ -.-~..
PIDG &
PLASTI. GRIP g _-
,_s_
-s xx TERMIN ALS
_% g f f f7q g, % -v - e x x
.s s
--L 1i- !
~
i
~
~ ~
~~
(
p,2W/
/A YD 2;;;=
>Gid
.fN ?/ A YD
\\ '\\
,\\
\\
O y
N
\\
\\
a i
W-rq e
3 y
3^
,{
~
.. =
~^~~ -
^
._m r
m c
x
_x x
_ x x x
x x Q ('
r-_
S v///////n, L
n '
l' )
>=4 f 7/////// A y x x j
m h
PIDG BUTT SPLICES s
5
?a g
f(
1 4
g 2
4 wiaE M
5 "N s'-
sica
@ Wire insulation extruced. Onsulation crime too tign on PIDG terminals and solices) See Paragraph 2.3.1.
@ insulation barret is in firm contact witn wire insulation.
@ Wrong det code and colorcoce combination.See Figure 5.
@ Correct color coce cot code. and tool ecmbination.
@ Wire size is not within wire range stamped on terminal
@ Wire size is within wire range stameed uncer terminal tongue or solice.
tongue or on center of solice.
@ Crimp not centered on wi e carrel. (Terminal was ner
@ Cnma centerec on wire carrel.
Duttec against locater. See Figure 2).
@ End of ecnouctor is flusn with, or extenes beyonc end of
@ Enc of conductor is not flush with or exteacing ceycnc te'minai wire carret.
enc of wire carrel. (Cheen for correct stric len;th.)
Enc of conductor against wire s:co of solice. or at least
@ Excessive flasn or extrucec insuiatio9. Iwrcr g tool. ter-
@ f ausn with, of extenced slightly beyonc wire Carrel, minal, or splice ComDination. cr cama;ec cies.)
(.
h Wire insulation coes not enter were carrel, h Wire insulation entered were Carrel.
@ No nicked or missing concuctor strands.
@ Nicnec or missing conductor strancs, Figure 6 is "f;
I
'NST AUCTICNIM AiNT EW AN0EliNSDE CT'ON Sac ET
[
A DOT CODE M OR 2 DOTS) MUST A APEAR REJECT l AOCIEY !
Cr4 ALL CRIMDED ITEMS l
%' 4 D, A/F' E
,@g
'~.
m l,2 i
i t 'C
^
,,/D OVW. Lc x
4 i
0-4 x
u Npp
'y x@
h h
/
PLASTI GRIP hh BUTT SPLICE r
/
Q
- w.,
x
.,2.--
~-
7 t===5 k g !
2.. ~ ' EE"E_
N wtaE a
[f
[
PRE-INSULATED ENVIRONMENTAL fg '[
i SEALED SPLICES x
4 h&
~4 5
g J }/
C,.
s G---
"~
i l.
_ _.__= _ _.. :=_ M:--
I s.-
I s 1 L,'
m _-_
=u t
WIRI SToP N
8
(
O7 6
SP ARE WIRE CAPS
(*
4
__ /
g c.
-_ M M 3
i m
4 u "\\*"
'- ~G2 j
,g
@ Wrong ser.1 liner and teot color coce combinaticn. (Pre.
insulatec Environmental Sealed Solices) See Figure 5.
Correct seal liner anc tect color code combinations (Pre-insuiatec Environmental Seaiec Soiice.)
h Ex:essive flasn or extruded insulation. (Cr'mped in wrong tool.) Also. che:k for camaged cies.
h No flash orextruded insulation.
h Correct c0 lor code, det code, and toof combination. Oct h Wrong cet cooe and color coce combination. See Figure 5.
Cocing cis&Deears on sealed splices when they are heat incorrect wife slZe Usec.
sealed.
h Co* rect wire size used, h Wire insulation enterec wire barrel.
h Wire insulat;on coes not enter wire barrel of splice.
@ End of concuctor is not flusn with or extending beyond end of wire barrel. (Check strip length.)
End of coricuctor against wire stc; of SDitCe Or at least flusn with. or extenceo siigntly beyond wire carrel.
h Enc of conductor not bottomed in cap.
h Enc of cencuctor eettemec in ca.
[ wait of crimo off ene of wire barrel (Ca:
was not c:t-tomec in recess of locator.)
h Full wioth of crimp is over wire carrel.
Nicked or missing cc,ndt: tor strancs.
@ No nr xec or missing conductcr strancs.
h Crimp not centered on were Darrel. (Toot locator not seated in window incent of s sce.
h Crimo centerec on wire barrel.
9 Sch:e insalat on is in contr.et wit" wire insulatien.
@ Solice insulation is ret in conta:t witn wire insulatic -
- w.
- Teo v.u.sTa m :E ms==: m.sasz-i.er*.
Femove ramaining egreising compound with a ! int l SUGGESTED PLUG G AGE DESIGN.W;RE Er.RRtil CRir/P "eo cicin. W. en degreasin; com cunes us not i
wo-acaiiatie. teci may De wi;;ec clean with a lint fraa
- = ~ ^sumi coow.
r 6
00N'GU""0'
-+5"
24
!:in. Re'ueneste toc!, as instructed in ::aragraon
.: 2 cef cre pla::ng it tack in serv!:e.
r ci v - --
Cr Z. ^.,
o e
4.2 VISU AL !NSPECTION z,s
<at ins:sct trie tool f 0r missing pa ts or re*ainirg r'ngs. If Carts are missing or cefective, efer to Figure 12 for CiE CLOSURE GAGE VEYBEnt-r u s.-A
- m -s7A.
Customer replaceable parts.
\\0g~
G3 I " U'G U l GO (c) Inspa:t tne die clesure surfaces for flattened, Droken 46123 voo v aso l n 1 : m ossa l Mas.
or entpped conditions. Although dies may gage 473c4 u co t as:a i un jom eesal m,
within permissible limits, worn or damaged die 4:3s6 900 m l
1:n i ns: ; c9cm31 na u closure surfaces are objectionable and can affect the
! M9c l ns: ! en asim45-473ss.2 ue: 7 cuality of the Onmp. Examples of possible damaged 473a m co a e
u 9e I 2s: : n w n n I 1249,:
die closure surfaces are shown in Figure 8.
473si 2 Mco =
l
.t'90 t
tm l 90 n n
- s, -
479c7 Moo L I
o890 09sC l 390- :s23 094b 0-479C7.1 l
059o 0950 t OEL Ca;3, ag4;.,-
h 43518 M 00.v
.063:
.:sn i ML D6:3 l osak >
68343-1 M19e i
1:5C ! n 93 u S3 l.1249
- j p 6915t.1 MCO 7 1:}3 i
1150 1 100 t M } 114e '
/
69152-1 Moo F
.1000 1263 }
- 00-!2:3 6 1259 9
}
691E3 l
0630 0690 i os3 - 0533.o629-o t ole CICsure Q mensices 3; ply ween wire t aiei sa*: Bet 0210
/
Dut not uncor pressue
/
?? Mate.nal - Tool stees Figure 9 s
SUGGESTED PLUG G AGE DESIGN-INSULATION CRIMP ott closure Go dim.
CONFIGURATION
=*==o="c" "G
.e-4
(
-r oiu - ----
- g (j
p 4
25c rYo -* - as-
~
ott CLCsuRE DIM's. 4** (set G AGE MEM8ER *?
W1oTM Tool Insulation Adjustment GtM's. -G*
"W" Figure a u o.
p,,,, se, pe,,ien,
,u....
4.3 LUBRICATION I
co i No-co i co i No.co Lubncate all pins, pivot points and bearing surfaces 46121 Mco u l es:o esoo i e m e r si e499.:soci
.23 with a good grade S.'A.E. #20 motor oil as follows:
473c4 voo L i :30c csoc t : soc-c3:3 c499. :sa
- s Tools used in daily production - Lubricate daily 473se veo a i cac I esoo 0300 cr31399. csocl 2
Tools used daily (occasional) - Lubricate weekly 473e6-2 Moo T re i esoo osoo. cr31.:499. : soc i 12 Tools used weekly - Lubricate monthly usa 7 woo a saco ceco i c400 04:31 es99. asoci 9
Wipe excess oil from tool, Darticularly from crimping 473s7 2pco a i c.40c
.osco c4ao.u:3Lesn. ceco 9
area. Oil transferred from the crimpinn area onto 479c7 9co. L i 03:c I esso c30c cssai c499. s::i
.9 certain terminations may affect the electncal 479 era l c3co
- soo
- soc-:3ni een esoci 99 charactenstics of an application.
4sste uco. v i 03:n osco c30c. :30313499. :s= l
.25 5a3431
!- :72c l os2a cr2o-: m ie919.:s2:
. tar C"CC3!'*C*
,' C 4.4 DIE CLOSURE INSPECTION
- i' 0 " "C3
- I C3" i
C5 69152a voo e 1 0400
- 60c c4co-c4:31 es99-osoc !
9 Each tool is inspected for proper die c!csure before
"' 53 C' 'o 034c
- s o c143: :=9. :34:t es packaging. An inspection snould be performed penodically to check the tool die closure for exces-t Cie ciosure emns.ess a.ca. men.<e car. ia*:
'""S***
Sut * """r ensure sive wear.
?? vaienai tw see -
Fi "" '0 9
NOTE: The following plug gaging information for insulation crimD die Closures is proVided for cus-listec In Figures g and 10. The following pro ect tomers sDeCIfically requiring this information if Clug is recommenced f or tnsce: ting the cie closures.
gaging is not recuired. inspect the die closures using
{a) Clean oil or dert from tne c\\e c\\csures anc piug ga; an alternate procedure, i.e., performing the " Insula
- memoers.
IIc.' Crimp Aojustment" (see para. 2.31 and " Visual (D) Remove tocator assemtfy.
Inspet.. Hon"(see para. 4.2 ).
NOTE: 00 not lose scring on locator assembly.
The die dsure inspection is accomplished using (c) Close handles of tool until wire carret ent eng ja GO NO-GO plug gages. AMP neither manufactures are bottomed. Do not apply accitional ::resJure nor sells plug gages. Suggestec designs and GO tool nancies.
NO-GO dimensions for the clug gage memcers are m
fMk inst AucTioNiv AINTEN ANcs/IN",*E TicN s-as ET (d) Witn wire carrei crimping jaws bottomac, chtek the 4.5 CERTI CRIMP RATCHET INSPECTION wire carrel crimp die closure using the procer plug Check the CERTI-CRivP ratenet to ensure tnat gage. Hold gage in straignt alignment with tne cie ratenet does not release prematurely. allowing jaws 10sure anc carefully try te insert, without forcing, to cpen oefore they have fully Octtomed.
tne GO memoer. See Figure 11, cetail A. The GO To eneck ratenet feature:
member must pass complete!y througn the die (a) Tnoroughly clean bottoming su*tates of jaws.
closure.
(b) Mase a test enmp using tne maumu n wire ca.:. i.e..
<en Try to insert the NO-GO rnember. Tne N O-G O a No.16 AWG wire in a 22-16 terminal. When tnis member may e9ter partiaily. but must not pass crimp i mace, s:;ueeze handles until ratenet is free.
completely tnrough the wire carrel enmp die closure.
however, D0 NOT RELAX PRESSURE ON TOOL (f) Reinstall locator assembly.
HANDLES.
(g) Insert tool insulation adjustment pins in the No.1 (c) Bottoming is satisfactory if bottoming surfaces of position.
dies make contact with each otner or if clearance (h) Wath wire barrel crimoing jaws bottomed and adjust-between bottoming surfaces is.001" or less.
ment pins in No.1 position, check the insulation (d) If the.001" shim stock can ce inserted completely crimo die closure usi9g the proper plug gage in the between bottoming surfaces of dies, cies are con.
same manner as steps (d) anc (e). See Figure 11.
sidered as not bottoming. Contact your local AMP detail 8.
field representative.
NOTE: Due to the scissors action of the crimping laws, tne opening of the msulation crimp closure is 4.6 REPLACEMENT PARTS slightly smaller at the back than it is in front. There-It may be advantageous to sto:k certain repla:eatie fore, if the NO GO gage does not enter the back of parts to prevent less of production time. Figure 12 closure but does partially enter front of closure, the lists the customer replaceable parts that can be closure is considered dimensionally correct, purchased from AMP inccrporated. Parts other than (i) If bott wire barrel and insulation crimp die closures those listed on Figure 12 must be replaced by AMP meet the GO NO GO gage conditions, the die incorporated to ensure proper CERTI-CRIMP ratchet cicsures may be considerec dimensionally correct.
adjustment. For tool repair service or CERTI-CRIMP (j) If you find that the die closures ce not conform with ratchet adjustment, too! should be returned to AMP the GO NO-GO gage conditions contact your local Incorporated, Tool Repair Service.1523 N. Fourth AMP field representative.
Street, Harrisburg, Pennsylvania 17105, or a whcily owned suosidiary of AMP incorocrated.
./
DETAIL A DETAIL B INSPECTION OF WIRE B ARREL INSPECTION OF INSULATION CRIMPING DIES WITH PLUG G AGE CRIMPING DIESWITH PLUG GAGE O
O o
O 0%
h A CJus? MENT PtNs OlA k
iN No 1 Pos: Tion
%)
/
O e
M
(-
Dl wl AE BAR A EL j
J AWs BOTTouto 5
N ButNotuNCEA PRESsVAE "GO" member must pass I
)
completely through the
_%pg[
die closure.
f 7
\\
"NO.GO" member mey enter (g
\\
partialiy, but must not pass k
j
]--
l
_ l comoletely through the die
\\ = V&
Vf closure.
17 j'
-~sL c ; -.....
_AM ins- = u en c u.14. N T E N A Nc E ws= E -* cN s-E E-I DETAIL A
%v.
g anemoy A'
- taama, 9" S-C=T wANOLE.
2..
r,S-cat *. ANDLEi r
NG a4N0i!
m.Os 3., A N OLE
?
6 _ @s j
7x:.
j.
@@8 4 p p g e i
17
. + -
n
. M N.~ h s M.7%
i' DETAIL B m (
%s,., 'l h[h.
1 vd V
a 8
't
?
DETA L m i,.
w
/ I i
6 ';;a4
@h 8
8 TOOL NUMBERS. DETAIL REF.. AND COMDONENT PART NuMsERS 6121 MOD. M 47334 MOD. L 47306 MCD. R 47386 2 MOD. T 47387 MOD. P } 47037 2 MOD. R ITEM DESCRIPTION DETAIL A DET AIL 8 DETAIL A DETAIL A DETAIL A i
OETAll A LONG H AN3LE SHORT H ANDLE LONG HANDLE SHORT H ANDLE LONG HANDLE ' SHORT *. AND' E 1
RING AETAINING 21G45-3 l
21C45 3 21C45 3 l 21C45-3 l
2*:45 3 l 2 :. -?
L 2
- IN. RETAINING 300432 l
300432 3004:2 1
300432 l
20C4:2 1
E 4";
DIN. ACJ.
39237 392C7 39207 1
392;7 l
33207 l
2T.
j SPRING 39364 33364
}
39364 l
29M4 1
3W j
a 5
COLLAR 39366 1
09366 l
39366 39366 1
3936e j
6 RING. RETAINING 210454 l 21045-6 I
21045-6 21045-6 1
21045-6 l
300449 l
30C449 i
die 1
7 PtN. RETAINING 300449
)
300449 l
300449 i
~
I e
SCAEW 3-306105-9 l
3-21016-4 i
S 3059;7 1 I
9 3079:71 l 9 30592*'
- l
..'N'-
'd j
}
09193-l 9
Sup* ORT 302755 6
6
[
6 10 l
STOP l
- tSG. LOCATOR 3C2994 l
3:2994 a
3C2994 i
3C29,4 l
- 2Mi
'1 12 I
SPetNG
_ 301201 I
n120*
l 30* C' l
3:120*
I 3 *
- 2h 13 6
iCCATOA
- 304052 6 I 200%J I
32'M; i
45%!a l
48 -
TOOL NUMBERS. DETAIL REF.. AND COMPONENT PART NUMBERS ITEM DESCRIPTION 47907 MOD. L 47907 1
' 48518 MOD. V 69151 1 MOD. F ; 69152 ' ' MOD. F i 69163 G.;10 s DETAll A DETAfL A DETAIL A DETAIL A !
DETAIL A DETAIL A DETAc. A SHORT HANDLE LONG HANDLEI SNORT HANDLE' LONG MANDLE l LONG HANDLE.SHORT H ANDLE LONG MANOLE 1
GING. AETAINING -1 21045-3 t
21045 3 1 21Cd5 3 21045 3 21045 3 e 2W53
- 'Q,,
2 PIN AETAINING t 300432 1
300432 300432 3 0432 300432 W 412 N'-
3 i
PIN. ACJ.
39207 39207 39207 39207 39207 V'
?Y1, 4
I SPAING I
39 A4 6
39364
.39364 33364 0754 39366 29356 3M66
?M5+
0-39386 l
5 i
CO6LAR I
39306 2 t C4 S-6 21045-6 21^4 M 2' 04 M U *- M i-6 A'NG. RET AINING I 210454 t
2104 S<5 i
i l
7 P'N. RETAINING I 300449 1
300449 300449 J00449 300449 30044*
- " 84'*
' 300927 1 3-30e.C54
'*3'f2;
l 8
SOPEW t
6-305927-1 1 9 305927 1 1
3 E6105 9 9-305927 1 s-(
i 9
l
$UcpORT d
i l
l 10 l
STop 6
4
'* ' L
%2994 302994 Y2994 l
11 aSG LOCATO2 1 302994 6
3C2994 3:2994 301201 i
3:1:01 3:1n1 r1=*
12 So=>NG 30120i I
301201
+
I 13 LOCATOR I
3:3542 i
073542 e
3 3*,4052-6 3:2993 45M54
>3340*2 ?
4*"*>
Figure 12 N--
R EL. D ATE REV,DATE l
APPROVALS 12 56 8 77 p Qg,
/
/
w INSTRUCTION /M/-,1NTENANCE/'NSPECTICN SHEET
$ M96 n _::_n
- 1. INTRODUCTION
( '8 C ""' 23 5"PP'Y ## FC'2 0*f C *I-f (I) A '"* E"*"O*i I*
' ** "" d ' O I 5 25'd* #1 5' I.!i T!us u struenon sheet is intended to provide you with handles until dies bottom.
!! E "Instruenons" on product application and a "Mamtenance (t) Tighten both die holding screws whi'e die are bottomed.
- nd Inspcenon Procedure for the following interchange-E"
l $ Te able enmping dies:
(h) Toolis now ready for ope = tion.
4 F.t'
!MPORTANT: CHECK DIE ALIGNMENT AND TIGHT-
-)I SERIES ENC AND TNC DUA', CRtMP
.EN DIE HOLDING SCREWS AT LE.\\ST TWICE DAILY.
?
CONNECTOR CRIMPtNG OIES
- j j (FOR USE IN HAND TOOL NO.69710 ijj O A PNEUMATIC TOOL NO. E9365) l}l 60664.1 80726 220034 1 E5 69669 2 69727 220067 1 21 220026-1 220088-1 MOVING
-jj
'~
DIE 3x i{
First read instructions shipped with tools for information y' /
i-concernmg enmping procedure and general tool usage.
4 v-
)
N
,h Then refer to selection chart shipped with connectors for 3?
proper connectors, cables, and cable senp lengths to use.
E*
Basic instructions on the use of these dies are provided in
{'O
}!
[ -vQ #j
'j N
j_ }
Section 2,"Instruenons." Section 3 contains "Mainter.ance j
p
';;i and Inspection Procedure" which will enable ycu to 3
t4 3 V establish and maintain a die certificerion program.
O TIGHTEN OtE Hot. DING -
SCREWS WHILE DIES
- 2. INSTRUCTIONS 2.1 DIE INSTALLATION AND CRIMPING PROCEDURE L.
.~
. ARE BOTTOMED (a) Shut off air supply for pneumatic tool.
- : STATIONARY DIE (b) Each set of dies consists of a moving die and a stationary die.See Figure 1.
,,,., y,
y7 p
,;=!
(c) Position stationary die in stationary die holder. Take up Figure 2 g,4 f !
on die holding screw enough to hold die in place. Do not 5o tighten screw.
2.2 CENTER CONTACT CRIMPING
- 55:I (d) Position moving die in movinC die holder. Take up on die (a) The die assemblies have two sets of c-imping dies as shown jg$E holding screw enough to hold die in place. Do not tighten in Figure 1. One set enmps the center contact; the other
- <<J
- screw, set enmps the braid ferrule.
Ill (b) Slip ferrule on cable, then strip cable and flare braid as shown on instructions packaged with connectors.
j g; 2,. :.:.--.....-..
..-._m.-,,...;,..
(c) Place the Jack or plug center contact, assembled on the sg st.-ipped conductor,in enmping dies as shown in Figure 3.
- E s(,
015
[a hcl. DING C
^
m 3
SCREWS _
' ~.a.;..;
'.';.., Jf.
h I
3 t
53
. BRAID FERRut.E.
.s CRIMP I.
jRji
- A f %.
~ ' '
,2 i:4 s.f
, I2 3 o
- STATIONARY.
~
l
~
s a
tUEf
' DIE
+
\\-
5 Q
. - ne -. -
lpg5
' ' '.=
iyj$
TIP OF CONTACT 80TTOMS iN
%gg ]
_j ajg l
l MOVING OIE I
cj MOVING
/
l 03[
otE
/
i q
i CENTER CONTA" C"UM8
-l f
s,
.e tes C-'-[b Figure 1 Figure 3
,.a...,. ce.w p mcoeuarse.a AMP incorporated, Harrisburg, Pa., U.S.A.
PAGE 1 CF 6
Ni t NsT R u cTi o N/M A I NT E N A N C E/I NSFE CT r o N SH E ET (d) Make certain that plug or jack center contact is bottomed We recommend an initial frequency of inspection of once a month. This frequency may be adjusted to suit your re-in enmptng die, (et Hold ecble in place and press tngger or close tool handles qmrernents through expenence. The frequency of an in-to complete enmp.
spection is dependent upon:
(f) Remove enmped contact from dies.
- 1. The care, amount of use, and handling of the dies.
2.3 FERRULE CRIMPlNG
- 2. The type and sine of the products enmped.
(a) Insert enmped center contact into connector body until
- 3. The cegree of operator skin.
dielectric ori cable butts against dielectne inside body.
- 4. The presence of abnormal amounts of dust and dirt.
Flared braid fits around support sleeve. (Refer to instrue.
- 5. Your own established standards.
With proper maintenance and inspection, these dies will tions pack 2 Fed with connectors.)
f b) SUde ferrule forward over braid until ferrule butts against give years of sa*dsfactory service.
shoulder on connector body. Assembly is now ready to be All AMP dies are thoroughly inspected before being ship.
Ped from the factory, however, since there is a possibDity cnmped.
(c) Pirce ferrule on stationary die so that shoulder on con-of die damage in shipment AMP recommends that new dies be inspected in accordance with this section when nector body butts agamst die. See Figure 4.
received in your plant.
?
~ ~
3.1 CLEANING Do not aHow deposits of dirt, grease and foreign matter to P@ may SHOUL.DYR'bN l
cause excessive wear in the die closure surfaces, thereby affecting the quality of the cnmp. The dies should be BCDY BtnTS,
M** Ann wiped clean frequently with a clean cioth.
. AGAINST DIE
- ~ "
I I..
3.2 VISUAL INSPECTION
)
Visua'ly inspect the die closure surfaces for broken, pitted,
,. (,'"
or chipped areas. Although dies may gage within permissi-b~ - A
.h
['" e.. >
ble limits, worn or damaged die closure surfaces are ob-4 jectionable and can affect the quality of the crimp.
3.3 DIE CLOSURE INSPECTION
-1
~
Every AMP die set is inspected and tested for proper die
/
'2 u
N D#
gg,","y D E 1
5 closure before being shipped from the factory. An inspec-tion should, however, be performed penodicaHy to mea-o sure the center contact die closure on the dies listed in
?
l-
- =
Figure 5, and the center cantact crimp configuration of all
~'
other die assemblies. Correct crimp configuration is deter-d, t
-- * ]
mined by measuring a crimped slug. Recommended materi-
. }
..a
..w.
Figure 4 '
al for this slug is No.14 solid AWG commercial w.h.
Die closure inspection is a:complished using GO NO-GO (d) Hold assembly in place and press trigger or close tool plug gages for braid ferrule enmping dies on all die assem-blies listed in Figures 6 thru 8, and center contact crimping handles.
dses for the two dies listed in Figurc 5. AMP neither manu-(e) Remove crimped assembly from enmping dies.
factuns nor sells plug gsges, however, suggested plus gage
- 3. MAINTENANCE /lNSPECTION PROCEDURE design: are shown in Ftgures 5 thru 8. The GO NO-GO dimensions of plug gages for the center contact crimp (on AMP recommends that a maintenance / inspection program be performed periodically. This is necessary to assure that applicable die assemblies) and the braid crimp are listed in continued use of the dies will result in the Jame dependable Figuas 5 thru 8.The following procedure is recommended and urnform terminations for which the dies were aesigned for measuring the die closures.
SUGGESTED PLUG GAGE DESIGN - CENTER CONTACT DIES
- ~
-GO DIM.
NO GO DIM.
- * ~ * "
DIE CLOSURE fT"""'"&
NQ CONFIGURATION 0
TG2 *(
)
GSJ 0
4 t
i..
I i
=vs R
J1 t Q(
R.
.'B g
MAX.
MAX.
"A"D W.
GAGE MEMBER" DIM'S.
DIE CLOSURE dim'S. "A-t DIE DIM. B "W"
RADIUS MAX.
"R" (M AX.)
NUMBER GO NC-GO GO NO.G O
,g 69726 0750
.0790
('
.0750 0753
.0789.0790 / ) ~
.068
.034 7
.034 E
020034 1
.0750
.0790
.07503753
.0785.C790
.vue Figure 5
IAA iNsrau:TicfwM AlteTEW ANOEllNGPE CTIC.N SHECT SUGGESTED PLUG GAGE DESIG?d-BRAID AND INSU'_ATION DIES l
DIE CLOSURE -
CONFIGURATION GO DIM.
JO-GO DIM. -
"W"-e-w
+ -- ;
l!
i.
i' q
w oiM.
lfi If.Ox ; I f
l l
0 g
^ 'b l
t..
..R'I t
~ 1-Min.
-v' 3
s-t MAX.
7y p, M A X.
o' i
GAGE MEMBER" DIM'S.
DIE CLOSURE DIM *S. "A t DIE DIM. B
'Ti" RADIUS NUMBER GO NO-GO GO l
NO-G O MAX.
"R" (M AX.)
220067 1
.2150
.2210 7150-2153 I 3209 4210 l
210
.os
[A 69726
.2150
-S t o 1~
a,en...e-6 m...,o y
..e i
69727
.2150
.2210
.2150-2153 1209-1210
.210 105 220034-1
.2530
.2530
.2530-2533 1589.2590
.248
.124 j
E9669-1 1530 2190 I.2530-2533 1589.2590 0
248
.124 63669-2
.1670
.1730
.1670 1673
.1729.1730
.164
.382 220088-1
.3270 2330
.3270.3273
.3329.3330
.322
.161 Figure 6 SUGGESTED PLUG GAGE DESIGN -INSULATION DIES DIE CLOSURE GO DIA.
NO GO DIA.
CONFIGURATION f
+
a@]
-S=-
}l i
V
~A~ c M.
'O 4
O I
6J.
l e. ".
t c3 t
w "I~
"B" 2" MIN.
T. M..-
p TYP.
DIE CLOSURE DIM'S. "A".'
dim. "B" DIE GO NO GO GO NO GO
- 20026 1
.1000
.1050 l
.1000.1003
.1049.1050 I
Figure 7 SUGGESTED PLUG GAGE DESIGN - BRAID DIES DIE CLOSURE
.w-CONFIGURATION GO DIA.
s '- -0,'
-GO DIM.
NO "A"OlM.
t v.
1 E
+
O i
i D
't eLJ t
..q t
t 3..
i min.
s" max.
. ~.,
tt OlM'S.
GAGE MEMBER I
DIE CLOSURE DIM'S. "A"t DIM.B DIE GO NO GO GO (Di8.)
NO GO f,1
..R' ( A
.)
1 l
4 220026 1 l
.1670
.1730
.1670.1673
.1729.1730 l
.162 l
081 k
, 0 i. u....
.......... to,. 4 Figure 8 out noe uno., or ur..
t t M. tert.e - Teos Ste.6 P AGE 3 CF 6 IS2396
d f NSTRUC*loN/MAINTEN ANcE/t N3FEcTION SH E ET 3.0.1 Center Contact Dies Die Ass:mbliss 69726 (nd (f) If the die closures meet the GO NO-GO gage conditions, 2200341, and at! Braid Crimp Dies the dies may be considered dimensionally correct. If you (a) Remove traces of oil or dirt from the die :losure and plug find that the die closures do not conform with the GO gage members.
NO-GO gage conditions, contact your local AMP field (b) When unng pneumatic tool, reduce air supply pressure to a reeresentative.
- range between 15-20 P.Sl. Actuate tool to bottom dies.
3.3.2 Center Contact Dies Measurement of When using nand too!, close handles of tool until dies Crimp Configuration bottom. Do not apply addit 2onal pressure to tool handles.
(a) Remove traces of oil or dirt from enmping area and wire (c) With crtra. ping dies bottomed, check the center contact slug to be enmped wtre barrel crimp die closure usirg the proper plug gage.
(b) Place slug on center con:act die and close handles or Hold gage in straight alignment with the dies and carefully activate tool to complete crimp.
try to insert, without forcing, the GO element, and then (c) Remove slug from dies and measure dimensions over the NO-GO element. See Figure 9. The GO element must
" cats" formed in dies with square configuration, or over pass completely through the barrel enmp die closure.
radius formed by dies with round enmp. (NOTE: The (d) The NO.GO element may enter partially, but must not die assembly with round enmp, lirted in Figure 11, cannor pass completely through the length of the barrel cnmp die be plug gaged since it contains an sndent forming area closure. See Fir,ure 9.
inside the radiur of the die.) A typical measuring device is (e) Check the braid and insulation crimp die closures,using the shown in Figure 11.
proper plug gage, in the same manner as steps (a) thru (d).
(d) If dimensions do not conform to those listed in Figure i1, See Figure 10.
contact your local AMP representative.
INSPECTION OF CENTER CONTACT CRIMP!NG DIES D s\\e.
BOTTOMING SURFACE CRIMPING OF DIES
/ DIE h
D
/
p g
GO,
t -.=w=.ey
(
g f ),
1hrough t$es die slanure. -
]
Q).
G[.W.
/.Ib7 PLUG
'6 I
t i
Nm GAGE 7, [
pg
- WO.GO"' esgo mer enter partially, but man:t not pass comedessiy & rough the lenge of the die esasure.
Figure 9 INSPECTION OF BRAID AND INSULATION CRIMPING DIES PLUG GAGE
~.,
CRIMPfN3 DIE MEhasE R l,. ?
NOTE: PLUG GAGE MEMBER h
MUST BE HELD VERTICAL IN CRIMP Dli! CLOSURE A
/pa<
"GO" esos must pas somgeewy FOR PROPER MEASUREMENT.
1erough the die atosure.
4 BRAID AND INSULATION
+
~1f ~
' " ~
CRIMP PLUG GAGE
(
e
/s t... J F'l G
\\':#
C-w AI j
"NO4XO" page may enter partially, but yc
=t p.s.om.e-y mr. n m.
Figure 10 FAGE 4 OF 6 IS 7396
IA M Pt INSTAUCTioNdM AsNTEN/.NCI/INSPEOTION SMEET 3.4 CERTI CRIMP
- R ATCHET INSPECTION The CERT 1 CRIMP ratchet feature on AMP hand tocis PRESSL'RE ON TOOL HANDLES.
thould ' e checked to make certain that the ratchet does (b) If a.00; or s:naller sh:ta can be inserted between the bot-c not re: ease prematurely allowing dies to cpen before dies toming surfaces of the dies. or if there is no opening wnat-h.ne fully bottomed.
ever, the CERTI CRIMP ratchet is satisfactory.
(c) If the clearance between ti.e bottom:ng surfaces of the To checx ratchet feature:
( a) Make a test enmp. When this c tmp is made, squeeze hand-dies is greater than.001, the dies are constdered as not les until the rat:het is free, however, DO NOT RELAX bottorning. Contact your local AMP field representat:ve.
MEASUREMENT OF CENTER CONTACT CRIMP SF:NDLE CR:MPE3 WIRE SLUG ANVIL (NO.14 50 LID AWG
\\
W.-
WIRE)
' ' ' 3(N[.'.' '
\\
DIM. C
-g
\\
4 I
l b
K s
DIE DIM
- PART CRO::S SECTION C
gg*
f7 OF SLUG FROM
.4 OlM. C
. _/
O.c 4 gg,,
ROUND CRIMP BLADE
' 69669-2 b ' '-
[J b_']-
ar 2
220025 1
.0530 220067-1 M
f/
2200C81 OlM.C I. I
.074 B
CROSSSECTION OF SLUG E
M FROM SQUARE CRIMP OIM.C CRIMP HEICHT MICROMETERS
' one sioe con so.0025 out et toierence n ione se ene The micrometer shown here is conventional outside
- "*""'*"'*""8'"8"""*"8***
type with exceptionof the design of anvil and spindle.
The anvil's measunns surface is a blade, perpendicular to the movable spindle, which is conical. AMP does not stock or sell these items.
Figure 11
(. -
PAGE 5 OF 6 IS 2396
M INSTQUCTION/M AINTQP$ANCEllNSDECTION BMEET 3 5 REPLACEMENT PARTS It may be advantageous to stock certain replaceable parts to prevent loss of production time. Figure 12 hsts the customer replaceable parts that can be purchased from AMP Incorporated, Hamsburg, Pa., or a wholly owned subsidiary of AMP Incorporated.
h 3
4 1
2
\\
~
/
\\
S,
/
N m
3,.__-
f^
O e ea tv.r
-==<
f a
_e
[
{
r;
=:
m
~'.
~
]
?
O
@4 t..rJ
.a ::r.=.=.um
)
s
'\\
s s
PART NUMBER ITEM DESCRIPTION QTY.
Die No.
Die No.
Die No.
Die No.
Die No.
Die No.
Die No-Die No.
69669-1 69669-2 99726 69727 220034 1 220067 1 2200261 220088 1 1
SCREW. SPE CIA L 2
30E5921 308592 1 308592 1 308592 1 308592 1 306592 11 3f18592-1 1 308692 1 2
ANVIL. 8M AIDt 1
308618 2 3088182 305507 1 308507 1 307263 1 308818d 307178 1 3086184 3
Sa4CE R. UPPER 1
8358327 5305832-7 5 308832 7 8 305832 7 8 305832 7 t 1832 7 8 305632 7 8-305832 7 4
RING. RET AINING 2
1 210864 1 21046 3 1 21046-3 1 21046-3 11 210464, 210a63 1 21046-3 1 21046 3 6
SPACE R. LOWE R 1
8-3088224 3-306332 4
- -4 4308832 4 8 305832 4 8 3058324 8 3058324 8405832 4 8
IN3E NTER. 8 R AIDt 1
308817 2 30Elit7 3 308799 3N508-1 3C7264-1 308617 4 307179 1 306617 5 7
LOCATOR 1
6-304062 2 6 304052 2 6 304052 4 S304524 6 304052 4 6 304052 2 6-304052-2 6-304052 2 307180 1 8
ANVIL. INSULATION 1
3071781 9
(NDENTE R. INSU LATION 1
{
t Asee enmos tenuse over insusemen en est osos oncent P/N 220026 1.
Figure 12 R EL. D AT E R EV. D ATE l
APPROVALS UNE
[
Q 11 75 1-5-73 1S 2396
.. -- a a r a
s INSTRUCTIONiMAINTENANCE/INSPECTICN SHEET 151542 2-+-rs k..
1.
iNTROCUCTION Easic inetru::icns en :ne use of :nese : cess, wire 3 e ihis instruction sneet provides "In:tructions" :n re:aration, et:.. are :reviced.n Sec::en 2. "In:truc-1 pr:cuct a:clication anc a " Maintenance and inscec-tiens." Se::icn 3 features a terminal anc splice tien Pro:ecure for-
"enmp ins ection" pre:ecure. See: en 4 centains j
sousTRANo* AND STRATO. THERM
- HAND TOOLS a " Maintenance and Ins;ecti:n Drccscure" wnten weil enacle you 'o esta:lisn anc maintain a tool cert //ics.
j 46447 49900 4sg3e hon program.
- W 43592 43935 693C3 l
The tools listed acove and in Figure 2 are used to g
crimp:
IM e
- SOL! STRAND terminals anc splices on wire sizes M
i
'Q' i
26 tnru 10.
CERTI CRIMP'
- STRATO THERM neat res:stant and hign tempera-S}
ture terminals and splices cn wire sizes 22 teru 10.
/@ RAT NET
-f
' This instrdction sheet covers tools naving 3-crtmp,
[
j 2-cnmo and 1 crimp jaws as shown in igure 1. The
',fjj
~
cnmping procedure is the same for all three types of 5
, cf m tools.
[
0 35 These instructions may be used for tools not' listed y,
in Figura 2 but ac:cmpanied by this IS. For un;isted
- l CRg,P,,
_2 C,R_ IMP 3 CRIM_P f3 tools, ut e the wire strip dimensicns given in Figure 2 pig,7, 3 d
for an ::t cal si:e tool.
~
/
wing state
-s
/ LENGTM Q133475 j
p
[
1-u N
i k
'[
3g e9 J
V
-s-D.
G
/ is?4No4acw rH yE BUTT t,1CE en wrreouf
/
[k
-s t:vALs wiat 5AA8E:.
'kr ^
- v..._' " ". lii@.:@>
s=
isru
- ' h
- $ e
. WIRE STRIP LENGTH jl TOOL WIRE TERMINAL l
BUTT SPLICE l
PAR ALLEL SPLICE jj NUMBER SIZE MIN.
l MAX.
l MIN.
l MAX.
I MIN.
l MAX.
E 22 16
- h I.
11/64" 13/64" is 4993s 16 14 I
l 1210 l
1/4" l
9/32**
ll
=> a
,,,o -
22,u-
!e 49936f 16 14 1/4" 9/="
5/16" 11/22" E3 12 10 1
1/4" l
9/:::"
k#I 22 16 4 3 11/64" 13/64" 4.
499c0 16 14 60 12 10 1/4" i
9/32" I=4 3
49592 l
14 12 l
11/64" 13/64 "
l 5/16" l
11/32" 1
-1 3 g l
25 24 l
1/8" l
5/02" l
9/64" l
11/64" l
I 693&7 l
22-20 l
11/64" l
13/64" l
13/64" i
15,64" l
I l
22 16 8
46447*
11/64" 13/64" 1/4" 9/32" 5/16" 11/02"
/
16 14 l
( a 12 10 6
1/4" l
9/::"
m AMP incorporated, Harrisbutg, Pa.171C5, U.S.A.
PAGE1CF$
~
]
instmucTioNmainTssaNesnssrecTrew swes-JAAPi (g) To enmc otner half of butt s= lice, remove it and 2.
INSTRUCTIONS recesition unenmced half in tool and fonow same 2.1 WIRE STRIPPING AND CRIMPlNG procecum used to enmo Wst haU of a: Hec. U spH:e PROCEDURES cannot be tumed, tum tool around.
Dies are coatec with cil to creveilt rust and corresten.
(h) Refer to paragrsch 3 and cigure 4 for terminal or wice tna oil frorn dies, particularly from enmoing setice "Onmo inspection" =rocedure.
2.2 CROR COM (a)' S no were to dimensions listed in Figure 2. Strio (a) STRATO-THERM nign temterature terminals and lengin is cetermined by product to be enmped and spHces am color codec orange.
wire si:e. Do net nick or cut wire strancs.
(b) STRATO-THERM heat resistant terminals anc spH:es (b) C1cse handles until CERT 1-CRIMP rat: net releases and SOLISTRAND terminals anc solices are not color and enmoing jaws are cpen. See F gure 1. Note that coded.
once rat: net is engaged, handles cannot be opened until tney are fully closed.
3.
CRIMP INSPECTION (c) Dia:e terminal or solice in enmcing dies as snown in inspect crtmoed terminals and solices by enecking Figure 3. For best results, when crazed seam on the features cescribed in Figure 4.
splice is visible, pos: tion seam toward indenter.
Use only the terminals and SDlices that meet the NOTE: Se certain terminal or splice is placed in conditions shown in tne " ACCEPT" column.
correct closure for the wire size being used.
" REJECT" terminals and solices can be avoided (c) Close handles until terminal or splice is held firmly tnrougn careful use of instructtens and chart in in place. Do not ceform terminal or solice wire carrel.
Section 2, and by performing regular tool mainte-(s) Insert stnpced wire into terminal or splice wire barrel.
nance as instructed in Section 4.
NOTE: Do not use wires with nicked or missing strands.
4.
MAINTENANCE /tNSPECTION PROCEDURE (f) To ecmplete enmp, close handles untti CERTI CRIMP AMP recommends that a maintenancelinspection ratchet releases. Handles will open automatically and program be performed periodically to ensure decend-enmoed item may be removed.
able and uniform terminations. Tools should be
~
once a month. Frequency of inspected at least m
mt:~. -~. --.w. 3. =
g,==
inspection may De adjustec to suit your requirements
- J. j,'@,;.7.".% pp.-gt.,,' T :.7 ;,
g j c u.- R.'
through exparience. Frepuency of inspection is
'.. + c i "..
S dependent upoh:
/
~ t
.c.g-; y {,g aj.. g,?p7,q'y
- 1. The care, amount of use, and handling of the toci.
O.C.
lT,E,R,MI N AL, (
,. _y?],
- 2. The type and size of the products enmped.
C
".' r..
~
-Q.t 3;O w
- '; 'M.. J jf -
m;
- 3. The degree of operator sklH.
A N ** d **== d M W i ! "i 9
g cEuTER TERuM. I',
'.. < e.
.2 dirt.
^ WIRE BARRELIN
.~.' 4 g.#
5.*Your own established standards.
7 All AMP
- cnmcing tools are insoccted before being
. CRIMPING QIES
- WITH TONGUE
,4
- shippec from the factory. Since there is a possibHity g.~
gr of tool camage in shipment, new tools snould be PC,s,t],1CN ED, AS,$yo,,w3 ]y9.
.;'"'"'"h.A.;..Q'@.-j.
inspected in accordance with Section 4 when
" ~'
- --- " "Q,-W W.R....,
re00ived in your plant. Due to the precision de:Ign.
,E w oENTER.
- J. ;
it is important that no parts of these tools be inter
-8UTT SPLICE, changed except those replacement parts listed in c
>.- L
\\ f'
- (h -
q
.. CENTER HALF oF N
v.- -
,7 7., -
gfgy7,g
.s,.. /
. sPucE 8ARRELIN.
\\
- g 7 The tool should be immersed in a reliable commercial V
.WJ.v
- MC*41MPING DIES h
~
q '4;., 2 degressing compound to remove a umulated dirt,
' '.~,"./;
l _e.
7;,
greasing compound with a lint free cloth. When l~
ON SPUCE !S V!S38LE,'
3,.e,'T 1.f.' +%Dl *
'. WHEN eR AZED SE AM ' S cegreasing comocunds are not avausble, tool may
" Y ' ' --
3 '.
y be wiced clean witn s lint f ree cloth. Relubricate teol
~'*
- postTioN SEAM
~'
d'O 4
as instructed in paragraan 4.2, before placing it bacx
. 7ewage isogn7;n
~~,y
- -w
... Q,.
In service.
- p, r
~
^
4.2 LUBRICATION Lubricate all pins, pivot points and bearing surfaces
. PA,L,A,ptEL SPLtCE With a good grade S.A.E. No. 20 motor oH as follows:
R Tools used in cally crocuction - Lucricate caily g
Tools used caily (occ3sional) - LuOnCate weekly gg $pggg
~'$
Tools usec weexty - Lucrtcate monthly SARRELIN Wipe excess cil from tool, particularly from crimcing CRIMPtNG DIES
..J, a..
area. Oil transferred from the crimoing area ento
,'. Nj,1.2 certain terminations may affect the electncat enara:-
c, tenstics of an acclication.
Figure 3 IS 1542 PAGE 2 OF 5
. _. ~
ins?%Uc'*toNAeAIN?tNANCEitNsDsc"*f ON sMEE?
f A *'*. kI lACOEPTl l REJECT I
\\
4 3
TERMINALS s
d 3
%g S
-E 1
N N
.w
\\
2 4
2 l
3
. s-s 1
StGHT s
gcLe
\\
l OR
' [
PARALLEL SPLICES Y
STRAP g
4 TYPE 4
..i N
5 3
eUTT sPL!CES
@ Camced off enc of 3Dlice or terminal.
@ Crimes centered. Crtmos may te o*f center SUT Q Wire size teing used coes net maten were size NOT OFF ENO CF WIRE BARREL.
stamped on terminal, sciice, or teol.
Q Wire size being used matenes were alze stamped on
@ Wire net inserted far enougn in terminal or solica.
terminal, sclice, and tool.
End of wire must ce visibie througn insooction noie Q Wire is visible througn inscoction note of butt sDilce, of tutt 3:lices, and extend beyonc end cf terminal
}
and extends beyond end of terminal were barrel.
wife carrel.
@ Insulation does not enterWire Carrel.
@ Insulation entered barrel of terminal or SDlice.
@ on caraiiei sciices, bare nire encs must be flush CHECK FCR INCCARECT STPIP LENGTH.
with or extend stigntly beyond end of barrel.
@ Excessive "flasn" on terminal or splice incicates wrong wire, s lice, or teoling commination was used.
@ Nicked or missing strancs.
Figure 4 4.3 VISUALINSPECTION
?.._ _
--- n.-
'~
. piTTso (a) Visually inscoct the tool for missing pins or retaining y.e rings, tnen operate the tool and note the return action q) i of the spring-loaced nandles. If parts are missing or g
cnip,Ec sannq in mancies is cafective, refer to Figure 8 for
.. EDGE
[
customer replaceable parts.
(b) Visually inspect tne die closure surfa:es for flat-
! ' ' '[~ 3 '.
i i
tened. Droken, patted or enipped conditions. Al-
,,.PlATTENE3 thougn dies may gage within permissible limits, wom L'sAREA g
or damaged die cicsure surfaces are oblectionable
~-
and can affect the quality of the enmp. Examples of
. f' s RcKEN possible damaged die closure surfaces are snown in CORNER Figute 3.
u A~
- ~- " ' - - - - - - - -
Figure 5 4.4 DIE CLOSUREINSPECTION (a) Clean oil er dirt from tool enmoing area anc ofug Every AMP nand tool is inspected and tested for gage members.
Proper die (jaw) closure Cefore snipping. An (b) Close nancies cf t0cl until cnmping jaws are bet
- Inspection should be performed genodically to tomed. Do not accly accitional Oressure to toci measure the tool cte closure.
Mancies.
Tne toof cle closure inscection is accomolisned (c) With enmoing jaws Octtemed. Oneck tne wire carrel using GO NO-GO plug gages. AMP neitner manu.
enmo cie closure using tne rocer clug gage. Hole L
factures ner sells plug gages, newever, suggested gage in straight alignment with the cie elesure anc plug gage cesigns anc the GO NO-GO cimensions of carefully try to insert, witnout forcing the GO the clug gage mem ers are listed in Figure 6. The memcer. anc then the NO-GO memeer. See Figure 7.
following procedure is recommendec for measunng The GO memcer must pass comoletery tnrough tne the tool die closures.
were barrel enmp die closure.
131542 PAGE 3 08 5
MPI insinucTioNNAIN7ENANCEMNFE TI:N SHEET fd) The NO-GO member may enter cartia:ly. but must not (c) Bottoming is satisfactory if bottoming surfaces of pass : mpleteiy tnrough tne wire barrel enmo die the dies maxe contact with ea:n other er if tne clear-ance between the b ttoming surface is.001"crless.
s.
closure.
(e) If the die closures meet the GO NO GO gage condi-(d) If the.001". shim stock can be inserted completely tions, tne tec! may be consicered cimensionally between the bottoming surfa:es of the cies. tne cies are conricered as not betteming. Contact your local correct.
(f) If you find that tne too; cle etesures Oo not conform AM P field representative, with the GO NO.GO gs;e conditions, contact your 4.6 REPLACEMENT PARTS local AMP field representative.
It may be advantageous to stock certain replaceable 4.5 CERTI-CRIMP RATCHETINSPECTION parts to prevent loss of production time. Figure 8 The CERTI-CRIMP ratchet feature on AMP hand tools lists the customer replaceable parts that can be shoulc be enecked to make certain that the ratchet purchased from AMP incorporated. Parts other than coes not release prematurely allowing jaws to open those listed on Figure 8 should be reciaced by AMP incorporated to insure proper CERTI-CRIMP bef ore tney have fully bottomec.
r ::P.e* adjustments. For tool repair senn e or CERTI-To eneck ratenet feature:
(a) Thorougnty clean the bottoming surfaces of the jaws.
CRIM.1.-M: net adjustment; the tools should be (b) Mane a test cnmD ustny the maximum wire load, i.e.,
retumed *o AMP Incorporate, Harrisburg, Pa.17105, c No.16 AWG wire in a 2216 terminal. When this ora who.ly owned subsidiary of AMPincorporated.
enmo is made, scueeze handles until the ratenet is free, however, DO NOT RELAX PRESSURE ON TOOL HANDLES.
SUGGESTED PLUG GAGE DESIGN WIRE BARREL CRIMP NO GO DIE CLOSURE GO DIM.
DW, CONFIGURATION
~8
~8,
S.
C.}
C t o 1 g;=amr J O
- W f
f4 w
0-MIN.
"A" DIM.
TYE 2* L1tN.
TYP.
TOOL CRIMP DIE CLOSURE DIM'S. "A" ?
l GAGE MEMBER ?? DIM *S. "B" l RADIUS NUMBER SIZE GO l
NO-GO l
GO l
NO-G O l
"R" 49935 22 16
.0460 I
.0520 l
.0460.0463 i
.0519.0520
.062 49936 16 '4
.054c I
.0600 l
.0640.0543 l
.0599.0600
.078 49900 12 10
.0760
.0it20
.0760.0783 i
.0819.082o
.109 49692 1412
.0000 l
4750
.0890.05 3 1
4749.0750
.078 26 24 l
.0260 l
.CC20 4290 4263 4319-4320
.0305 22 20 1
.0370 I
.0430 l
4370 4373 I
.0429 0430
.047 22 16
.0510 I
.0570
.0510.0613 1
.0569.0670
.062 46447 16 14
.0500 l
.0680
.0500.0893 1
.0649.0650
.062 12 10
.0830 i
.0800
.0830.08:3 l
.08e9.0e90
.093 e co.io.or. aira.a ons aooi, wri.a i
.r. eerro,n.e.
out act une.r pre wr..
Figure 6 et u.i.,iew7 eat si.
f51542 PAGE4OFS
tr.stRuc to%ma NTENANO2/ INSPECTION 3 MEET W T INSPECTION OF WIRE BARREL h
CRIMPtNG OIES
)
l rEi MeiS 3G7"'O%tEO
^
B*.i' NOT UNOER
- RE SURE "CC'* gnes must pass completely mrougn tr's die closure 0
i,- i%
y I
t
' J" i
- 0) w Ny g
"NQ GQ" sage mey enter partmly, but must f
not peu comp #etesy erougre the die efoeure.
Figure 7 h
2 1
APPROX.
[
'(SHORT H ANOLE)
APPROX.
' ' NQ.f.K. ~..
I\\ * (LONG M ANOL1) 2%" (SHORT H ANDLE)
^'
3"(LONG HANOL2)
~ W: "
- I
' %I..$ h,.:,., _
- r;-
t e
,,,w 3,,,,7 %,
)
O,'..
/
}
Q
% 2.?;:.. ).
C.
Q m
o-
/
..i.)
I l
\\
@@@5 O@
^
NUMBERS N MSER 49935 Long Hande t3 crimost 1
)
RING. R ETAINING 21045 3 1
4 49636 Short Henote (3 crimsel 2
l PIN. P ETAINING
{
300432 i
49900 short Henale (3 crimasi 3
l COLLAR l
39366 1
49592 Long Handle (1 crtmol 4
l SP RING I
39064 1
5 363 Long Handle (2 Crimes)
PIN. RETAINING 300449 1
46447 Lang Hanse (3 crimos) 6 RING. R ETAINING 21045 4,
2 Figure 8 '
R E L. D ATE l
REV.DATE I
APPROVA LS l
1 E
'us.
gg 9 87 2 -74 PAGE S CF 5 15192
--__1 3 ;i INSTRUCTIONiMAINTEN ANCE/INSoECTION SHEET
)
,_ s -
S
.e/
11 --t 9-73
- 7..
~*
J4
- k INTRODUCTION
~
yj
- d. 7 This instruction sheet is intenledlo orbe(5ia with msu.u c= aca: smsW 1.
7
" Instr';ctions" cn procuct asclication and a "Mainte-y nance and Inspect 6cn erocedure' tor:
Lcc,uNo senEw j
qa
~ - -
. sLLAr:c"4 AQUsTMENT,
EI PIDG', PID?s STRATO. THERM *, PLASTI. GRIP *,
' ) INOsCAice g
g
& Pre-insulated Envirenrne ital Sealed Splice Crtrnping Tools.
p 5917C Moc. AH 59c75 Mod. W 696321 Mod. C
. gewa,,
t8 53 59250 Mod. AB 593c0 Mod. H 636331 Mod. B j ji g
ef cf
.coLcRCODE..
{
7:
t f
[g ll These tools are used to enmo:
1 ')
gc
- PIDG vinyl and nylon terminals and solices or PIDG STRATO-THERM termint.!s en wire sizes 2S ucnage.up.
>l g{1 5 GCE=
,J 4:g,
thru 14 as listed in Figure 2.
l :Lo3.w l
- PICG insulation restncting nylon terminals on wire puts tg' q
c sacWN
- 23 sizes 26 thru 14 as listed in Figure 3.
g 4 9. *,
3
- Pre-insulated environmental sealed splices on wire C
/w.
6 h.3, s Zes 24 thru 12 as listed in Figure 4.
8 'g ' 'f %' '%
~'
p
- PLASTI-GRIP terminals on wire s!:es 22 thru 14 as @
3gs listed in Figure 2.
K'
\\s
~
-2 Basic instructions on the use of these tools, wire (?,..
e, -
J..
j3g3 345 preparation, tool adjustments, etc., are provided in Nd.
't
)
2Il Section 2 " Instructions." Secticn 3 features a termi-
.' ~
~
nal and splice "cnmp inspection" procedure. Section 2r.-
4 contains a" Maintenance and Inspection Procedure"
? 7 i.
.<[
%r N
'1 which will enable you to establish and maintain a tool 4(
Y certification program.
?
7,,
".g, 4 I eg,;,c,,,,-
I Toois are coated with oil to prevent rust and ccr.
- i enmoing area.
~-
, ({
rosion. Wipe this oil from tool, particularly from narcser u
yy.
=
.._.. _ f. ;
1p Figure 1 jyi 2.
INSTRUCTIONS 2.1 WIRE STRIPPING AND CRIMPING into splice until wire butts against splice wire stop.
'((}
PROCEDURES See Figure 6.
PfDG Terminals and Splices & PLASTI GRIP (g) Hold wire in position and comclete enmp by closing 39 3 nandles until CERTI-CRIMP *atchet releases.
=3 Terminals (h) To crimp other half of splice, remove it and reposition
$j (a) Strip wire to dimensions listed in Figure 2 or 3,
'J.9 crimped half in dies. Fol'ow same procedure used "3
depending on wire size and product to be crimped.
to crimp first half of splice, lf spllce cannot be Do not use wires with nicked or missing turned, turn tool around. See Figure 7.
$h NO7E:
r re-insulated Environmental Sealed Splices
~sa
- strands, 8
"i d (bl Open enmping dies by closing handles until CERT;.
"1?
CRIMP
- ratchet releases. See Figure 1. Note, tnat (i) Thermal strip wire to dimensions listed in Figure 4 NOTE: Thermalstripping eliminates the possibility of
.hI*
onca ratchet is engaged, handles cannot be opened nicks and scratches on insulatton and wire strands,
~h$
until they are fully closed.
thereby ensuring a reliable moistureproof seel when g
Crimp the color coded terminals and solices in the
-g_y sol /ce is neat sea /ad on wsre.
~2, matching color coded portion of the tool. Refer to Refer to IS 2375 (packaged with solices) for further -
(j)
QI paragraph 2.3.
wire preparation and heat seal procedures, k6j (c) Place terminal in crimping dies so that terminal tongue slides under locator. See Figure 5.
(k) Crimp splices as instructed in steps (d) thru (h) in 9_ !.sj
- ll (d) Raise locater and place splice in locator as shown in paragraph 2.1.
y Figure 6. Window incent f aces top of tool.
(1) Refer to Secticn 3 for termmal or solice " Crimp
\\
inscection" procedure.
^
NOTE: To proceriy pcsition pre-insulated sealed splice. a:cly and maintain pressure against end of 2.2 (NSULATION CRIMP ADJUSTMENT splice until step le) is completed. See Figures 6 PIDG Terminals and Splices and 7.
NOTE: P!DG terminals and solices feature a wire Press quick take-up trigger and cicse handles until
" insulation grip."
(e) terminal or splice is held firmly in place. Do not (a) Each tool has 4 insulation enmp positions. See Fig.
detorm termmal or splice wire barrel, ure 1.
(f) Insert stripped wire into terminal until wire butts (b) To determme wnien insulation enmp position is agamst locator. See Figure 5. Insert stnoped wire PME 1 OF 7
- Treceenora of AMP sacorporateo
MN INSTRUCTION /M AiNTEN ANCE/ ins #ECTeoN sME ET recuirec. first cusn in insulation adjustment can an or solice shoulc retain grip on wire insulation, turn incicator te the No. 4 position. See Figure 1.
(f) If wtre pulls out, set insulation ac;ustment incicator Make certain insulation acjustment lo: King s:rew is to next tignter position - position 3.
loose. Use an allen wren:n to loosen screw.
(g) Maxe test crimp anc repeat a:justment as necessary
(:) Place terminai or s lice in tool.
until Cesired insulation grip is octa:nec. Do not use a
~
ac) insec UNSTR:PPED wire into ONLY the insulation tignier setting inan recuire.
t:arrei c' terminal or schee. See Figure 2 or 3.
(n) To lo:k insulation crimping die in place, tlynten (e) Make a test crime (paragraon 2.1L Remove crimped insulation adjustment iocking screw w;th allen terminal or splice anc check insulation Urio as wrenen. See Figure 1.
follows: Bend the wire ba n and forth once. Terminal PIDG TERMINALS & SPLICES; PIDG STR ATO THERM TERMINALS AND PLASTI GRIP TERMINALS PIDG TERMIN AL PIDC SPLlCE FINISH ED CRf MP WtRE STRIP
!: 8 -
C B
WIRE STOP CR!MP DOT LENGTH =e b
3 "C" EQUALS INSULATION BARREL "B" EQUALS WIRE CARREL WIRE STRIP LENGTH TERMINAL OR TOOL COLOR 007 3PLICE Terminals Soliess PIDG Type '
Wire Range Min.
i Max.
Min.
Max.
VINYL 26 22 YE LLOW ONE DOT li 5/32" 3/10" 5/32" 3/16" AND NYLON 24 20 WHITE TWDDCTS 3/16" 7/32" 13/64" 15/64" STRATO-25 24 BLACK ONE DOT 3921 N. C THERM 22 20 GREEN TWO DOTS I
VINYL
- 24 20 WMITE TWD DOTS 3/16" 7/32" 13/64" 15/64" 593o0 Mod. H AND NYLON :
22 96 RED ONE DOT b
09170 Mod. AH &
VINYL
- 22 16 RED ONE DOT
$9250 Mod. AB AND NYLON 16 14 BLUE TWO DOTS 13/64" 15/64" 1/4" 3/32" STR A10 18 16 ORANGE ONE DOT
.8 THERM 14 WHITE TWO DOTS O ALSO 2216 AND 1614 PLASTI. GRIP TERMINALS Figure 2 PIDG INSULATION RESTRICTING NYLON TERMINAL O
FINISHED CRIMP
_e WIRE STRIP
(
l l
j CRIMP DOT BAND LENGTH I
COLOR CODE b
YdM hQ
.a r
"C"EOUALS INSULATION BARREL "B" EQUALS WIRE B ARREL INSULATION COLOR TOOL INSUL TERMIN AL INSUL.
WIRE STRIP LENGTH TOOL WIRE COLOR CODE COLOR &
DIA.
NO' SIZE DOT CODE RANGE insul.
Band Min.
Mex.
YELLOW 26
.026.055 YELLOW BLACK 3/16" 7/32" 59275 Mod.W i 007 24
.031.055 YELLOW BLUE 22
.038.110 RED GREEN 20
.046.110 RED RED 1/4" 9/32" 59300 Mod.H 3
7 18
.056.110 RED WHITE 22
.038.110 RED GREEN RED 20
.046.110 RED RED 18
.056.110 RED WHITE 1/4" 9/32" 16
.063.13o BLUE BLUE BLUE 2 DOTS 14
.078.130 GLUE GREEN D3 IS 1610 DAGE2Or7
[ M P]
ihsTauctioN/M AINTEN ANCENNS*E cTiON sME ET PRE.lNSULATED ENVIRONMENTAL SEALED SPL10ES SPLICE SODv INSULATING SLE!yE CRIMPED SPLICS
\\
ST R l
- LENGTH -+--*-
m
.W.;- _ _.7,7 w
- -~
Y:5 W55 M ]
.._ )
CU.i.5%liuly
?MY2"i Ubs2l:.lf
~2c
.mp COLOR C00E0 SEAL LINERS C -'I MO OCT 0032 SEAL LINER DOT WIRE AND TOOL TOOL NtJMBER RANGE CODE COLOR CODE l
M,n.
l v.ax.
53:75 Mod.W 24-2o Red One Cot 12/64" f 5/64" 59275 Moc. W 201G Stue Two Dots 15i64" 17/64" 59300 Moo. H M2 Mow Cne Cot U4" M 2"
$6250 Mod. AB 59170 Mod. AH 59300 Mod. H Figure 4 3
....,......v-m.m...c...,......-.+
.m
(*iEE msLiaTEo.
' TERMIN AL-SPLICE
?-'
l
' SEALED sPucts 4
- ;7 SECONDpl*. j Na remuisat sampEtJ -
J" i"4
- ; CRIMP y,'E'
~
i I aEsis asamst t I
y a,3,337,y3 c u ccArop x
.I ^ ~ ~.
~,.
~l l o 3.~.
. ;z y r.
1 I
~
~
I wine aurrs t _. - -
~.-
- y jh i acAinsitecArea, '
.425
- ,34 y.
wwp.;2 i- -
Z-_,
q
=
m-.
..~.
rEnumacicusut
.~- W r-
- u l wmoowmotsr.
-C q.
4 t
egnest..(ye..
c '.d
't
. gd. Factsrcror L suoEs uNoEm WM"
.i7
(_ & ~...
- y.'. '
,.:. j.._..>.'y-QlQ
- m.s m
r.;. u ; _.; a,. A. n w root
. t; w :.Aion t
+-
?
Figure 7 Figure 5 Set insulation enmo adjustment indicator as directed
~.w -..,..,
.a.
,~
SPLICE,,.
in steps (i) thru (1) in para;rach 2.2 wnen enmoing
'"osN c h j sealed splices that are not to be neat sealed.
[I l
sEALE nlMp
< catr> AP*LY j
2.3 COLOR CODE
, PRESSURE PIDG Terminals and Splicas & PLASTI GRIP awmoow mosur.
, -acAmsTEwo Terminals Paces roa or %-
700'
'. D -j Note that tool handles and terminal and solice a
%.g.E _.
insulation are ccior coded fcr a given wire range as g d -QXM
__I M % d W od - J listed in Figure 2 or 3. Cnmo the color coded termi-nals and splices in the matching color coded portion
- wist tut s AcAmsT [.
V-of the tool. For examQle, when using tool No. 59275
?
s
,J' wise step g
drMoi L.j Mod. W. yellow coded PIDG terminals and s;:lices w.
~
and red coded pre-insulated sealed solices must be Figure 6 enmoed in that portion of tool displaying the red and PLASTI GRIP Terminals yellow coded dots and yellow nandle. See Figure 1.
NOTE: PLASTI-GR/P terminals feature a wire 2.4 DOT CODE
" insulation support"only.
Note that Figures 2. 3 and 4 indicate the number of (i) Set insulation adjustment indicator in position No. 4 dots that appear embossed on a enmped terminal or -
for wire having a large insulation diameter, splice for ea:.n tool listed. Observe the det code on (j) Set insulation adjustment indicator in oosition No. 3 finished crimp to insure that correct SDlice or for wire having a medium insulation diameter, Wminal and tool ccmbmation was used, (k) Set insulation adjustment indicator in position No. 2 3.
CRIMP INSPECTION for wire having a small insulation diameter.
(1) Set insulation adjustment indicator in position No.1 Inspect enmoed terminals and solices ey checking the features desenbed in Figure 8.
forwire naving thin wallinsulation.
Terminal insulation should iceally be in contact with Use only the terminals and solices that meet the conditions snown in the "ACCEcT" column.
N.
wire insulation.
" REJECT" terminals and solices can be avoided Pre-insulated Environmental Sealed Splices Set insulation enma adjustment indicator at No. 4 through careful use of instructions and charts in Section 2. and by performing regula tool mainte-oosition wnen crimping all sizes of sealed solices nance as instructed in Sectron 4 tnat will be neat sealed.
PAGE3OF7 IS 1610
- ~
- 8NST AUCTION /M AINTEN ANCE/tNs7ECTION SHE ET I
S l
REJECT l AOOEPT
-./
.' 5' &,-
5 ay l
3 PIDo a PLAST 1omim
]
""'"^'
3 3
7 5
4:q
- 4 1 -
+ ;L Eb.:,
w 2
rw e
0 4
WIRERANGE g
3 ST AMPE0 HERE
'N b
wl
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- 3. 9_. 4
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m _-
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s WIRE S ARREL
,, 9' N,,
INSULAtlON DLEs CRIMPEo CRIMP IS SPUCE C
I f'-
g 8ACKWARDS INsuLAT1oN 3
N hj' L.-.
-x; 3
sPUCE WAs RCyERSgge'#
7 (N c:ES g
s m'oO D
3
~-
@1 i
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i 1
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7
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. ' ii;,se:
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a.
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\\ WIRE RANGE N
STAqpEo HEFit
' OO CRIENTEDW'TH osES 3
SEAL uNER 2
- ./
I
- d. -
fbe g
I 00d"000E0 f
N 2
PRE-INSULATED SEAL S
N,. '.
Co'.oA UNER Cotoa CCOED ENVimoNMENTAL g
ce ca SEALED sPUCEs
'U n 'C UNER
,j SEAL SEAL UNER j
Wirs not f ully inserted or wrong stric length.
@ Crimp not centered on wire barrel. (Terminal was not NT Cox DisAMEARs butted against locator. See Figure 5.)
WMEN *EAf SEALED
@ Wrong dot code and ccior code combination. See charts, Figures 2. 3, and 4.
@ Wire futty inserted.
@ Excessive flash or extruded insulation. (Crimped in sa d es o ong a ot
@ Cnmp centered on wire barret.
@ Correct color code, det code, and tool combination. damaged dies,
@ AWG wire size is witnen wire range stamped on @ End of conductor is net flush witn or extending terminal tongue, or sotice.
beyond end of wire carrei cf terminal,
@ End of conductor is flush with, or extends beyond
@ End of conductor not visible. Conductor s and of wtre barrel of terminal.
beyond wire carrel.
@ Enc of conductor against wire stop.
against wire stoc.
least be flush with, or extend
@ Wire insuiation einched. (Insulation c imp too tight NOTE: If conductor is not on PIDG terminals.) See Paragraph 2.2.
concuctor must at
@ insulation barrel is in contact with wtre insulation.
@ Wrong seat liner and tool color code combination.
beyond wire barret of sches.
Ref er to chart, Figure 4.
@ Correct seat liner anc tect color coce combinations.
@ Splice was reversed in dies (toot locator was not
@ Toot locator must seat in window indent of solice seated in wandew indent of sciice).
in order to property orient solice with dres.
IS 1610 e
A pt msinucriewm,Tcmcenstascries s es 4.
M AINTENANCE/ INSPECTION r)ROCEDUriE AW recommenos tr:at a maintencncelinscecticn E
N(g;,;n c.NEg r
t crogram oe perf ormed per ocically to ensure depend.
Mic aole anc uniform terminations. Tccis snould te E -
t, inspected at least enc,e, a mentn. Frecuency c-ms:sction may ce adjusted to :u.t ycur recuirements through exper:ence. F*eouency of inspecticn is j
I de:encent upon:
y
- 1. The care, amount cf use, and handling of the tcol.
- 2. Tne type and si:3 of the products crimced.
?-
W Jg7 f
- 3. The degree of operator skill.
N b.e
- 4. The presence of abnormal amounts of dust and G
Citt.
- 5. Your own esta::lished standards.
All AMD* tcols are inspected and calibrated before shipoing. Since there is a possibility of tool damage y
in shipment, new tools should be inspected in I
accorcance w.th Section 4 when receivec in your plant. Due to tne precision design, it is ir1portant that no parts at these tools te interchanged excect Figure 9 those replacement parts listed in Figure 13.
4.1 CLEANING Cican oil or dirt from tool Cnmp closures, bottoming (a)
Immerse tool (handles partially closed) in degreasing surfaces and plug ga;e members.
compound to remove dirt, grease and foreign matter.
Close handles of tool until wire barrel dies are bet-(b)
Be sure degreasing compound does not attack paint temed. Do not apply additional pressure to tool or plastic matenals. Remove remaining degreasing f
handles.
compound with a lint free cloth. When degreasing With wire barrel dies bottomed, check the wire barrel' (c) compounds are not available, tool may be wiped crimp die closure using the proper plug gage. Hold clean with a lint free cloth. Re!ubncate tool, as gage in straight alignment with the die closure and instructed in paragraph 4.2 before placing it back in carefully try to insert, without forcing, the GO
<3 service.
member and then the NO-GO member. See Figure 4.2 LUBRICATION
- 12. detail A. The GO member must pass completely
..i Lubricate all p;ns, pivot points and bearing surfaces through the barrel crimp die closure, with a good grade S.A.E. No. 20 motor oil as The NO GO member may enter partially, but must not '
(d) follows:
pass completely through the barrel crimp die closure. '
Tools used in daily production - lubricate daily Set insulatton adjustment indicator in No.1 position. '
Tools used cally (occasional) - luoncate weekly (e)
Measure both insulation cnmp die closures with the Tools used weekly - fuericate monthly proper GO plug gages in the same manner as steps Wipe excess oil from tool, particularly from enmp (b) and (c). See Figure 12, detail B.
closure. Oil transferred from the enmping area onto Set insulation aciustment indicater in No. a position.'
certain terminations may affect the electrical (f)
Measure both insulation cnmp die cicsures with the charactenstics of an application.
proper NO-GO plug ga;es in the same manner as 4.3 VISUALINSPECTION steps (b) and (d). See Figure 12 detail 9.
(a) Visually inspect the tool for missing parts, then If die meets GO NO-GO gage conditions, dies are operate the tool and note the retum action of the (g) dimensionally correct.
sonng-Icaded handles. If parts are missing or cefective, refer to Figure 13 for customer replaceable (h) If dies do not conform with the GO NO-GO gage conditions, centset your local AMP field representa-
- parts, t!ve.
(b) Visually inspect the die closure surfaces for flat-4.5 CERTI CRIMP RATCHETINSPECTION tened, broken, pitted or chipped conditions. Al-The CERT:-CRIMP ratchet should be cnecked to '
though dics may gage within permissible limits, wom ensure that it is not releasing prematurely, aflowing -
or damaged die closure surfaces are objectionable and can affect the cuality of the crimp. Examples dies to open before they nave f ully bottomed.
To check ratchet feature:
of possible damaged die closure surfaces are shown Thoroughly clean the bottoming surf acas of dies.
(a) in Figure 9.
4.4 DIE CLOSUREINSPECTION (b) Make a test enmp using the maximum wire load. i.e.,
a No.16 AWG wire in a 2216 terminal. When this Every AMP hand tool is inspected and tested for prcoer die c!asure dimensions before snipping. An enmp is mace. squeeze handles until the ratchet is inspection should be parformed periodically to free, however. DO NOT RELAX PRESSURE ON TOO' HANDLES.
measure the tool die closure.
The tool die closure inspection is accomplished (c) Bottoming is satisfactory ;f bottoming surfaces of tne dies make contact with each other or if the clear-g using GO NO-GO plug gages. AMP neitner manu-ance between the bottoming surf aces is.001" or tess.
factures nor sells plug gages, however, suggested plug gage designs and the GO NO GO dimenstons of (d) If the.001" shim stock can be inserted completely between the bottoming surfaces of the dies. the dies the plug gage members are listed in Ffgures 10 and are considered as not bottoming. Contact your local
- 11. The following procedure is recommended for AMP field representative.
measunng the tooi die closures.
PAGESCF7 IS 1610
4
- INsTfluCTloN/M AINT ENANCEnN3PECTioN SHEET REPLACEMENT PARTS incorrerated to insure procer CERTI CRIMD ratchet 11 r tay e a: vantage:us to sto:k certa:n re iacea0te adjustments. For tooi repair service er OERTi.ORIMP i
q par.s 10 creveat loss of procu: tion time. Figure 13 ratenet aclustment tne tools snould be returned toI lists the customer replaceable pa"s inat can De AMP incorporate 0, Hamsour;, Pa.17105, Or a wnotiy curenase: trem AMP incorporatec. Parts Otner than Owned subsidiary of AMP incorporated.
those hsttro en Figure 13 should De replaced cy AMP SUGGESTED PLUG GAGE DESIGN WIRE BARREL CRIMP
=
NO GO DIM.
e
+"B" O t A.
GO DIM.- B" DlA.
DIE CLOSURE CONFIGURATION wm l 4f ggcr 0:
+
A31 L 2" MIN.
TYP.
G AGE MEMBER " OtM'S. "B" DI A.
A" D #M.
DIE CLOSURE DIM'S. "A" NO-GO TOOL WIRE GO NO-GO NO.
RANGE GO
.1149.1150-
.1090.1093
.1150 1090 I
.1249.1250 22 16 j
.1190.1193 59170 Mod. AH &
.1250
~
59250 Mod. A8 16 14 D
.1190
.0689.0690
.0630.0S33
.0690
.0630
.0949.0950 26 22 4090.0393
.0950 5G275 Mod.W
-- 24-20
.0890.0393
.004r..0950
.0890 4050 24 20 l
.0890 1090.1093 l
.1149.1150
.1150 53300 Mod H 22-16
.1090
.0900 4903 l
.0939.0940
.0940
.0900 1079.1cS3 26 24
.1040.1043 1080 22 20
.1300 1303
.1339.1340
.1040
.1340
.1300
.1539.1540
~
IS 16
.1500.1503
.1500 l
.1540 14 Figure 10 SUGGESTED PLUG G AGE DESIGN INSULATION CRIMP NO GO DIM.
GO DIM.
"D"e
- 1. l 4
&l. D" l
ZO _
DIE CLOSURE CONFIGURATION 02 w
t"5 i
+
v" oo l
.i A 7v
.250 TYP.*
"C" Ot M.
DIE CLOSURE dim'S. "C" '
GAGE MEMBER " DIM'S. "D" WIDTH I
Set Insulation Set insulation "W"
Wax.)
TOOL WIRE Adjustment Pin Adjustment Pin NO-GO i
at No.1 Position at No. 4 Position GO NO.
' RANGE NO-GO GO 1099.1100
.125
.0300.0303
.1100
.0300
.1199.1200
.125 22-16 _
.0400 0403
$917 Mod.AH
.1200
.0400
- 9250 Mod Ab 1614 y
.0799.0S00
.093
.0300.0303 2ti 22
.0800
.0300
.125 59275 Mod.W 1099.1100 24 20
.0300. 0303
.0300 1100
.1099.1100
.125 24 20
.0300. 0303
.1100
.0300
.0749.0730
.093 22 16
.0250. 0253
.0750
.0250
.093 26-24
.0849.0350
.0350. 0253
- gg7,
.0850
.0350
.125 Mod.C 22 20
.1099. 1100
.0300.,0303
.1100 18 16
.0300
.1199 1200
.125
.0400.0403 f
69633 1
.1200 Mod 8 14 l
.0400 j
Figure 11 Die cieswee o mensions sooty wnen dies are cortomeo, IS 1610 but not uhoor DressJee.
unter.a tooi sies.
s t
l
~
{A%kj e
tres?PtJOT!CN/MAIPITEN ANCE/ INSPECTION SHEET _
IN3PEC7 ION Cf*!NSULA7!ON INSPECTION OF hlRE D ARREL CRIMPtNG DIES e
C91MPlNG OIES
!NSU'JDCN ANUSTMEN*
IN04CATOR f
N I
N
/
$ES [aE EcTTcuEs /
l
\\
T BUT NOT tJNOER PRES $URE DETAll 8 OETAll A A
T ENT tN lCA*0A IN Cef' 9jgY {j No.1 po$lTICN
- C0* gage must pasa compseiety
'CF gage must psee comp 6etery enrougn tne on caesure.
througn the die oosure.
INSULA 710N NDI TC N NC. 4 POSITION ObOi = _d-.
i
- NCLCC" gage may entee partialty tiut
'NCNIC* gage may enter parthely, but must not pass comedoissy througn the muet not pass cornpeste y thfougft the r
die closure.
' ~ ~
Figure 12
~ ~ ~
U,-
)
tWITH HANDLES CLOSED) k APPRCx.0tM.
2 718"tSHORT HANDLE)
'\\
2 718" fLCNG H ANDLE)
.e 2
1
/
/
w>
/
s "
/
A Q
..s 1
l
/
APomCX.
8" (SHORT HAN DLE)
,/
MIS * (LONG H ANOLES L
/
TOOL NUMBERS 59170 htGO. AH SHORT MANOLE
$8275 MCD.W SHORT MANCLE ss4921 M00. C esses.1 Moc. 8 53250 MCD. AS LQNQ H ANDLE 58300 MOD. H LONG HANDLE LONG HANDLE LONG MAN 3iE 53755 1 557 %.2 Suoport. Locator 1 21002 3 1-21CC2 3 2
Screw Figure 13
.R APPROVALS REL DATE REV. D ATE l
f w g, Q g,
hgg a.ms n-in-n PAGE 7 OF 7 IS 1610
. _. _., _ _...... _.. _ _ _ _. _ _ _.. ~ _.
s f"
/$
-b AwM D instructi=nchtet1 4
li"N f 7 % l
, i APPLICATION AND M AINTENANCI
{
M@*y%
FOR AMPT HAND CRIMPING TCOL 902721 O
}
HM'M l E. ELE ASED t 3 2.9 7 : l Section I of this instruction sheet covers tne contacts Section ll covers maintenance and inspection recom-l and a: plication procedures reccmmenced for tne mended oy AMP to assure reliacility of AMP nand AM? Hand Crimping Tool 902721.
crimping tools.
INSULATloN CRIMP The insulation adjustment lever is used to contro!
FRONTor the crimp height of the contact insulation barrel. It ADJUS MENT LZVER r
r 3
[chae.,
can De set' at any of three positions: (1) small, AMP sloe)
(2) medium, or (3) targe.
O The locator / insulation stop has two functions. First, CONTACT it positions the Contact between the crimping dies,
%*b y
suPeo RT and second, it aidsin locating the wire in tha contact.
NCRIMPERS In use, it rests in the locator slot. See Figures 12 and CRIMPING Y
l-3, N^ " v ' '5 o:Es O soz72-i O The contact support prevents the contact from bending during the crimping procedure.
The ejector pulls the locator down and ejects the crimped contact when the tool handles are FULLY r
h opened.
The two green color code dots on the BACK of the tool indicate the combined wire range (24 to 20) vf
~
)'
the tool crimp sections. Note that the applicable loore q
f' piece contacts have a green color code dot on the underside. See Figures 12 and 13.
~
}
The CERTI-CRIMP ratchet assures full crimping of is the contact. Once engaged, the ratchet will not pl release until the handles have been FULLY closed.
..... CERTl-CEUMP*.
Icsunon l The crimping dies bottom before me CERTI-s&'$ Q";7 %
- R A TCH c.., '-
CRIMP ratchet releases: This isadesign fencuw..
T AL,n -
g mat assuret maximum electrical and tensile
}$
~' "
cy performance of me crimp. Do NOT re-adjust
- "#####E
.3 FIGURE l 1
- sg j{g{
/
SECTION I APPLICATION U","R EL
/,NsuL ATio N
- 11. INTRODUCTION AgpgL g3 AMP Hand Crimping Tool 90272-1 is designed to crimp the AMP Twin Leaf loose piece (LP) contacts Ed listed in Figure I 2.
Read these instructions GREEN gjj thoroughly before starting.
QORCODE N
s
.M c WIRE l nort l All dimensions presented on this instrucdon locator STRtP
[hh sneet are in inches, unless omerwise stated.
slot LENGTH z
Qs
- 12. DESCRIPTION ist The FRONT OF TOOL (Contact Side), into which WIRE CRIMP SECT CONTACT No.
WIRE gg ojc SIZE WIRESIZE STRIP v.i the contact.is inserted, has the tool number marked (AWG)
MAJ6?NG l STRIP otA LP LENGTH Qjy on it. The BACK OF TOOL (Wire Side), into which 24 t 22
.o48 2 & 22 583853 4 Esc 852 2 s/54 the wire is inserted, has the wire size marked aoove t
58 8 m t.1m the crimp section.
2o
.080 20 583853-5 583853-3 This tool features two fixed dies (crimpers), two 583853 4 s-
.e moveable dies (anvils), an insulation crimp adjust.
58::853-9 53::8534 ment lever, a locator / insulation stop, a contact 1 583853 1 1-583853 0 1m53 2 suoport, an ejector, two color code dots, and a CERTI-CRIMP ratchet.
FIGURE l 2
- r..
...or w eico.. m.
oa e ' e
- is1536 AMP HAND CRIMPlNG TOOL 9027i 1 4
- 13. CRIMPING PROCEDURE 6.
Hold the wire in place and squaze the tool Ref;r to thm chart in Figure 12. and then ssitet wira handles until the ratchet reicases.
, of the specified size and insulation diameter. Strio the wire to the lengtn mdicated - do NOT cut or nick 7.
Allow the tool nandles to open FULLY, so the wire strands.
me egh can p me contad M d We N
crimpers. Remove the crimped contact from the Sst:ct the applicaole loose piece contact, and identify
.ao-th2 appropriate crimp section (according to the wire size markings on the BACK of the tool). The color cod 2 dot on tne contact must match the color code B
OF dot above the aporopriate crimp section on the tool.
(wire stoc) c;cCTom Proceed as follows:
\\
1.
Hold the tool so the BACK (Wire Side) is facing you. See Figure 13.
2 auTT wsRe 2.
Make sure the ratchet is released by e
U","n",' r squeezing the tool handles and allowing them to
<g t.CC A To R open FULLY.
V ga 3.
Looking straight into the BACK of the CONTACT LOC ATo R/
Cs appropriate crimp section, insert the contact INSULATION
[
/ support (insulation barrel first) into the FRONT of'the y
crimp section. Position the contact in the f
l-wiRc crimpers so that the locator enters the locstor
.\\
\\
, ::d-l -
l-s A R R El.
slot (see Figure I-3). Now, push the contact in 159 f
until the WIRE BARREL buris against the T
,s y'
locator / insulation stop (see Figure I-4).
U 4
Hold the contact in this position and w
wtRE slot squeeze the tool handles until the insulation IN LOCATOR anvil starts entry into the insulation crimper. Do A
NOT deform the insulation barrel or wire barrel.
)
5.
Insert a properly stripped wire through the wire slot in the locator and into the wire barrel of the contact until the insulation butts against FIGURE l-4 the locator / insulation stop. See Figure 1-4.
1-4. INSULATION CRIMP ADJUSTMENT
^
The insulation barrel crimp height is controlled by A! u NT CNTACT
{NT the in$ylalion adjustment lever. To determine the i.svra FRONT p
proper setting, test crimp a contact using the setting 3
["y z
which approximates the insulation size (1-small, C%r 2 medium, or 3-large). If the crimped insulation ons O
barrel is too tight or too loose, change the setting accordingly. The crimp should hold the insulation i
E zCT N f5 firmly Without cutting into it.
IARK No-l 5. DAILY MAINTENANCE Remove all foreign particles with a clean, soft brush, I
or a clean, soft, lint free cloth. Make sure the proper
/
9 LOCATOR /
INSULATION proper retaining rings. If foreign matter cannot be 7
sToP CONTACT' removed easily, or if the croper replacement parts are not av3ilable, return the tool to your supervisor.
\\
Make certain all pivot points and bearing surfaces are j/
i I
protected with a THIN coat of any good SAE No. 20 SACK OF LcCATon motor oil. Do NOT oil excessively. When the tool is wR s;nor)
- N CONTACT) not in use. keep the handles Closed to prevent objects i
from becoming lodged between the crimping dies, FIGURE l-3 and store the tool in a clean, dry crea.
' AGE'2 OF 4
/...l? HAND CRIMPING TOOL 902721 15 7556 Section I of :nis instruction snee: covers :ne con:act.: Section ll covers maintenance and inscection recom-J and acclication procedures recommended for the menced by AMP to assure reliacility of AMP nand i AMP Hand Crimoing Tool 902721.
crimoing :cols.
l 1
/
l o
Op
. a v
e t
b3 'h
,O D
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./
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o l
i s
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t J
D t
TOOL SPECIFICATIONS REPLACEMENT PARTS KITS 125218 5 DIMENSION WElGHT ITEM DESCRIPTION PART NUMBER QTY PER KIT A
21/2 1 lb 4 or il Ring-Retaining 21045 3 120 to 130 B
11 7/8 2
Ring Retaining 21045-6 l
25 to 30 C
3/4 CAUTION: CO NOT REMOVE THE RETAINING PINS AS PERMANENT
[V Enginsonng Approval Date
~~
oAMAGE TO THE TOOL MAY RESULT (see Paragraon 18-3).
9~9 o
%/u FIGURE 11 1 SECTION 11 MAINTENANCE /lNSPECTION cloth. Do NOT use objects that could damage the tool.
11 1. TOOL CERTIFICATION These instructions have been approved by AMP 2.
Make sure the proper retaining pins are in Design, Production, and Quality Control Engineers to place, and secured with the proper retaining provide you with documented maintenance and rings.
inspection procedures in accordance with AMP Cor-porate Policy Number 3 3. We have, through our test 3.
Make certain all pins, pivot points, and laboratories and inspection of production assembly, bearing surfaces are protected with a THIN coat established the procedures described herein to assure
~ of oil. If necessary, oil with any good SAE quality and reliability of AMP hand crimping tools.
No. 20 motor oil. Do NOT oil excessively.
The parts listed in Figure 111 are customer replace-4.
When the tool is not in use, keep the able parts. A complete inventory should be stocked ~
har.dles closed to prevent objects from becoming and controlled to prevent lost time when repla. cement-lodged in the crimping dies, and store the too' in of parts is deemed necessary. When ordering, order a clean, dry area.
the replacement parts kit listed in Figure 111.
n.
PERI mc IN9ECTioN 112. INSPECTION PROCEDURES Regular inspections should be performed and A.
oAILY MAINTENANCE recorded by your quality control personnel, with a The importance of daily maintenance cannot be over-record of scheduied inspections remaing witn tne emphasized, as it is the most effective method of tool or supplied to supervisory personnel responsible ensuring tool reliability and continuous production.
We recommend that each operator of the tool be ~
for the tool. Thougn we recommend at least one inspection a month, the inspection frequency should 4
made aware of - and responsible for - the following four steps of daily maintenance:
be based on the amount of use, ambient working conditions, operator training and skill, and your 1.
Remove dust, moisture, and other con.
company's estaolished standards. These inspections taminants with a clean brush, or a soft, lint free should be performed in the following sequence:
par r 1 rir a j L
I
157556 AMP HAND CRIMPING TOOL 90272,
B 1.
VISUAL INSPECTacN 1.
Rsmov2 all lubrication and accumulated POSITION o
film by immersing the tool (handles partially Pb"rE 7 N c
closed) in a suitaole commercial degreaser that WIRE B ARREL will not effect paint or plastic material.
OPPOSITE SEAM l
l 2.
Make certain at: retaining pins are in place, and secured with retaining rings. Refer to parts
\\ \\ //
\\j listed in Figure 11 1, if replacements are 4
n:icessary.
il 4
3.
Close the tool handles until the ratchet I
l'
!]
r:. leases, then allow handles to open freely. If j"
[,*o$2 lj q]
they do not open quickly and fully, the spring is Q8{ LED d&fective and must be replaced (see Para-grapn 11-3).
4 Inspect the head assembly, with special emphasis on checking for worn, cracked, or CONTACT UM A
WIR E SIZ broken dies. Make sure the depressions above NUMeER "A
(MAX)
MARKING the wire size markings are color coded green (see g
g 3,3
,g33 Section 1). If damage to any part of the head 58385.15 assembly is evident, return the tool to AMP for 5838s3-9 20 20
.C39 evaluation and repair (see Paragraph 113).
i.s33ss31 8-2.
CRIMP HEloHT INSPECTION
~
FIGURE Il-2 This~ inspection incorporates the useEf-a m.icrometer with a modified anvil as shown in Figure 11-2. We recommend the Crimp H eight Comparator 2.
Position the contact and wire between the RS-1019-5L which can be purchased from:
crimping dies, according to the Crimping Procedure described in Section 1 (Steps 1 VALCO through 5)....then holding the wire in 634 Stefko Boulevard Bethlehem, Pennsylvania 18017 place, squeeze the tool handles until you are
~
certain the CERTI CRIMP ratchet has released.
Proceed as follows:
Now STOP and HOLD the tool handles in this 1.
Select one of each of the contacts, and the position. Maintain just enough tension on the maximum wire size for each from the chart in tool handles to keep the dies closed.
Figure 112.
3.
Check the clearance between the bottom-2.
Refer to the Crimping Procedure in ing surfaces of the crimping dies. If the clearance Section 1, and crimp the contacts accordingly.
is.001 in, or less the ratchet is satisfactory, if clearance exceeds.001 in., the ratchet is out of 3.
Using a crimp height comparator,' measure adjustment and must be repaired (see Para-each wire barrel crimp height as shown in graph 11-3).
Figure 112. If the crimp height conforms to that shown in the chart, the tool is considered if the tool conforms to these inspect. ion procedures, dimensionally correct. If not, return the tool to lubricate it with a THIN coat of any good SAE No. 20 motor oil and return it to service.
AMP for evaluation and repair (see Para-graph 11-3). For additional information con-113. REPAIR cerning the use of the crimp height comparator, refsr to AMP instruction Sheet 157424 Parts other than those specified in r-igure 11-1 must be replaced by AMP to insure certification of the tooi.
3 3.
CERTI-CRIMP R ATCHET INSPECTION When repair is necessary, return the tool with a First, obtain a.001-in. shim that is suitable for written description of the problem to:
checking the clearance between the bottoming AMP incorporated surfaces of the crimping d,es.
i Customer Repair 2roceed as folicws:
1523 North 4th Street 1.
Determine the maximum wire size,'and the g,
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or a wholly owned subsidiary of AMP incorporated.
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EB ASCO SERVICES INCORPORATED EBEO T*: b'.; toira:e Cete* New Yo'a'N Y 10045 September 28, 1983 LW3-1330-83 File: 1-N-1 70-C-8 Response Required: No Mr G B Rogers, Site Director Louisiana Pos.er & Light Company P O Box B Killona, LA 70066 Re:
WATERFORD SES UNIT NO. 3 NRC INFORMATION NOTICE 83-08 COMPONENT FAILURES CAUSED BY ELEVATED DC CONTROL VOLTAGE Ref:
- 1. W3P83-2036 dated June 21, 1983
- 2. LW3-1049-83 dated July 27, 1983
Dear Mr Rogers:
The subject NRC Information Notice (IN83-08) addresses the effects elevated de voltages may have in the premature failure of selective Class lE components.
Ebasco has reviewed this IN for its applica-bility to Waterford 3 and the results are presented below.
Ebasco's approach to this subject has been to specify equipment capable of operating under the anticipated voltage variations of 105 to 140V.
Basically this review consisted of the following:
- 1. From the supply end, investigate if the removal of 1 cell from the station batteries will reduce the float and equalizing voltages of the battery to values within the rating of all equip-ment without degrading the battery's required performance during an emergency.
The results of a preliminary investigation indicate that this option would reduce battery capacity to an undesirable level.
Therefore, no additional consideration has been given to this option.
l
- 2. From the load end, investigate whether all Class IE de equipment procured.and installed at Waterford 3 can tolerate the elevated de conditions described in the NRC IN, thereby precluding the neces-sity to implement Item 1.
The following is a breakdown of Ebascn's recommendation to each problem area outlined in the NRC IN.
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t EBISCO SERVICES I4C08POR4789 Sectember 28, 1983 Mr G B Rogers LW3-1330-83 Problem No. 1 - Breakdown of a lamp socket which when it failed scat-tered debris within the panel causing short circuits in adjacent control circuits.
Reason: The 125 V de socket (and lamp) was oper-ating at 130 V de continuously, solution: Remove two cells (Trojan Nuclear Plant).
Comment: CIWA 821925, 821926, 821927, 821928 indicates failure in the plastic part of the microswitch light (28 V de) module and socket (See attachment I).
Investigations by LP&L startup group concluded that the failure was due to poor quality in manufacture of the in-dicating light assembly and not to elevated de voltage for the following reasons:
- a. The microswitch lamps (28V) used in the RTG board are essent-ially identical to the model #1819 lamps in the 6.9kV switch-gear utilizing the same or smaller size dropping resistors.
No problems have been reported with the lamp assemblies in the switchgears.
- b. By calculation (See attachment II, sheet 1), the maximum volt-age on the 28V de lamp will be 30.7 (assuming no tolerance in the resistor) when 140V de is applied to the lamp-resistor ass-embly.
Similarly on the 14V de~ lamp, the maximum voltage would be 15.5 V dc.
If the frequency of equalizing voltage is as described in attachment VI, and considering that there will be voltage drop in the lamp feeder cable of 2-3 volts per design criteria, then the voltage applied to the lamp will be acceptable.
- c. The heat from the lamps or resistor could'not cause embrittlement and aging of socket plastic parts because:
i - The voltage droppings resistors for these lamps are mounted remotely from the lamps themsel'ves thereby contributing no heat to the lamp module.
ii - These lamp assemblies have been successfully prototype tested and documented in a qualification report which included thcr-j mal aging in an oven (Microswitch Report No. LTR-24407.
Test was initiated on August 19, 1975).
(See Attachment III).
On September 1, 1983, a voltage test in the RTG board was performed and L
the results are shown in Table I -
l i
==
Conclusion:==
The voltage test performed at the site has provided evidence that the failure of the lamp assembly was not due to elevated de volt-age but that incorrect lamps were installed by the operators.
Further-the voltage test on the correctly lamped modules substantiate
- more, 4
the Ebasco comments and calculations, and no action is required by Ebasco.
LP&L is~ advised that the plant operators must be instructed to utilize the correct lamp type in all future relamping operations.
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'EBISCO SERYlCES 3%CORPop4TED
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September 28, 1993 Mr G 3 Rogers LW3-1330-83 Problem No. 2 - One solenoid valve has a shorted coil, another a short to ground which blew fuses.
The solenoids were rated at 125V dc
+ 10%.
Reason:The battery was equalized at 140 V de with solenoid valves energized.
Solutioni Change solenoid coils to withstand 140V dc (Fort Calhoun Nuclear Plant).
Comment: A review of catalog numbers of all solenoid valves listed in the " Response to NUREG-0588" were evaluated and the following was determined:
- a. ASCO de solenoid valve catalog numbers were found to be covere'd by ASCO catalog number NP These valves are designed to oper-ate between 90-140 V de which is within the Waterford 3 design envelope (ASCO qualification specification AOS-21680/Rev.-C dated July 13, 1981, Paragraph 6.1) (see Attachment IV).
- b. Valcor de solenoid valves.
Two class lE de valves (Tag Nos.
t 3-CC-E640A and E641B) were provided by Valcor.
In accordance with their " General Qualification Test Procedure for Class IE Nuclear Service Valves", page 3, Rev. E, dated September 21, 1977, all valves were tested at " + 10% of rated voltage" or l
137.5. V de (see attachment V).
This' voltage rating is accept-able based on a 2 to 3 volt drop in the feeder cable per design criteria.
1 The balance of Class IE solenoid valves not located in the harsh en vironment were also reviewed and the results are as follows:
- a. The solenoid valves, model numbers V5H61090-120 V de and V5H61100-120 V de, supplied by Anchor / Darling valve Company on the A/DV hydraulic actuators have been qualified for a voltage range of 90 to 140 V de by the Qualification Report No.
I 43847-2 Rev. C.
- b. The solenoid valves provided by W-K-M Valve Division were manu-factured as per Specification LOU-1564.108.
This specification called for solenoid valves to be suitable for operation at 125 V dc + 15 or -25 V dc.
==
Conclusion:==
Based upon the above analysis no action is required on this item.
Problem No. 3 - One relay coil rated at 120 V de failed after 5 years i
of operation.
Reason: Overheating.
Solution: Replace relays with 125 V/130 V de coils.
(Zion Nuclear Generating Station').
4 Comment: Class IE de relays in relay cabinets are either Agastat or Potter - Brumfield type MDR.
Other remotely located Class IE relays, i.e., medium or low voltage switchgear, have been specified for operation from 105 V de to 140 V de and they are operating satis-factory.
m h
EBASCO SER\\lCES 8 %C 0RFOR 4TE D Sectember 28, 1983 Mr G B Rogers -
gg3-1330-83 Agastat relays were tested in accordance with Amerace Corporation Control Products Division, Qualification Report Document No. E 7014/E7024 (see attachment VII).
On sheet 4 of this report they were operated and successfully tested at 80% to 120% of de rated voltage (100 to 150 V de).
Potter'- Brumfield type MDR relays were qualified to Reliance Test Plan No. 753-ET-1 dated September 15, 1978 (see attachment VIII).
Though this provides qualification to IEEE 323-1971, the operating margins of IEEE 323-1974 or manufacturers' margins were employed to test these relays (per paragraph 4.0 of manufacturer Test Plan).
The margin of + 10% rated voltage suggested in IEEE-323-1974 will permit operation of this relay up to 137.5 V de and if the battery equalizing voltage is reduced to 136.5 V de or below this type of relay will be within its operational and qualified envelope.
There-fore, it is recommendedsthat the battery equalizing voltage be re-duced to 136.2V de (2.26 V de/ cell) as indicated in Gould Stationary Battery Installation and Operating Instructions Table E.
.The net results would be to increase the estimated minimum equalizing time from 74 hours8.564815e-4 days <br />0.0206 hours <br />1.223545e-4 weeks <br />2.8157e-5 months <br /> to 166 hours0.00192 days <br />0.0461 hours <br />2.744709e-4 weeks <br />6.3163e-5 months <br /> which would be required approximately once a year (see attachment VI).
This modification will permit all de equipment to be energized longer with an increased life expectancy and never be subjected to the 10% overvoltage operating margin re-quired by_section 6.3.1.5 of IEEE 323-1974 to which the equipment has been qualified.
General
Conclusion:
Based upon the above Ebasco can conclude that all Class IE de equipment will not be subject to operating stresses in excess of what it has been designed and tested to, and that no modifications to plant equipment is required.
In addition, CE Power Systems has indicated in their letter C-CE-2737 dated December 23, 1975 that they have no comments to Specif-ication LOU 1564.280 titled " Storage Battery.(Class IE)"
(see attachment'IX) which explicitly identifies a steady voltage vari-ation between 105 to 140 V de at their terminals.
However, to preserve the life and integrity of this equipment, it is-Ebasco's recommendation that battery equalizing ' voltage level and frequency be as follows:
t
- 1. When equalizing is required due to certain cells falling out of tolerance relative to specific gravity or cell voltage the affected cells can be individually equalized while the rest of the battery is float charged.
- 2. When equalizing is required due to emergency discharge or annual equalizing (if required), the battery equalizing voltage should be 136.2 V de maximum as explained earlier.
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EBASCO SEM ICES 1%CCBPDD47ED September 28, 1983 Mr G B Rogers LW3-1330-83 If the above measures are taken, Ebas=o feels that the concerns out-lined in the NRC IN will be resolved.
Please call us should you have any questions or comments.
Very truly yours, K Hancock Manager of Electrical Engineering HC:dns
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By:
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Central Records W3 (2)
Nuclear Records GO (2)
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Vz t J J Costello J P Padalino J K Tompeck R C Rossi J Horvath R J Johnson R Hymes J M Brooks-I R Marshall (3)
J DeBruin J Houghtaling J Holwell Project Record File WW) c.4. N
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Attechment'to LW3-1330-83 TABLE I Test Voltage Item j
Resistor Lamp Resistor lamp No.
CWD No.
Equipment (ohms)
(volts)
(volts)
Type Remarks 1
B424-2222 OCB 3A 1400 53 1835 Since the wrong lamp was installed a new lamp type No. 756 was replaced and the read-l Ings are shown in Item 2.
3 2
B424-2222 OCB 3A 1400 15.3 756 3
B424-2381 3B2 to 3B3 1400 17.8 111.2 756 4
B424-2332 3A3 to 3A2 1400 18.2 110 756 5
B424-2331 3A2 to 3A3 1400 57.2 72.4 1385 See remark of item 1 except that the read-ings are shown in it.cm 6
B424-2331 3A2 to 3A3 1400 14.7
- h 756 7
B424-2477 3A31S to 3AB31S 2500 26.1 327 8
B424-2527 3AB31S to 3A31S 2500 20.4 327
)
No reading was taken of the resistor because it was located in the swyd.
No reading was taken of the resistor Note: The readings were taken by Ddvid Gray from LP&L
Attachment to I.W3-1330-83
. ~
TABLE I Test Voltage j
Item Resistor Lamp Hesistor Lamp No.
CWD No.
Equipment (ohms)
(volts)
(volts)
Tyge Remarks 1
B424'-2222 OCB 3A 1400 53 1835 Since the wrong lamp was installed a new lamp type No. 756 was replaced and*the read-ings are shown in Item 2.
2 B424-2222 OCB 3A 1400 15.3 756 3
B424-2381 3B2 to 3B3 1400 17.8 111.2 756 4
B424-2332 3A3 to 3A2 1400 18.2 110 756 5
B424-2331 3A2 to 3A3 1400 57.2 72.4 1385 See remark of item I except that the read-ings are shown in item 6
B424-2331 3A2 to 3A3 1400 14.7 756 7
B424-2477 3A31S to 3AB31S 2500 26.1 327 8
B424-2527 3AB31S to 3A31S 2500 20.4 327
)
No reading was taken of the resistor because it was located in the swyd.
No reading was taken of the resistor Note: The readings were taken by David Gray from LP&L
A-r r s men r I De a
to tw3-133n-83 EMO
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cArg " June 30, 1983 FILE REF. COB-83-146 To M. I. Meyer/E. Senac 0FFIOE LOCATION.
k mou J. E. Holvell J. Engledov OFFICE LOCATION
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,n-SUBJECT IDUISIANA POWER & LIGHT COMPANY
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WATERFORD SES UNIT No. 3
~ - A gG 4KV BREAKER MIMIC ANNUNCIATOR FAILURE CIWAs 821925, 821926, 821927, 821928.
y;j.,73g;p m da py,3g gi"nLnG Pe.r your request. v'e have reviewed the subject documents and offer the following information.
The Micro Switch model #2F206' indicating. lamp is utilized on RTCB CP-1 for the mimic display of the feeder breaker status of the safety and non-safety buses.
While trying to determine the reason for this high failure rate, Jim Engledow asked the operators how often the bulbs were replaced; this vould be the main reason for removing the seal ring and lamp sockets.
They stated that the bulbs required frequent replacement.
The bulb is a Chicago miniature lamp #CM-327.
28 VDC and 0.04 a=ps.
It is designed to operate at resistor is vired in series with each lamp.To drop the supply voltage (nominal 125 D states the following:
The FSAR (Section 8.3.2.1.2)
"To assure equipment protection in the de system from dama-ging overvoltage fro = the battery chargers that may occur due to a faulty regulation or operator error, each battery charger is equipped with built-in overvoltage shutdown pro-tection circuitry to sense output overvoltage (setpoint adjustable) and shutdown the battery charger af ter a (ad-justable) time delay.
For the float and equalizing volta-ges set at 132v and 139.8 respectively, the charger alarms at 144V and shutdown circuitry is set at 152V."
LP&L Preop' for system 2 said that from testing, the battery voltage is a nominal 140V DC.
This means that the resister in series with the lamp should be sized to drop 112V at 0.04a.
tage should be 2800 oh=s (R=112vi.0.04a=2800n.).The resistance value to prote With the existing 2500 ohm / resistor, the bulb, which is designed for 28V DC is actually sensing 40V DC.
the life of the lamp, thus the operators vould not be required to relamp nunciator and prolong the life of the plastic retainer r,ing and socket which must be removed for relamping.
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Another alternative is to replace the la=p as requested by the CIWAs. The Micro Switch Model #2F206 and #2F6 are interchangeable units. Micro Switch said that the only'eption would be to replace the 2F206 with the 2F6 which requires a tool to rela =p.
Micro Switch has sent their catalog for these units, but not a sample of their 2F6 unit for our inspection. When it ar-rives, a better evaluation can be made whether to replace the 2F206 unit, with the 2F6.
We recommended to authorize ESSE I&C to formalize documentation to revise their circuit design for the resistor in series with each lamp. That is change the 2500.tLto a 2800.n.resi'stor which appears to be the simplest so-lution for long term usage.
If you have any questions, or comments, please advise.
JEH/JE/das ec:
R. M. Milhiser
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Attachment IT Sheef I.F 3 LW3-1330-83 LOUISIANA POWER & LIGHT CO.v2ANY WATERFORD SES UNIT NO. 3 EFFECTS OF DC VOLTAGE VARIATIONS ON DC INDICATING IMJS 125VDC Iy 2500f R Lamp = = 7 0 Crt 4g 2BV c s Lamp at T = 2500 + 7 0 0 = 32 0 0,rt. VL 40 ma t = h 0 = 0.04375A y at 140V VL at 140V = 30.625V-L at 105V = x 00 00 22.97V = 125VDC R 14V 1 L""P " D 68 = 175n., ~ 140h R T = 14 00 + 17 5 = 1575.f? a T at 140V = h 5 4V at I Lam = 0.08888A yL Y 1 L at 140V = 0.08888 x 175 = 15.5V_ (. 0 8 V p,.y,105 x 175 = 11.6V t')
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.40C i 20 i C.2F l 20.000 i s,s 1N i 42 ' andicato'*3 i T.1 L4 l S C. Mid -Fig 14 I .30 C ' 48 i C.2F i 15.0C0 I he i Na 12 5 1 Indicator 43 7e n T.13/s l S.C.Mid. Fig l 28 .15 C l .04 i C.2F i 10.000 t 'Its { 33hs 06 iinacator*3 1 T.13;4 i Mioget Grooved i 14 i .30 C I .08 i C.2F i 15.000 l als {Sa t it? I Indicatoru n i T.131 i S.C Mio. Fig. I 28 1 .30 C i .04 l C.2F l 7.000. j he l s/s 4 ist i insicator z 76 i T.13: a 1 M.oget Grooved ! 28 i .30 C 1 .04 i C.2F l 7.000 l he l Ses 4 194 l Indicator 76 i T.1h4 l S.C. Mio. Fig l 12 I .10 C i .04 ; C.2F i 10.000 l-ha l Us )35x Sorciat Service Flashlign B3W S.C. Min. Fig. 3.0 .15 C .07 152 50 8/4 1W 20 Cells l l98 IIndcatorsn T 13a i Miege' Grooved 63 l .55 C i 20 i C.2R 5.000 l No l Na i 600 i Aireratt . T.3144 lWooge i 28 1.6 C l.10 i C-2F l 1.000 (.562 lInns bot i Toy Flasne Lamo. I D Cellik 6: 1 G4W l Min. Screw l 1.25 l .09 C l 25 lC4 l 153 l 'es ( 18 tis blX 1 Sig.aiJasher Larno 9 G4W l Min. Screw i 1.5 l 1.2 i.33 i C-6 l 503 i *es i1846 n5 i Siga,a Jasher Lamo 1 G.4W l Min. Screw l 6.5 i 1.9 C l.50 i C 2R 5003 l this l lins $06 I Toy Flasher LrTo-2 D Cetis G4 W $ Min. Screw 12.6 I 43 C l .30 i C.2R 503 l 'Is ' 18.'?s 501 Hand Lantern Flashee Larno G4W wn. Screw 4.9 12 C .30 C-2R 503 84 6 18hs g 4 F Celts $425 i Hand Lantern 4 F Cells G41/r lon. Screw 1 5 2.3 C ( .50 i C.2R _ l 15 l 2hu 18hs $25 i Toy Train .l G4W I Min. Screw l 8 l 1.6 C l 25 ( C 2R " ( 250 '{2hn 1846 E427 j Arcraft Ernergency Lagnting G4W j Min. Bey. 1 5 2.3 C } .50 : C.2R l 15 lW l 18hs {428 i Toy Trem G4W i Min. Screw i 12.5 t 2.4 C l 25 C.2v.3 1 250 !*3W: line 3433 i Toy Train l G4:12 } Mirt. Screw i 14 2.7 C l 25 t C.2V j 250 l 2hn lins 2' i Toy Train G4 W l Min.* Bay. I 14 } 2.7 C 1 25 i C 2Va 6 250 iW l Inna 14 Toy Train, Outside coated G4 W Min. Bey. 14 25 C.2V3 250 L Redsi 114. p. }. i
- w.
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{ Centei l Oversu aseren. mateg g,,, l nene c' er o=wea : 6: Las e i Lewin priaury sema. euin ame verti ers tm an,s rit. nt. (n. m l naciwse ' onen.s> lsrioibo " T.13, e IMegn Groovec 10 I.006 C l.0126-1 C.2F l 50.000. l *is t *is I I I .o154 I I i 1 A teratt ' '4.7L 79 lT.1 l wire Ternt i5 l .09 C 1.075 l C.2R l 25,0CC l - l84 3 i l l l l I m25 % ! I I l l 4AS10 l Aircrattn **.76 4 T.1 [ wire Temt l 5 l .D9 C .075 l C.2R l 40.000 llia l l l I m10 % l l I Arcratt u. 74. 4. 79 lT.1 Suo. Mic. Fig. 5 .09 C l.075 C 2R l 25.000 agi.
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/ t 225 % l l l BAS 15 i A,rcraft8!. 74. 7L 79 T.1 lSub. Mic. Fig. l 5 l .09 C l.075 l C.2R 25.000. 3h6 l3si l l l l 2 15 % I i l h A,rcraftn.74.7L 7s T.1 wire Temt 5 .15 C l.115 C-2R l 40.000 l - RJ4 mM% i i i bas.10 i Air:rstin.14.75.7, T1 l wire Term. l 5 i .15 C .115 , C.2R l 40.000 l - ise I l l210% l l $As.15 i Aircrattn.74.4 4 T.1 [w re Terrr. 1 5 l .15 C .315 a' C.2R I 40.000 sie l 1 l ' 2 15 % l l 5 i Aircratt** 7'.78. 75 lT-1 l Sun,Mic. Fig. 5 l ".15 C .115 i C.2R j 40.000 l alas ses I i I i 2 25 % i .I I l8 AS.15 l Aircraf t n.14. 4. 79 lT.1 lSub he. Fig. l 5 l .15 C .115 l C 2R i 40.000
- afi, afs l
l l 1 l 215 % I l h5 Indicator l T 3 sis ; Min Bay l 6.3 i .33 C i .15 i C.2R ! 20.00043 l nin 1%.
- / ls l andi.ator 1 T.31.4 ! Min. Bay.
I 14 : .31 C l .08 l C.2F I 15.000'3 i S/s 1%s g w b7 6 tacicato' , T 31.4 IMin. Bay. l 28 l 62 C l .08 lC-2F t 7.50CW3 l Sta 13/s. bgM s anstrument3*- 6; 4 G.8 iMin Screw I 70 i BW l l C.7A 600 l 18 s j 13 t /4 .t: 1 Aircraft. Gunsign: G9 lD C. Eay. 12.8 1.31; i C.Sli j 300. li/e 28/s l l 12.8 1.31 i C.6 l 300 36 i Arcratt.Gunsignt G-9 l D.C. Bay. 28. j I' .68-l CC.6/ I 3001 l-28/s l l 28 I I .68 i CC-6 1 300 l 3 Aircraft, Gunsign: G.9 D.C. Bay. 28- .857i CC.41 300e 18/4 23/s 28 .857 CC-6, 300 ,41 ! Arcraft I G.12 1 D.C. Bay { 12.5 1 3 0 l 3C.6 1 300 l l 23,s 44 l Ar:ratt.Gunsignt lG9 i D.C. Bay. l 2Br l .68-l CC-81 1 300; 28ts l 1 I l 28 l .68 i CC-6 1 300 b47 l Aircraft-.Gunsign: Butt l G.10 D.C. Bay. 12.Si 24 W j 2.Di C-6/ l 300! li/e 2846 l Reflectorized. Clear Window l 12.5 24 W I 2.0 C8 l 300 lbT2 j Bu n Base up to Horizonta. 1 4.a Min. Bay. 8 9.0 .90 C.6 50 1*is g instru nent-Photoelectric [ lScanner Ie04 i Aurs. Ucense.Marmer-T.5 weage 13.5 4 .69 C 2F 5.000 I.813 1.49 I l Heavy Duty i 106 Auto. Dome. Counesy. Map, T.5 wedge 13 6 .66 l C.2F l 1.000 l.813-1.49-Marker. Heavy Duty 'l l l [912 Autc. Doime, Courtesy. Map. lT.5 l Wedge 12.8 l 12 l 1.0 C 2R 1.000 l.81 1.49 Navf Duty l l l l l ' 947 l Signa: l T 3isa l Min. Bay. l 9.84 l 4.6 l .50 l C.2R I 200 la l1466 957 i Signai T.4 sis J Min. Bay. I 9.84 1 4.6 C 1 .50 C.2R t 200 l l 1he 358 Searchtignt?3 8urnerg G.163/2 D.C. Bay. I 5.5r 14 C 2.00' C.8Z l 5 01 1 3 ~ ' ~ Posit % l 6.0 5C 0 82 C-12 l 100 l 965 Hand Lantem-4 0 of 8 F Celts T.4 ia l Min. Screw I 9.84 6C l .50 C.2R l 15 t ahaa ths 1003 AltMnterior 84 l 5.C. Bay. l 12.8 15 C l .94 C4 spi 200 d latis lhe 1004 i Auto-antereor and Marine B.6 i D.C. Bay i 12.8 i 15 C i .94 {C6 i 200 lihe I si. 1005 Special Service 58 D.C. Bay l 12.8-21 Cs l 1251 C 2R/ 300t 11/e 2 ! 12.5 21 C l 1.26 C.2R 300 O 1016 Special Service S-8 D.C. Inden 12.8' 21 Ci 1.34I C.6' 300/ 11/4 2 14.0 6C .59 C6 1.500 31. Searenligatt'3 Base Down G.It /> S.C. Bay. 12.8 100 C 4.75 C.2V 100 1 814 3 To Horsweitat 7
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.er!..: E' T : } : elf..1:.:.ry :.21uation of "L5, "35", " CMC", "P "", and "S-; ries 2" Type 3ritches Ur./cr Eisetrien; Aging, Enviren:nental atin;; and Seis:f: Vibratie. Tes*.s. ... _:.e_- Provide: info:.:tica concerning switch performance during ele.ctrical s:;in,, environ-
- ents.1 se,ing and scisnic vibratien o de=anst' rate a switch capability unier the appliesMe port ons of IEEI323 and IEEE34 CCSCL*.:57 CNS :
The "L5", "HS", "CM0", "?I", and " Series 2" switches de=ensttated their abilitics to perfer= their intended switch functicn throughout the selected tes:s. It is the intention of this report to provide infor=ation concerning switch perf or. ance in the arcas of Electr:esi, Environ = ental, 'and Seisnic '.'ibratior testing. Produt: accepts.r:e or su tability cust b'e established by custceer review of this infer-nation in conjunction with his applicatica re:;uire=ents. ' rHS IZA>*T CTITJe62 W.; w'=C?t97 C.fr. lima (C4 f.h3 C 5 PGCeWr D' I:te.tc s:.ntt.s, a y.=;ce;fp n'op *st.g.sj,. C3 (** eracerpgAgr 70 g g sgp 74 ; - _.lD W*Ts*0'/T Tr 8 4WW,91 Or sp_t o s.#F.M. g~ mm 9.8ACa0 Sw!Ttst !aGne!! RIH *. TCS? Lt5.**t*.* r O e*9 swa rvc: s._'.' s'..a-;
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r.',:C"..: 3 C '. :. ";., ,ac r r -:. at.: 12.-<< ,-'.,,(._ . n.v.s.e., e,.. :.s c.,u.. -~ E 13!::EERING. REPORT l 93_c3333_;c 3., ..a TEST SEOUI':CE 1. Basic Measu e= cuts 2. Electrical Life (Initia3 Aging) 3. Environmental Aging 4. Basic Measurements 5. Electrical Life (Extended Aging) 6. Basic Measure::ents 7. Seis=ic Vibration 8. Electrical Lif.e (Functien Verification) 9. Basic Measurements e 9
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,m -- IEST 0.'.T.2 : his ten was initiated on 19 Aupust 1975 by R.P. F:dley. One of ea h of the f ollowin ; Cataleg Listings was received f or testing. e Cataleg Listing' Date Code LSA2B-1D 7524 LSDlA 7534 / LSQ051 7533 FIP2233 7519 PTH2214CCC 7519 (2C203 with 2D9 7527 ~SEE f"" U ~~~ ' @i.i. m DC206vith2D33 7532
- 8# '* ##
911BGD211MC with 2 PTCC 7440 910;CF511 with 4 FTCC-7542 lHS1 7531 CINERAL I::GINEERING CC P.INTS: These tests were initiated because of a variety of customer r.-quests for- "Qualif2 cation" to IEEE 323 or IEEE 344. Qualif t:ation or acceptance under these specifications is a function of individual custo=er renuire=ents. Obviously ve would not have specific infor=ation availa5ir under such a vide varfety of possible test conditions. The Evaluation Laborator. (MICRO SWITCH) was asked to conduct tests that sould shev switch capektlities under simuisted IEEE 323 and IEEE 344 test cenditions. This Info:c.r. tion could then be sub=1tted to the custor,er for approval. 'The test infor= tion acquired is contained herein. TFST EQUIPMENT: The MICRC SWITCH Evaluation Laboratory maintains records of test ec.uipment, labor-atory identification, and as applicable, equipment calibration. The equip :nt used, conducting the tests reported herein; was examinad prior to cath use end validity of calibration period verified. The test equipment u:2d was as f c.;iov,. Iaboratory Frequency Scrial No. cf h uip ent
- AB-C a l t h r.'.t i ca.
Characteristics Fixture-Micro =eter Wone Aa used Characteristics Fixture - Protracter Ncne As used Force Haasure ent - Scale 5-22 3 mob.ths a 5-2 3 menths Pilot Lamp Indicator 20-16 As used (7.5 VAC, 0.170 ar. pere) Megeb: Meter I;-55 3 inenths Volt =cter 0-250 VAC 4-l!!! 6 : nths 0-250 VDC 4-253 6 r.cnt:is A==eter 0-10.a=ps, AC 4 cc 3 nsnths 0-50 amts, AC 4-121 6 anonths 0-100 anps, AC A-13 3 months A:=cter 0.5 s:rps. DC .-161 6 een:.ns 0-5 a:aps, DC 4-143C e months
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_.,e e_ Fqui;..cn: (Cont.) L:horatory Free.uent: of . E:p:1p. n _Seri_cl No. Csfibrc: ton Industrial Analy:cr 4-25 6 m nths Ir.ductor DC, MIL-I-31C23 10-2AE NA 10-24G NA Opera' tion Recorder 16-7H -NA la-Sc g; 18-1 NA Oven 100*T to'500*F 1-12 NA 1-12E NA 1-12D NA Pyr-0-Vane Centro 11er 100 to 600*T 8-14C 3 months S-143 3 =enths 8-14L 3 months Euridity Chamber 1-19E NA Recorder Controller - Pry Bulb S-36E 3 months Recorder-Controller - k'et Bulb 6-16 3 mon:hs Vibrator 55 H:. - Mechanical 2-2 6 r.ouths t Lincar Actua:cr 1-250 per min. 0-83 3 NA Table D NA Table E KA 4 Table H NA 1 NA i Kotary Actuator - Motor . 11-1FD NA Chatter Datector 20-79 3 months ' TEST PROCELURE: Unless otherwise specified a31' tests were conducted at roc: te=perature, pressere and humidi:y. EASIC MT_tSURE G.'.TS: A. CFJJACTERISTICS: ~ Switch travel cha'racteristics were sedared (when applic.ble) using a n.icrene:er fixture graduated in.001 inch incre.ents or a protr:c' tor fixture. graduated in 1 degree inerenents, whichever was appropriste. The svi:ch actustor eas coved at a slow uniform rete (approximataly.002 in:h/secend er 2* rcr recend) using a manual drive. Switch circuits were conitored tu continuity throughout switch travel using a pilo: light circuit (Lab 20-16) operr. ting a: 1.5 vat. and.170 a:; ere. ? Although switch characteristics t:easurements were r.o: cypl.4 cable to manually operate devices, switch funreton was verified urin th: -ilet li,ht circatt. Operatin: ferces -(when applicable) were =casured ud:q .t ::a'e (f.sb Nc. 5-2 er 5-22) mwing the actuator at a sl v unifor: rate. The scale 0:s gradus:ed in 1/.* s.snec ~increronts. Circut.t continuity ves, as noted above, ecc.itored throup.hout the svi:ch plunger travel. ,t i l . - - - - - - - ~ ~ - - - - - ~ ~ ~ - - - - * ~ ~ ~ " - " ~ " ' ' ' '
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iG ,, a - 5 -.__e..g .~ ... - = - - - - 5. INS"*.ATICN RESISTA';"E: Insulatien resistance was measured a: 200 V30. Iquipment a: curacy Jinited tae range of-readings fro: 1 =cg:h to 100,000 megshes. Poin:s af messuremen: vere es follows: Mu" ually insulated ter=insis of the same pole for those poles scheculad for 1. electrical tests. 2. Ter=inals to grounded esse (when applicable). , ELECTRICAL LIFE (Aging): The object of this test was to apply sufficient mechanical sad electricci operatient, on typical 125 VDC and 125 VAC loads, to approxis.'.:e switch conditions fclieving a 40 year mech:nical and electrical service life. For each avitch type ve sale:ted a servi:e life that was ccapatible vi:h projee:2d switch use in the applica:f on. The operational life and loads selected do not necesserily reflect seximu: switch capabilities. The life and load condi:fons selected were typical of these en-countered in various customer specifications a:.d applicar. ions at this tinc. This test was divided into three sections. The first was the initial electrica* aging of the sa=ples, intended to. represent a 10 yes: life. The second was an overtest -following esvironecntal aging. This was intended to verify sustained electrical function following accelerated degradation of the switch dielectric The th'ird was verification of sviten operation following a simulated materials. earthquake condition (seismic vibration). Operational details for the various evitch listings are shown on the char's titled " Electrical Test Parameters." One sample of each catalo; lir:ing vs: subje::ed to the specified load conditions follcuing 1.-izial "Essic Measure:en:s", "Er.viron-cental Aging", and "Seis=le Testing". Each switch opers:f on v:s m:nicered e n c suitable chart cype reccrder. These charts were reviewed to verify proper avit.h cperation throughout the life tests, f2WIRONMEJTAL AOING: The environcental aging portion of the tests censisted of three cycles. Each cycle included Therral Aging, Humidity Exposure, and Sinusoidal Vibration conducted in that croer. A. ' THERMAL AGING: In-h switch constructi:n sad 1es relstud esto:icls verc c..a.ined carefully to dettruine the maxiuum re perature at which the switch weul' survive, vi:hou: significen: deterioration of :s:erisis cc periornssce, icr a peri:d of at less: ~00 hours. The teuperatures selected were Intanded to provide an a:eelerated thurssi cegradation which would approximate a 40 yest per:cd of suf:ch use under norm:1 operating condicions. O' vies:1y vc do not have 40 yes:s of ozpwrien:u o accanalst:d on the svi:ch li: tings tested. As a con =equca:c, Aging Tsapo.ateres vare bact.d on our engineering jude.enents and svai2sbie informarina. L'^ - ~ ~. - -
El ECTRICAL, TfEST PAR /@, TETE'IS, Current Inductor or Actuation tcirg stin,g, VoltaRe_ Aggeres Pnwer Factor Type Rate Circuit Teste l A2D-ID 125 VDC 0.25 Ind. MIL-I-81023 Linear 6/ min.
- 1-2,it.C.
7-8, N.O. 01A 125 VAC M60-B6 Ind. Il22%-B28% Linear 30/nin. 3-4, N.O. QG51 125 VDC 0.5 Ind. HIL-1-81023 Linent 6/ min. 1-2, N.C. 7-8, N.O. ?2285 125 VDC 1.1 Ind. HIL-I-81023 Linear 6/ min. 3-4, N.O., Block #L 3-4,!!.0., Ulock f2 'll2214CCC 125 VAC M60-B6 Ind. H22%-D28% Linear 30/ min. 1-2,ti.C., Block fl 5-6, N.C., filock #2 123 VAC M7.5-B1.2 Ind. H14%-D33% Linear 30/ min. 3-4,11.0. Illock # 3 7-8,it.o., Diock f3 ,233, 2D9 125 VAC 5 Res. Linehr 30/ min. 1-2, !!.0., Dasic f t 4-6, N.O.. Danic #2 7-8, N.C., It.in ic # 1 10-11, N.C.,liasic F4
- 206, 2D33 125 VDC 0.25 Ind.
HIL'-I-81023 Linear 6/ min. 1-3, N.O. Basic dl 4-6, N.O., JLiele (2 7-8, II.C., l'a s ic # 1 10-11, N.C. liasic #4 L1DCD011HC, 2 PTCC 125 VDC 1.1 Ind. IIIL-L-81023 Linear 6/ min. 1-2, N.C., fil ock fl 5-6, N.C., Block #2 l0CCc511, 4 P1tc '125 VAC M60-Dri Ind, M22%-E28% Rotary 6/ min. 1-2, N.C., Block #1 5-6,!!.C.,1: lock #2 3 H7.5-Bl.2 H14%-D33% 3-4, II.O., lit o.-k # 1 7-8,11.0., Illock # 3 250 VAC H30-D3 H20%-D30% 5-6, N.C., Block F4 15 1 125 VDC .5 Ites. 1.inear 6/ min. C-N.O. - Make or inrusti load parameters.
- f 78
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m, l 91-05505-10 ,c. _ _?_. e, _ P., _, ti,e cos: of ec-ple.x verift:ation tests. We can only off er our terts fo-cust::er consideration and/or cceep,tence. s Each of the three tes: cycles consisted of a minimun cf 23~. Leurs exper.ure at the selec:cd tc=perature. The total exposure ti=c in all cases was in excess of 703 hour. The ther al acing was conditeted in cire=1 sting air t.sens with unzentrolled hu=idity. The individual test ta=peratures.nd exposure :ir.es are shown on the char: titled " Environmental Aging - Ther=:1 Aging". B. MOISTURE ABS 0;.PTION: This portion of the Environ: ental /.ging test eas included to evaluate the prope,rties of ca:erials as ebey are influen:ed by thc absorptic. and diffusion of noisture. Absorption of ncirture by =any ca: 4 ?ials resul:s in swelling, loss of physical strength and degrasstien in dielectr.: proper:tes. These affects are further magnified by ther=al aging. It vrs. therefore, logical to include such a tes: in our Environmental Aging. Each switch vas subjected to a mini u: er.pesure of 48 L: prs de:< tion a: 101'T ar.d 95 to 100 relative hucidity following each cycle of therta' agin. A 43 hour time period was considered sufficient to allow caterial sat.*ativt. for the material vole =es used in the tested switch lirtings. ,C. VIBRATION (SINUSOIDAL) AGING: 0 The purpose of vibration aging was to iepose mechanical stresses on the s.*i.ches, co=pensating for these introduced during shipping, ins:c11ation and servi-e li f e. These stress factors are variable in the custerer applications. P.:ving r.: lea: definition of vibration aging parameters frus IFEE 323, the author selected a sinusoidal vibratisa having a frequency range of 10 to 55 hertz. The L.reanic motien had a disp.'. ace =ent as specified in :he chart titled "Envircr.r. ental .4,. ng - Vibration Aging". The entire frequency range from 10 to 55 and back to 1; nu.:z van traversed in 1 minute, the frequency being varied uniferr3y be:veen th ase li=its as per MIL-STD-20 E, He: hod 201A. Each svi:ch, courtad by its nart:1 mounting means, was subjceted to one half hour of vibration in each of i:s three major planes, following each of the three " Moisture Absorption ** cycles. "ac. tal vibration tinie was four and one half he'ars. Since the purpose of this test v s to provide mechanical stress, we did not at:empt to conitor evitch.conta:ts fer separa: ion or transfer. Following each vibration exposute the switches were exc=ined visually for breslage or deforentzon, and techanical fune: ion was vecified using a pilot lamp load (Lsb No. 20-16). SEISP.10 VIERATION TESTING: The scist c vibratica portion of this svi:ch tosting vas confucted et /.::cn i haviren=cn:sl Testing Corpors: ion by Espucito oe. 3 Cec.:r.be r 1976. The foll:vant section of this report concerning these tests was extractad from the Acton rep rt nur ber 12762.
p .Y T...., r.. t..... - .w . o.u,.o~ c. - -c.,.e.. 1 ENGINEERIN.G REPORT l --v. i ,, _ n. 3 3 3.m 10 ~u 6,.. this tire vc have no well defined recuirc=ent: At fore, we decided to monitor contsetThis must be specified by the indivi aal custc e during vibratien. ~nere-separation er tra sfer as applicsbit, the duration of any separation or cransfer and Ici the custe:er seterrinc if report the search performance would be satisfactory in his application. A. TEST M30"T!NC: The ten switches were mounted to an aluminum test fixture which van securely attached to the small biaxici table of the Acton E.wierr.r.tr.tel resting Curosration (AETC) 45* biaxial scis=ic test facility such that che fixture had a trans= ss-ibility of 1.0. si=12ar to actual field mounting.the switches were attached to the tesc fixture in a =enn as follows:* The noenting configuratien ui each switch was Swttch Mountine Configuration 1. LSA2B-1D 2 Allen screws through svitch to auxilary t.cunting plate and 4 allen screws through this plate to the test 2. LSD1A fixture. 2 allen screws through switch to tast fir.ture. 3. LSQ051 Same as LSA2B-1D. 4. IP.51 2 allen serevs through svitch to the 3/S inch angle fixture.
- 5.. PIT 22BS Panel type mount.
to 1/4 inch for maunting. cross section of 3/8 inch engle fixture reduce. 6. PTH2214CCC Sa=e as PTP22EB. . 7. 2C203 Panel type mount, cross section of 3/8 inch angle fixture (2D9) reduced tc 1/8 inch for mounting. 8. 2C106 Panel type mount, cross section of 1/4 inch angle fixture (2D33) (furnished by MICR0 Sk'1TCH) reduced to 1/3 inch for svisch mounting, an le fixture at: ached to test plate usi g 2 allen screws. 9. 910CCTS11 (4-PTCC) Panel type mount to the 3/8 inch ang3e fixture. 10. 911BGD011MC Same as 910CCT511. (2-PTCC) Refer to included photographs. C B. TECT MONITORING: The ten switches were visually monitored for any evidence of uechanical damage or deterioration. The cyitches were monitored with accelerometers by AITC personnel to determine their mechanical response. Data from.these accelerc=eters was recorded on visicorder chart paper. The five conitorine ac:clare..tr.cr: accelereneter vere =cunted in the following locatiens:* sad one c:ntrol
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'[. 't . r..- ,.t g. ste:u m: ..n.e l n o.vxo.. :e e.c < t e.. 13, f,7 7 t, y, y f, ;, i ENGulEERING REPCRi 93_c333_;2 9 u m 8.c c c1c z c=e t e r N*arber Axis Lorction* 1 Vertical on Svitch 9115 0011):C 2 Vertical On Switch ~10:GF511 3 vertical on Switch LSQ051 4 Vertical On Switch LSA2S-1D '5 Trent-to-back on fixture angle 6 Vertical On fixture plate (centrol) MICR0 S*.' ITCH personnel wired the closed contacts of switches LSA23-13, LSD1A, LSQ051, 1HSI..PTP2233, PTH2214CCC, 2C203, 911B7D011MC, 910CCF511 and the open contacts of Switch 2C205 for conitorir.g of cent. t chatter or zalso clnsure by means of a 10 station detector previded by MICR0 S'a* ITCH. The X:CRO SUITCH dccceter had four ranges of detection-as follows:
- Refer to included photographs.
Range No. Detection 1 In excess cf 10 ricroseconds 2 In excess cf 100 tieroseconds 3 In excess of 1 millisecond 4 In excess of 6 millisaconds C. RESONANCE SURVEY: i A resonance survey using a sinusoidal input of 0.2 g's (vertical and horizontal peak acceleration) at frequencies of 1 through 35 Hz. was condutted at a c;eep rate of 1 octave /=inute. The input was applied to the s:all bicxfal table of the AITC 45' biaxial seismic test facility in cl.e felicving sequence: Test No. Biaxial Direction 1 Tront-to-Back & Vertical 2 Left-to-Right & Vertice1 3 Back-to-Front & Vertical 4 Right-to-Left & Vertical . D. SINE BEAT TEST: The sine beat test consisted of a:pittude rodulated sinusoids with a vertical anJ horizontal peak seceleration as shovn.in the attached Generic P.im Specificatior., Tigu,re 1, limited by 20" DA and 90"/sec. piston velocity. The sine bist test was i to be performed at any resonant frequencies found in the " Resonance Survey" as vell ss at Ji Hz. The test for a given f ecquu:::y -2.4 3 ".. eats, 10 cycles / heat, with a sufficient ;-suss between bests to prt:1cic :.; s.;p.' pesition of notion. The sine beat test parformed in the fall: wing scquence.: 2 c- -,--e ~ -c 7 ---,,,,r. ,,,---,.,,..,-,-,-,-,,ng,-----+w ~~,-,,----.-,,--w+-,,,------+,e-- -n-------
F, - ", 7 r i....P. 4 a...s. 3 ' 6 E S t e. 8:.... atsses m-easts te* u== a s e a y,.p-- n. , e.v.,o,er ,. t.. e.. Et:Gl.q'EERING REPORT l -g... :
- 91-055cS-:o 2o
.. a Test No. 31 axial Directien 5 Right-to-Left & Vertical l 6 Back -to-Fror.t & Vertical 'l Left-to-Eight & Vertical 8 Frent-to-Sack & Vertical E. .Y.'LT1?LE FREQUE';CY TEST: A biaxial multiple frequency excitation was applied to the switchu for a period of 30 seconds per test. The horicental and.verticci input levc1 of cultiple frequency excitation was such that the Test Resounse Spectra (TFS) cesputed at Q-10 by a Spectral Dyna.ics SD321 Shock Spectru: Analyzer wou'.d envelop the Re-quired Response Spectra (RRS), Ficute 2,- li=ited by 20 DA and 90"/secund velocity. The input was applied 6 eines in each axis, S OEE's fello cd t,y one SSE. OBE - Operational basis earthquante SSE - Safe shutdown earthquake The'multipic frequency test was performed in the following sequen:e: ' Te.st No. Biaxial Direction 9 Front-to-Back & Vertical 10 Left-to-Right & Vertical 11 Back-to-Front & Vertical 12 Right-to-Left & Vertical o
e _ =.. _..... - Series 2 Pushbutton switches andIndicators BARRIER MOUNT FEATURES Doctey screen e Easy ayassemble modutos provide A (page m mousands at esplayc:witrol com-gi twneDons Hausmo ~m e f.@ to 4incandeaconflamps .,.v. <seu e, ,L . r,ans-anteda 4J
- F e Negralhadde co# opcon provides remote released contacts. Pull in 7
8: _ e_ coils (ffange mount only) ens >6e re- -e oc,u.- (page is} e Switch guard and panel seal ac. ~ ossaones tn 7O T s.=n una W 77)
- CHANGE LAMPS OR FILTERS FROM PANEL FRONT
.Moun0ng bamers attaen to either the long or short sades of the hous4ng. They operation. Multiple units can be at-have sonng chos wNch gnp the panel. tached tegener in a stnp ard snapped g Mounting bamers also separate drsplay Into a panel slot; or they can be ) screens to proted against inadvertent mourned individualty, r a q FLANGE MOUNT h / Dway soM . N1 d', ; 1 E N* W!thout tool. Remove display screerv ) Larnpholder assembly from 2C200 oper- /y ator-ird.cator (or 2F200 indicator. Unit ( is keyed to maintain proper onen)tation -gj A H""*'"E I when replacing. Use or9y flange base (P*98 4
- s
( T-1 % lamps with 2C200 and 2F200 devices. P N. (page 77) Flange mount urvts have mounting chps roacy atta:hed to the housing. They placed; and enable use of an overlay can be individually installed or re-panel. 61 desired. Groupings can be /g? separated by optaonal Spaesng bamers \\y With tool. Remove display screen from MODULES ASSEMBLE EASILY 2C operator. indicator (or 2F indicator). A!! rnedules are ordered as separate Then inseft 15PA32 tamp tool untit it Items which snap together for easy bo' toms the lamp base and pull out. assembly. (Glass butb portion is gnpped when in-s.alkng) Grooved base T 1 % tarnps are recommended. LAMPS AND FILTERS Orcer lamps and filters for projected color trom page 81.
.~ i Pushbuttons switches and indicators Series 2 l N' ' BARR ER MOUNT MODULES Bamer moun' assembl.es are identcal Bame's a*e necessa'y for moureng g = m panel appeara'ce Ooerator-endca. They can be spec'e:: tot a tachment to tor housengs have sonng chos for at-tne eng or short side of t*Mr hous:ng. as p tadung switch rnoda'. s. Ths feature es stated an the oroer guees. not prowded w-th indcator housings. BARRIER MOUNT HOUSING ORDER GulOE Typcat baaing circuits for coi;-oovipped modules are se on page 83. Requirse Lamp Toot Tool Not Requ6ted / Barriers No. of m Artmen Con Lamp Operator-bdicator Operstor-traficator On: Type Sockets hdkator Onfy incsostar Onty Laig Norm 2(A & C) 2C7 2F7 2C207 2F207 se nors on iong edes sees 4 (A-D) 2Cs 2e9 2C209 2F209 o' Housmg 6VDC 2 (A & C) 2C19 2C219 Hoid-en 4 (A-D) 2C21 2C221 28VDC 2 (A & C) 2C31 2C231 ht*s-en 4 (A-D) 2C33 2C233 48 VDC 2 (A & C) 2C.13 2C243 s 'N Hodd m 4 (A-D) I 2C45 2C245
- U Short None 2 (A & C) 2C1 2F1 2C201 2F201
( f Sees 4 (A-D) 2C3 2F3 2C203 2F203 I { Housmg 6VDC 2 (A & C) 2C13 2C213 Hoed in 4(A D) 2C15 2C215 )I { N[ 28VDC 2(A & C) 2C25 2C225 I *- Hoc-in 4 (A-0) 2C27 2C227 48 VDC 2 (A & C) 2C37 2C237 Hond-m 4 (A D) 2C39 2C239 Bamers on short sees MOUNTING BARRIER ORDER CU!DE For sinp rnounting. spect*y one more barrier than the number of ints in the group. CW Ustings Mounung serrter For eene Type Thicknees Gesy Bledt ' White Red A.". men to .06.19 rL (1.52-4.83 mm) 282 2S4 2Bi4 2B15 N ') - .19.31 tri (4.83-7.87 mm) 2D6 298 2B16 2B17 .T ) Anace to .06.19 m. (1,52-4.84 mm) 2B1 283 2B10l2811 I N )h, ' ',\\ Nf f Short Sdes .19.31 in. (4.83 7.87 mm) 285l287 2B12l2B13 r UmYm MN""" *" w r FrT h k $1 7 MICRO SWITCH. n Honeywell division 75
....~...-.-I.~...~. . w. t SerIOS 2 Pushbutton switches and indicators gggm FLANGE MOUNT MODULES 4 7 Flange mount assembles are identcal Barriors are not required, since the .,1 [ in panel appearance Operator-irc::a-panel mounting clips are ready at-l l tot hwsings have spring clips for swn::h tached to F.ange sides of the housngs. J g mc:M atta:hrnent (not prcmood wrth However, spaong batners can be used inc ator houemps). Scr color-coding. They also aid in pre-g) venting inamertent operabon of two - ~ ~* l FLANGE MOUNT HOUSING ORDER GUIDE Tyoical bamng circuits for coi!-oouipoed rnodules are shown on page 83. Fianges on W esdes Requires Larnp Tool Tool Not Required No. ot F1engen CoM Larne Operator-honestor Operstor-bcscator On: Type Sockets hescoact Onfy indicator Onfy Long None 2(A & C) 2C4 2F4 2C204 2F204 Sdn 4 (A-D) 2C4 2F6 2C206 2F206 of j. Houseg 6 VDC 2(A & C) 2C16 2C216 Hold c 4 (A D) 2C18 2C218 28VDC 2 (A & C) 2C2B 2C22s i Hold-m 4 (A-0) 2C30 20230 / y 48VDC 2 (A & C) 2C40 FC240 ,g. Ho66-m 4 ( A-D) 2C42 2C242 M 28VDC Pull-m 4 (A-D) 2Cae* 2C2es** Short None 2 (A & C) 2C1C 2F10 2C210 2F210 } S des 4 (A D) 2C12 2F12 2C212 2F",82 of Hous4ng 6VDC 2 (A & C) 2C22 2C222 Hood-in 4 (A-D) 2C24 2C224 ,g 28VDC 2 (A & C) 2C34 2C234 t 2C236 Hoedm 4 (A-D) 2036 48 VDC 2 (A & C) 2C46 2C246 Hold-c 4(A-0) 2048 2C248 N 28 VDC N , ) pud m 4 (A D) 2C80* 2C269" k 1' Man"s am,*ea. so.ory acm. N V SPACING BARRIER ORDER GUIDE i For.06-31 in. (1.5-7.9 mm) thick panels. C W Uenage Species sorrier Type Grey I shes when Red For Long Flange Housing 290 l2B18 2B19 2B46 For S%1 PW Housings 2B23 l 2B24 2B25 2B26 j l 0, l)
r shbutton switchas and fr[ Icators Series 2 .j SWITCH MODULES 9 interchangsabie type 2D swrtch mod-ues attaen to sonng clips on the bottom of operator ndicator houssngs. Them es s a moe seleccon of orcu.'try, ebeince.1 e ratings, operating actions and tennnsbons 1/ h SM SUBM:NIATURE MULT3-SPDT SWITCH MODULES g; La ~g._,, .. ~..wou s: Sitver contacts: ~ r ,e F;) 30 VDC: 5 amps res. sea level or 50.000 ft, 3 amps end. sea level, 2.5 ? i amps 50,000 ft. Max. inrush, 24 >g3 amps. Momem acten Anomate action UL and CSA rating for basic switch: 5 amps,125 or 250 VAC. SM switch modules offer a choice of two momentary action styies, one wrth repeat actuation. Also ava!!able with aL Gold contacts: a pronounced touch feedback, the temate-action and combination rno-30 VDC: 0.5 amp ind., t emp res., sea mentary'attomate action modules. Ex-other with low operating force for rapd tra lengt*1 turret solder termnals levet and 50,000 ft. Max. inrush,2 I amps. SM SWITCH MODULE ORDER GUIDE Momentary Action Mom / Alt. Aha.T.Etz Acton Astlon Touch #eeeeck Type LowTarw Type No. of SPDT Sever GoM SDvor Gold sever Gold asher I CJrcutts Contacts Contacts Contacts Contacts I Cw.^4 Contacts Contacts 1 2D100 2D113 2D4o2 2D320 2D118 2D174 2 2D2 201 2D130 20140 2026 2D25 20161' 3 2D5 2D4 4 200 208 20151 20152 2033 2D32 20182** 20101 2D2B
- w..=_ _ _., ne
==w.m e =c .r-- ~, one m. _1_ __ me V3 COMPACT SPDT'DPDT SWITCH MODULES ELECTRICAL RATING 8 V3 SWITCH MODULE ORDER 4 3 30 VDC: 10 amps ind.' sea level, 6 GUIDE amps ind.,* 50,000 ft. Motor load, 6 amps.** UL and CSA rating for basac No.ot sPDT CircuMs Momentary Action awrtch: 10 amps, % Hp,125 or 250 g-VAC; % amp,125 VDC; % amp,250 1 2D70 .VDC. 2 2072 . ann e,
==-s.ra mone userme V3 switcf1 modules have screw termi-w, e e r se e,m not t with'.lockwashers. Ouick-connect ) h tort iinals (not shown) are also avail S abh. When used wfth short ftange op-era y indicators, add spacing bamers to p event interference. MICRO SWITCH, a Fbneywell darsion 77 1U ..-.~...c,.--..3--.-,_. .,_, y
.w A77Ac y e[ NT f V to LW3-1330-83 nomdit Switch Co. ,.=u.6[,@. $==:e 1895 l p,Av DAk.NEW JERSEY OfG32 w : cn see r:o:
- e. v :rit s w aves i NOTICE:
I This report is the property of Automatic Switch Company and may not I be reproduced without authorization from Automatic Switch Company, nor may excerpts be printed and distributed. This book must be returned immediately upon request. TEST REPORT NO. AQR-67368/ REY. O REPORT ON QUALIFICATION OF AUTOMATIC SWITCH CO. (ASCO) CATALOG NP-1 SOLENOIO VALVES FOR SAFETY-RELATE 0 APPLICATIONS IN NUCLEAR POWER GENERATING STATIONS REVISION ND. DATE 155UED PREPARED REVIEWED APPROVED l i STATE OF NEW JERSEY PREPARED BY: COUNTY OF MORRIS i RONALD D. POWELL, New Jersey / Professional Engineering
- M Registration No. 14238, N R. SHANK being duly sworn, deposes Product Engineer and says:
Nuclear Products 2 Valve Engineering The information contained in this report is the result of REY!EWED BY: a carefully conducted and complete test program and is to the best of his knowledge correct and true in all r e s pe ct s. RONALD D. POWELL Product Engineering Manager 7 e En ne r g / APPROVE 0 BY: Sworn and Subscribed to before f 3 me this AM day of ffach I { ] q ~.- t,d ~ Mjww _m, (/ ~ ~ ~ ~ DAVID J. VDC MER Chief Eng 1 Va1ye Eng'jneer JUNE ALAANest iQeer_in2
~ D 73 Dlll([.5I' bWllCll CD. oEJGETE&c. i h, Smee 1885
- a T
yaa* NEA.;ERSEY C7332. h J :tm se6 too: p, = v tti su ates -.-g 4 -8 g 2 kgy AQR-67368 ~ ~ -S D k {N' h APPENDIX A i T m.TFICATIONSPECIFICATION NO A05-21680/REV. C SPECIFICATION FOR~ 9 AUTOMATIC SWITCH CO. (A5CO) ~ .g l ' CATALOG hP-1 SOLENOID VALVE 5 g. m N l INITIAL, ISSUE MAY 12, 1980 f s 1 e[. 3Fisich DATE I BY i APPROVED A ws a .._ E 11 21 80 928 f,- .._C 7-13-81 M M t i ,w'E t, L A> k kk' t-h h %a y I l
D74 1 1 CONTENTS PAGE -TION Introduction.......................................... Al
- 1. S' cope................................................. Al
- 2. Equipment Description................................. A2 3.
In s tallation Requirements............................. A 2 4. Mounting Orientation............................. A2 4.1 Connections and Interfaces....................... A2 4.2 4.3 Fixturing........................................A3 5. Specification of Valve Life ...........................A3 5.1 Design Life......................................A3 Installed Life................................... A3 5.2 Qualified Life objective......................... A4 5.3 Performance Specification............................. A4 6. Acceptable Limits of Operation................... A4 6.1 Safety Function To be Demonstrated............... A5 6.2 .........A6 6.3 Conditions Which Constitute Test Failure Lo a d i n g............................................... A 6 7. Me thod o f Lo a d S imul a t io n........................ A 6 7.1 Verification of Operability...................... A7 7.2 Environmental Service Conditions...................... A 7 E. 8.1 Normal and Abnormal Ambient......................A7 ............................... A7 8.1.1 Temperature Pressure.................................. A7 8.1.2 Re l a t iv e H umi d ity......................... A7 8.1.3 L Chemical Composition of Environment....... A7 8.1.4 Radiation Environment...................... A7 8.1.5 8.1.6 Seismic Environment (OBE) .................A7 8.1.7 Vib: ition Environment .....................A7 8.1.B Duty Cycle................................ A8 f 8.1.9 Process Fluid............................. A8 i L i 6
r f n, CONTENTS ~ Ep. SECTION B_ -continued-I- ) Design Basis Event and Post DBE 8.2 Service Conditions............................. -* Fleure 1 Temperature............................. Ik 9.1 8.2.1 Pressure................................ 2 8.2.2 I Relative Rumidity....................... 9.2 8.2.3 Chemical Composition of Environment..... I 8.2.4 Radiation Environme.nt................... 8.2.5 8.2.6 Seismic Environment (SSE)............... 9.3 8.2.7 Duty Cycle.............................. i Process Fluid........................... 8.2.8 i Qualification Type-Test Procedure.................... i 9. Description of Test Items...................... X 9.1 Inspection of Test Items....................... 9.1 X 9.2 Baseline Data Operation........................ I 9.3 Aging Simulation............................... I 9.4 Thermal Aging........................... 9.4.1 E 9.4.2 Wear Aging.................. 1 Appene Pressurization Aging.................... 9.4.3 1 A: Radiation Aging......................... 9.4.4 1 A:: Vibration' Aging......................... 9.4.5 I OBE Simulation and Resonance Testing.... 9.4.6 DBE and Post DBE Sinulation.................... 1 9.5 9.5.1 Seismic Event Simulation................ AII. DBE Radiatior. Simulation................ 9.5.2 a Environmenta'_ DBE Simulation............ k 9.5.3 Post Test Inspection & Disassembly............. 1 9.6 Reports and Certification........................... 10. a 1
'. s ~ ? .Al O 76 I CONTENTS ~ PAG LIST OF FIGURES Al g Ai Ficure No. Page 9.1 Seismic Qualification Required A!l I npu t Mo ti ori................................ A 25 33 3.f 9.2 Environmental Qualification Para-j meters for Combined Loss-of-Coolant Ai Accident (LOCA)/High Enercy Line ~ Break (HELB) Simulation..................... A 26 y' 9.3 Typical Pipe Schematic for LOCA/ A, HELB Simulation............................. A 27 x vf, F-ATl LIST OF TABLES g 9.1 Identification of Test Valves............... A23 Ej M( N LIST OF APPENDICES M-A pendix U AI. Valve Design Specification Sheets (VDSS) AI-l E) AII. Coil. Insulation Resistance Measurement K. Procedure................................... AII-l g Coil Dielectric Strength Measurement Procedure................................... AII-l X AIII. Individual valve Test Procedures............ AIII-l .W N E. r D r i r b l i I l
( D77 - Al-SC{ QUALIFICATION SPECIFICATION FOR 1 CATALOG NP-1 SOLENOID VALVES 2.' AUTO. ATIC SWITCH CO. (ASCO) M INTRODUCTION: i 1. This specification for qualification is for the purpa of conducting a program, the ultimate aim of which' is to provide generic qualification for a family of solenoid valves for use in Nuclear Power Generating Stations. Part. This document is divided into two basic parts: 3* E is the equipment specification, including those items re quired for demonstration of qualification by acceptable o d methods of type testing; Part 2 is the type test proce e f defining the specific environmental parameters during the application of which the equipment must demonstrate satit f actory operation within the constraints of the specifice Part 1 includes Sec-tions presented in the first part. tions 1 through 8; Part 2 includes Sections 9 and 10. 2. SCOPE:This program is being conducted in accordance with e suggestions and requirements contained in the following documents. IEEE 323-1974 "IEEE Standard for Qualifying Class IE Equipment for Nuclear Power Generating Statiens* 2.1. IEEE 344-1974 "IEEE Recommended Practices for 2.2. Seismic Qualification of Class IE Equipment for Nuclear Power Generating Stations". IEEE 382-1980 (Revision of IEEE 382-1972) "IEEE 2.3. Standard for Qualification of Safety-Related Valve Actuators". IEEE 627-1980 "IEEE Standard for Design Qualifi-2.4. cation of Safety Systems Equipment Used in Nuclear Power Generating Stations. The following ASCO documenta for acceptance and 2.5. production testing. Valve Design Specification Sheets 2.5.1. (Appendix AI).
- +#<>9)>
8' ((// d'4(g,
- f IMAGE EVALUATION g/g<>
,4 c c. b I.0 lf:3 E i= La g 2.2 rm l,l [m O@ idi 1.25 1.4 1.6 4 150mm 6"
- 4
'4* 4% A$/ dr/;4 $en*4% v 4* o r t e Nr.
+ ++ //j/ ' / [ (( +('g, k / ?/ / IMAGE EVALUATION 4)y e@"9// // TEST TARGET (MT-3) 97ppp- $> /g,\\ g+4, f 4 pppp + I.0 lff 2 M y 8[ HE i*i E m Illils 1.8 I.25 1.4 1.6 4 150mm 6" /4%
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7 piir. - D78 -n2-i 2. S;.2F.E: 2.5. -continued-2.5.2. Individual Valve Test Procedures ,2 (Appendix AIII). e purpa 2.5.3. Measurement of Coil Insulation Resistance e is to Procedure (Appendix AII). Measurement of Coil Dielectric Strength noid 2.5.4. s. Procedure (Appendix AII). Part. 3. EQUIPMENT DESCRIPTION: I ces re I The following equipment items are included in the quali-I able These items form the generic basis for selec-ficati n program. roccdwr ti n f the specific test units. ing the 206-380, 206-381, 208-448, 208-266, 206-832 3.1. Bulletins g ,g g, and 210-036. I cc., !1:n - REF: VDSS 3.1 gg, j 3 3.2. Bulletin NPB314. 10. ) REF: VDSS 3.2 3.3. Bulletin NPB316 with thi REF: VDSS 3.3
- "9 3.4.
Bulletin NP8317 REF: VDSS 3.4 Class 3.5. Bulletin NPB320 a ns' REF: VDSS 3.5 3.6. Bulletin NP8321
- 'o#
REF: VDSS 3.6 3.7. Bulletin NP8323 rrr REF: VDSS 3.7 ' ~ ~ ~ 3.8. Bulletin NPB344 t REF: VDSS 3.8 .ifi-4. INSTALLATION REQUIREMENTS: 4.1. Mounting Orientation - The mounting orientation during I I all phases of the qualification test program shall be cnd such that the axis of the coil (s) (or Solenoid 'A' i coil for Bulletin NPB323 valves) remains in a vertical and upright position. 4.2. Connections and Interfaces - All connecting tubing, a
....-.-.. ~ w a. ___._-,,_n m D79 -A3-4. INSTALLATION REQUIREMENTS: 5. SP 4.2. -continued-5. fittings, and other devices utilized for directing process fluid to the valve shall be constructed of materials compatible with the specified operating environments, process fluid and valve body.
- Tubing, fittings, conduit, electrical lines, etc., shall be constructed of materials suitable for operation in the expected environments and be of sufficient size
.and quality so as not to degrade the safety functiet or classification of the test valve. During the environmental DBE simulation phase of the 5. qualification test program, installation of the test valves shall include provisions such that the down-ward directed chemical spray of the simulation will not enter the solenoid housings through their con-duit hubs or the internal areas of the valves throu;- their exhaust ports. However, connections to the cc duit hubs of the solenoid housings shall not be hers 6. P 4.3. Fixturing - Fixtures shall be provided to accommodau 6 test valves in accordance with their particular meum ing and installation requirements as defined above c in the Valve Design Specification Sheets. Fixtures shall be used solely to facilitate holding test valu and are not to amplify or dampen motions that the valves would be expected to experience in service. Fixtures shall not interfere with the safety functic of the test valves. 5. SPECIFICATION OF VALVE LIFE: 5.1. Design Life - All ASCO Catalog NP-1 valves have a design life of 40 years, during which interval satis-factory performance shall be demonstrated for the design service conditions as presented in Section 8. 5.2. Installed Life - All ASCO Catalog NP-1 valves have an installed life of 40 vears and 20,000 cycles. Coils and elastomeric components may require periodi: i i _, ~,.
O4'94 ~ _3 e I 3 ~ ...w,=... .a. w s.......c. e .c ..we. ...e.... ..a. .s....e.......c......., I,y,- 3.0 TEC C'ONO '* DNS AND EO"IPMENI (Con *.inued) 3.1.2 The==v'=.us tolerances of enviren= ental test conditi ons shall be as follows:
- a. Pressure
+10% of, gage, not to exceed 10 PSIC
- b. Vibration Jumplitude:
+6db to the acceleration of the response spectrum at a mounting Point. a
- c. Vibration Frequency:,t2s
- 4. Temperature:
415 F*; except at saturated stes= conditions not to exceed 10 PSIC
- e. Radiation:
+10% ^
- f. Time
+105 of the period of time.the equipement is to be operational following a DBI. , g. Environmental Transients: The initial transient and the dwell at the peak temperature shall be applied at least twice. ~ h. Voltage +10% ok rated value unless o wise specified. 3. '2 Iquie* ment ard calibration 4 All equipment requiring calibration is to be calib rated in accordance with MIL-C-45662A. The equip:sent of outside testing laboratories shall be capable of measu i r nt and/or .contr.olling within the lir.i.ts specified in ' para. 3.1 ,All measurements shall, be made with instruments which are within the current calibration per. iod. Prior 'to using as (nstr.anent, it shall be verified th ' as the instrurnent does not become due for calibration d uring the. time peri,od when it will be used' for test purp oses. r e COoCLDLNT.NO. 5:15 96487 A
- i*'
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/ YALCOR ENG. CORP. 'SHECT 3 .A d \\
s M TAC t A EE W W 8.2 CONSTANT CURRENT METHOD to vc3-1330-83 l I3 9.2 FLOATCHARGE-FLOAT VOLTAGES If there is no limita, tion to the voltage that may be applied to the system equipment, The following are the float voltage ranges re-constant current charging may be used for commended for the various types of batteries. the initial charge. Charge the battery at its Select any " volts per cell *' value within the finish rate listed in the Tables on pages range listed that will result in the series string 14 and 15. Continue to charge at this having an average volts per cell equal to that value until the lowest cell specific gravity value. Do not interchange voltage ranges from remains stable over a 5 hour period. If the one type to another. l yI ampere charge rate used is below the listed TABLE C ] finish rate, increase the 5 hour stable period _ Recommended Float Voltan proportionately. For example, if the charge Lead Antimony Types 2.15 to 2.17 f rate is 1/2 the finish rate. increase the stable 9 period from 5 hours to 10 hours. Where high pg.y. 2 ambient temperatures prevail, cell tempers-ein pu mH tures should be monitored so that 1100F udCh Tw (43oC) is not exmeded. A reduction in the Nominal 1.215 sp. gr. 2.17 to 2.25 charge rate or temporary suspension of the y,g ,g charge should be made to permit cells to cool, Nominal 1.250 sp. gr. 2.23 to 2.33 Resume charging when m!! temperatures are at 900F (320C) or below. Nominal 1.300 sp. gr. 2.28 to 2.37 per m H 8.3 INITIAL CHARGE volts per cell' ELECTROLYTE LEVELS Modern constant voltage output charging equipment is recommended for the floating During the initial charge, there will be an in. charger method of operation of Gould crease in the electrolyte levels and they may stationary type batteries. This type of go above the high level mark (See Section charper, properly adjusted to the recommen-3.2). This is due to gases, that were lost dur. ded float voltages, together with adherence ing transportation or standing in storage, being to recommended maintenana procedures, restored to the cells. Do not remove any will assist in obtaining consistent service-electrolyte even though levels may be above ability and optimum life, high level. When battery is placed on floating After the battery has been given its initial charge (See Section S.2/,the electrolyte levels charge (see Section 8.0/, the cherger should should return close to the high level line. be adjusted to provide the recommended float voltage (see Table C/ at the battery SECTION IX terminals. For example, a 60-celllead-antimony battery should have 130 volts 9.0 OPERATION maintained at its terminals.. 60 cells x 2.U volu per mH W.W = 130 & FLOATING CHARGE METHOD Do not use float voltages for lead antimony 9.1 r Plantit types higher than shown in Table l in this type of operation, the battery is con. C, as excessive water consumption and re-nected in parallel with a constant voltage duced battery life will result. charger and the criticalload cirmits. The Lead-calcium types may be floated at any of the charger should be capable of maintaining the voltage values (Table C) shown for a particular required constant voltage at battery terminals nominal specific gravity, Use the lower V.P.C value and also supply a normal connected load in the appropriate nominal specific gravity group, where applicable. This willthen sustain the where system equipment voltage limitations will battery in a fully charged condition and also . not permit higher values. The use of higher V.P.C make it available to assume the emergency values may make it unnecessary to give an equaliz-g power requirements,in the event of an AC ing charge. However, the use of higher float volt-4 power intacruption or charger failure, ages whers high ambient temperatures prevail, may result in reduced battery life.
2 of 3 9.3 VOLTMETER CAllBRATION Do not exceed tnose voltage values listed in Table D or Table E on page 10. Pane! and portable voltmeters used to indi-cate battery float voltages should be accurate at the operating voltage value. The same SECTION X holds true for partable meters used to raad individual cell voltages. These meters should 10.0 EQUALIZlNG CHARGE be checked against a standard every six months and calibrated when necessary. An equalizing charge is a special charge given a battery when non-uniformity in voltage or specific gravity has developed between cells. t it is given to restore all cells to a fully charged ~~ 9.4 CYCLE METHOD OF OPERATION condition using a charging voltage. higher than the normal float voltage and for a specified This method is recommended for lead. number of hours. as determined by the voltage antimony and Plante type cells only. Lead-used. calcium ce!!s should not be cycle operated. Non uniformity of ce!!s may result from low in cycle operation, the degree of discharge floating voltage due to improper adjustment will vary for various applications. Therefore, of the charger or a panel voltmeter which the frequency of recharging will also vary. reads incorrect (higher) output voltage. Also, ) The recharge is conducted by manually start. variations in cell temperatures greater than S ing the charge. generally using the normal SoF (2.780C) in the series string at a given finish rate listed on pages 14 and 15. The time, due to environmental conditions or amount of charge necessary depends on the rack arrangement, can cause low cells. number of ampere hours discharge. if a ~ shorter recharge period is desired, higher h charge rates equal to the eight hour rate of 10.1 EQUALIZING FREQUENCY discharge may be used when the battery is rnore than 25% discharged and the cell voltage The following guidelines cover lead antimony, on charge is below 2.33 volu. When the cell Plante and lead calcium types. Recommen-voltage reaches 2.33, the charge rate should dations not applying to all types will be so designated. M be reduced to the normal finish charge rate. The charge should be stopped when the spe. A. An equalizing charge shoulu be given quar. i cific gravity is ten (.010) points below the terly or as required by conditions in the follow-normal fully charged value. ing paragraphs (Note: lead-calcium types at The battery is now available for the next dis-nominal 1.215 sp. gr. floated at 2.20 V.P.C. to charge requirement. The battery should be 2.25 V.P.C., nominal 1.250 sp. gr. floated at given an equalizing charge monthly by con-2.27 V.P.C. to 2.33 V.P.C. and nominal 1.300 tinuing the regular charge until there is no sp. gr. floated at 2.31 V.P.C. to 2.37 V.P.C. increase in specific gravity of the pilot cell for may n t require equalizing charges), three hours, when using the finish charge rate. 8. Equalize when the temperature corrected g specific gravity of the pilot cell (or any cell for s 2 the quarterly reading) is more than 10 points below its full charge value. (See Section 11.2.1 9.5 RECHARGE C. Equalize when the floating voltage of the pilot call (or any cell for the quarterly reading) All batteries should be recharged as soon as is below 2.13 volts (nominal 1.215 sp. gr.), possible following a discharge (within 8 hours). 2.18 volts (nominal 1.250 sp. gr.), and 2.23 With constant voltage chargers, this will be volts (nominal 1.300 sp. gr.) or more than.04 i 6 accomPirs8ed automaticaiiv. sowever.t. volt 6elow the avera for the bat 1erv. recharge in the shortest period of time, raise D. Equalize to complete a recharge of the the charger output voltage to the highest battery in a minimum length of time following value which the connected system will permit. an emergency discharge.
.L 3 eF 3 E. If accurate qua terly records are main. NOTE tained (See Section 14.0/ and the individual all voltages and temperature corrected spe-Time periods listed in Tables D and cific g avities show no increase in spread from E are for cell temxratures from the previous quarterly readings, equalizin9 70oF (21oC) to 900F (320C). For may be deferred. (See Section 11.2/. temperatures 550F (130C) to 690F (20.50C) double the number of F. Ecualize once a year even though preced-hours. For temperatures 400F ing conditions did not require. (Lead calcium (40C) to 540F (120C)'une four types floated per paragraph A, may ny require times the number of hours. annual equalizing.) The above recommended time periods are con-sidered minimum. Raise the voltage to the 10.2 EQUALIZING CHARGE METHOD maximum value permitted by the system equipment. When charging current has tapered Constant voltage charging is the preferred and stabilized (no further reduction for 3 method for giving an equalizing charge. De-hours), charge for the hours shown in the ap-termine the maximum voltage that may be propriate table and for the battery tempera. applied to the system equipment. This volt-ture at the time of stabilization, until the age, divided by the number of cells connected lowest cell voltage ceases to rise. Monitoring in series, will establish the maximum voltage of all voltages should be started during the per cell that may be used to perform the letter 10% of the applicable time period to equalizing charge in the shortest period of determine lowest cell in battery, time. For lead antimony and Planti types, refer to Table D and for lead calcium types, refer to g Table E to obtain various voltage and associ-ated time periods recommended. EQUALIZING CHARGE. 11.0 SPECIFIC GRAVITY I Recommended Voltages and Time Periods in a lead acid cell, the electrolyte is a dilute TABLE D solution of water and sulfuric acid. Specific Lead Antimony & Plant 6 Types gravity is a measure of the weight of acid in the electrolyte as compared to an equal vol. Cell Volts Time Hrs. ume of water Therefore, electrolyte with a 2.24 80 specific gravity of 1.215 means it is 1.215 f2 times heavier than an equal volume of water which has a specific gravity of 1.000. 2.33 36 2.36 30 2.39 24 TABLE E 11.1 HYDROMETER READINGS Lead Calcium Tvoes Time Hrs. Time Hrs. Time Hrs.
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"'"""I*""" 1.215 1.250 1.300 nate f chav. It & creams as W un h Call Volts n n n charges and increases as the cellis chargedi s 2' reaching its original value when the cell is fully charged. Specific gravity is expressed 2.30 105 to the third decimal place (1.215) and is 2.33 74 166 measured by a hydrometer float enclosed in 2,36 50 118 200 a glass barrel / rubber bulb syringe. Draw suffi-2.39 34 80 134 g cient electrolyte into the barrel, holding the 5 2.42 54 91 syringe vertical and with no hand pressure on 2.45 36 62 2.48 bulb, so that float is freely floating without 42 touching sides or top of syringe. m
( ATTAC H M E bJ T-VU to LH3-1330-83 NY-403575 - QA _ June 26, 1980 File: 2Q-A-6.C To: R Hynes Froc::: V Boynowaky
Subject:
WATERTORD SES L* NIT No. S QUALIFICATION OF ACASTAT RELAYS Ref: Frank Electric letter dated June 2,1980 (copy attached) We have reviewed the enclosed notification of the Contrcl Products Corporatien on the subject of relaxation in the perfomance specification ef Armstet relevs. types E7014 and E7024, for Class IE applications that was tra'es=itted to us by Trank Electric Corporation - vendor of Agastat relays - with above referenced letter. It is our conclusion that the subject relaxations in the perfomance 8 specification of Agastat relays, types E7014 and E7024, are of a minor ~ neture and will not affect the overall pefomance of the Agastat relays in the control circuits. We do not consider the subject cotification to be an identification of a potential defect or a failure in equipment, hence, it is not considered to be a reportable insident under 10CTR21 provisions. VB:dns cc: A DeMagistris J Padalino R Vidal D Puca J Hart W C Criggs I L Stinson Project Record File e [ l l , - - ~ -
( D res cm:t sci st. YW. Plc. YLVC.a 17405
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[ OE I d R 1 t (v. e..L= u. i R E .._., ;.r. :.... CUSTOM CONTRot PANELS June 2. 1980 EBASCO Services, Inc. Two Rector Street New York, New York 10006 Attention: Procurement Manager i
Subject:
EBASCO P.O.f NY-403575 (FEC 5.0. #3398) Waterford SES Unit 3 and WP3-3080-D (FEC 5.0.#4240) 10CFR21 Notification of Potential Defect Enclesures: A) Control Product. Division Letter to FEC Received 6/2/B0 B) Product Specification Doc.P E7014/E7024 Rev. D dated 4/3/80 3 i Gentlemen: The Control Products Division of Amerace Corporation has notified Frank Electric Corporation of a relaxation in the perfomance specifict tion of Aentat Delav types E7014 and E7024 for Class IE applications. A ccev of their letter and the revised Product Specification is enclosed. 3 This information is provided as notification of a potential defect ir. accordance with 10CFR21 for your review and analysis. For further infomation i please contact Control Products directly as indicated in their letter. i j Very truly yours, i FRANK ELECTRIC CORPORATION j i nanI i P Quality Assurance Manager li PEB:In Enclosures CC: NRC File j Mr. Mike Brooks, Field Purch. Agent t j Mr. Angelo DeMagistris. EBASCO Ingineer Mr. Don Fuca, EBASCO Q.A. i 5.0, File
(r, r- ~ RECJiVECf c.o..t;tr.0L PncDu:TS DIVISION l ... ; t ;. ; OccTactON 1000 H80*(0 ty C.TAEET ,..::.... 5.ONS tJ $3024 H14) 37T 0300 i I "a:uoer, fualit" 7_esurance [ FMHK ELECT.'dC C0t?* Trank Electric Capany P.O. Ibx 69 Willou Sprines Lane road 85 York, PA 17405 mn Yor Order 8 9721 4.ti c.n e.: Se fer at of er E series smacification dra dnn Pas ?een revin:: frc-a > size dra. ing to an 55 ): 11 s e:ificatinn t pa doennt. In a?14.tfon, the T7014 and D024 inferation has been co-hintyi into a sinele s w:!ffeation. At t'.ie, ti.ne, after a c:rmlete evaluation of acct:.alater] test dits, w are revisino cur t:fe rance npecification, fer Class ir applicatic-*, e-1 rull in volt. nee 1e.a.ls and rela, o rrate t!.vt. It is irnorta.t that 1:ra re"ie. these c't. n fer effect on s. car a,plicat!on and de-te_9-J.n= if eranec-are nc:c'.ei in a..: cf "Our calcalations. ';'.e c'.a.ev, ara: Taracra,+. 5.1.1 c'. anne.050 sec. to.075 sec. Paracra.:5 5.1.2 chance.7)5" sec. *w.075 sec. i Fara ::rh 5.2.2 C' oil o,aratin: voltagn cha.cn S** to S M chan e 35t,to 0*t. i ?.ela ' onerat<2 ti.m 4 change Sann a 75.s (2 placa.s) rela" P.elease (*te, cle) 'ri.T cFAnort 59: s tn 7ft s (2 niaces) i Paraers-h 5.7.3 e.wra'.ir.e coniitions c'a.rn 35-116 t, "-lin (la r: lace.=) i eranee 86-116 to E-110 (19 pla:es) YCrJ **ill rtdiVO a T&/iS?*. M"14/C024 soecification for ea:h T7"14 er DC24 c: der t'at har : ca. s'.im.2 to ycra. riacse destro
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r p i.ODUCT SPECIFICATIOp. PntPAni.0 DAli ".*") E7014 /E7024 q',.f 4(,,,j,- g' ' -'c N rJ " I E '4 R i' - EE csta E*'I'## riODEL E7014/ E7024 g {g~ j.'
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D f SH T 1 2 3 4 5 6 7 8 9 t 1112 13 14 15 16 17 13 19l20l2il 22 l TS PURPOSE 1 i 1 The purpose of this specifiestion is to deifine the perfome.nce i characteristics of Centrol Fr'oducts Division of A=craco Corp. (CT.') Agastat. relays identified heroin. The perforn:nco characteri tic stated voro derived frem the results of a qualification test pro-i grc=, which vas designed' to measura the perfomance of the devices ( under no=si and abno=al (Design Basis Eventc) conditionc cs spec-t i ified. Tno qualification test progrc:s used was in accordan:o with 323-1974 (IEEE Stcndard for Qualify- {; the require =2nts of IEEE STD. in e, Class 1E I IEEE'SID. 344 quit.cnt for I;ucloar Power Conorating Statiens) c.n:i197h i j cation of Cla:s IE Equip =ent for Nuclear Power Ganorating Stationc}.8 I NOTE 4 also bo =cdo to IEEE STD. 501 referenco willREC In the follouing infomation 1978 (IEEE St,andard for Seis=ic Testing of Reisys) JUN2 td0 i .0 1.TMITATIO'!S _OF TEST RE0dLTS. 2 WNK ELECTR Since it is not possible to define the conditions for cvory cen IC(op' 1.1 coivablo n,mlication for relays, those paranotors, which in 1 practico ence=pa:s the msjority of applications, havo been speci-I fied. ?.2 If this data is not appliccblo to a particular roe then Proof testing r.;ust be perfomed for that particulauirement; r caso. g. t l CONTROL PRODUCTS' occut i uT no.g7034.g7e34
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..- - g - - - -- ~ ~ '-~- ( -- - ~ ~ ~~' ~ ~ ~~3 Th3 data docunentnd in this npocificatic.n..:plien only to A.e nr o i i re)ays r.ounted en -j-!d is-t fi tn-3n and does not apply to relg:. j i mun'ted on suiteti~boaru:, puis or any structure. I 2, /. It is the retponsibility of the new ev st-- f. eility dad- --- } cc:abir.e data o:1 scir=ic and enviror.=:ntal p enornance ci b.;- ul: - rn to arrive ct an acceptable equip =ent design for a particular cppi:- i Cation. 1 l NOTE Control Products Division of A=erace Corpor-ation dcas not reec=.cnd the use of its products in the contai= ant arc.as of nuclear i power generating stations. l
3.0 cvALIFI_cj_TIca
3s7 op7ty;;3, 3.1 AGI!:G SII."JLATION. (10 year or 25,000 operations e.ualiff,-d life). The following sequence of tests was perfor-::d on Aa,actat-devicen identified herein (prior to seismic fr:~,ility testinr.). The cole intent beinr that the cerbinr tion of thoco toets, witn applied i nargins, deg,raded tha relays and thair relatad hardt are to a ethto i i; which constitutes the oc,uivalency of their end of carvice con-dition to satisfy 3'4-1975;.tha n ing requiroments of IEEE S73. 323-1974 and IEEE STD. t 4 ) }i 3.1.1
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(a) P.ndintion Ac,inf,. (2.0 X 105 i radu integrated dosn.) This l dosage is considered to bo of sufficient integrated c::- I posure, with carain included that c::cocds the adverre plant operatin; requironent: for crear outside the rer.: tor i t containment building. !!ainly the su:tiliary and control i i buildings. I (b) cveline *fth 1.omd.*.aj;c. (27 500 oporations with eno set t of contcets tue.ed to 120 vac,,60 Hz at 10 c::p or 125 vic l at 1 c=p, which is rated load.) 1~no objective of this test was to operato the devices at an accelerated rate i with contr. cts loaded. The intent bein?, to exceed by 10. the ecount of nochanical operations the relay vill seo in service. Also, by loading the contacts ths voar at the i I lifo conditions.end of the test chould excood their norr,al ond of qua !!OTE 1 0'". m a r r plus 10u,in added to cycles (25,000 = 27,500 operations) t i i 4 ... b. CONTl10L Pl100UCTG 000U*f t47 '10. E701/,/;700'. /. WCnAct conecnanon OlVISIOld CC".'95. !? '"C M '* '0
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(100'C for /.2 days) his test cum. cted the relays to on crtificially c):ve.t ~ 1 ter.:2::rsturo (103'C) for nn extended period of tino (Fo;ty tiro (42) days). The device perfor nnec stan it.ea:- ured before end of ter the th:r=al ctren::. Unr li r,f b.1.f 4 degradation in device perforar.nco stands as evidence of L capability to h. ndic tho themal cning requircuents of ( 1 Class 1E applications. i i (d) Saimic Acine. Since this was basically a fra,qility type. test cunicient interactions vere perfor::.ed at levels loss,than the fragility loval of tha devices in ord.:: to i saticfy, uith required car inn, the seic=ic orina. re:;.:ir:. ments of IEEE STD. 323-197 and IEEF. STD. 344-1975. g 3.2 IL$.SELI';E PERFORI!ANCE TESTS. l< t ' I 3.2.1 In cddition to thr cging tests, a serics of baselin2 tests ver con:!ucted beforo (in orcar to establich a data bane) cnd then t ! i it:.nedintely follo ting ccch c;ing sequence, uith the purnose being to =eccuro the offects, if any, on the various devicer. i 3.2.2 The baselins tosts consicted of: (a) Pull-in Voltage l l (b) Drop-out Voltage i1 i (c) Diclectric Stren;th at 1650 vac, 60 Hz (d) Insulation Resistance at 500 vde i 4' j (o) Operato Ti:1e (?!illiseconds) t i (f) Recycle Ti=e (?!illiseconds) l (g) Tice Delay (Soconds) r l (h) Repeatability (f.) (i) Contact Bounce (!!illisoconds at 28 vde,1 c= pore) j (j) Contact Resistance (llilliohns at 28 vde, 1 a pore) 3.2.3 The data from thoso tests uns naasured nnd recorded. This date ! j was u:od for cc=parison to function:1 data throughout tho qual-ification test pro;;cn to mansure any degradation in the por-l for::ance of the roisys. 1 f 3.3 SEISMIC Qt%LITICATIO:t (IEEE STD. 3I.4-1975 and IEEE STD. 501-1970).. 3.3.1 Tho artificiclly ac.cd devicos voro cubjected to ciculated coit-I { mic vibration, uhich veified tho individual dovf.ce'u abilit'/ A to perfom its requirc:t function, b:foro, during, t.nd/or fol'.C. ~ ing design basic carthtturd:cs.
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.[ COllinOL PRODUCTS A'.tnAtr. conron Ation ' 000U:';!!T fio. E7C1/ /170.'!. j. f..! - DIVISIOtt CC41" ""00"d 5 f**8
- . - - A-- - - - - - ( - ~~ ~ ~ ~ ~* ~~rf '
i '3,3,2 Using, a Generic Re ;uired Responso Spectra (RUS) for control l syste=s purposes for the ca.iority of nuclear pouer ple.t l locations in the continental United States as a Cuieh , th devices should havo =2t, exceeded, and/or establish 2:.i their own fra,ility Icv 01s. 3.3.3 The relays were tested in the following electrical states. (a) Non-operating Mode (Relay coil de-energi:od - off-delay relays ti=ed out). (b) Operating) Mode (Relay coils energi:cd - on-delay rolsys i timod out (c) Transitional Mode j voltago, less 105,(applied to coils. Relay timo delny) with nom twice during seismic test. Relays ti=ed out L t 3.4 HOSTILE E!NIRC:03NT. s 3.4.1 The relays are not reco raended for use in the actuel renetor I contaf n: ant croa, but cro ir.tonded cainly for use in the auxilicry and control buildin:;s. Thereforo, in lieu of a i i i i loss-of-coolant accident (LOCA) test, a hostilo environment test uss performed. l 3.4.2 After si=ulated a/.eing and soismic fragility testin;;, a ec= bin-ation te=perature'hu=1dit condue cd in order to ds=y nnd undor/over voltage test was onstrate that the devices vill ( function under cdverse plant operating conditions ovan cftar 4 i having undergono all the aforecentioned aging ciculation cnd 1 ) seisme qualification testing. L 3.4.3 The releys vero onorated at eini=um and =nxi=u= volta e 05 cnd 120 percont of rcted voltc ex trons t.: and 80 cnd 120 percent of rated voltages for;o for AC i.ovices DC devices. i NOTE Plus 100 was added to naxieum rated voltenes to satisf 323-1974.y cargin requiremants per IC2E STD. i 3.4.4 Fivo (5) einitum volter(o and fivo (5) na::i=um volts ;o o,or-ations voro perfor=ad tico delays rocerdad) in ocen of'the followin.*: environmontcl conditions: 950 relativo hur.iditv et e 1 40*F, 50*F, 70'F, 90'F, 110'F, 130*F, 150'F, 165'F cnd 172'F. l 1 NOTF. Plus 15'F uss added to maximum ur.o tonpornture I I-(156'F) to sati:fy the margin requiror:ents of l luc 0 STD. 323-1974, \\ r (- / CO?DROL FT COUCTS manAct compomion e,,,q g,a DMSION ccmnci. movets ommon - CUM NO.,7 M 4 / WC' umoN. N.J. 07Cl3 6.-._- ppy 3 l n,,. g y I ne
,,',_,_.u -_- -- ( .-- - -- ~ ~~ - - ~~ (, ~ ~ - c l j 3.5 P03T TCST I;;2PECTION 3.5.1 Upon ec.:pletion of all testin;;, caeh relay uns the:our.hly t incpected. The condition of mach.uical and cicetrical parts i cnd the rolsy ca:o vac recordad. 3.6 QUALIFICATION TTST S*J.0%RY. 3.6.1 The Baselino Performance Tests (Para. 3.2) were conducted before end after each s>ocial test in order to monsure and record any effects on the various devices. 3.6.2 The Qualification Test was condue cd in the following sequence. (a) Baseline Test (Initial) (b) Radiation - Aging Tost t 1 (c) Essoline Test - (Repeated) (d) Cycling with Load - Aging Test (c) Baselina Test (Repeated) (f) Tc=poraturo - Aging Test ( (g) Baselino Test (Hoponted) [ (h) Soismic Aging and Qualification Test j (1) Baselino Test (Repeated) I (j) Hostilo Invironment Toct i i l '(k) Ba:clino Test (Final) (1) Post Test Inspection I i 4 I i 4.0 DIVICE I. C:TITIC/. TION i 4.1 CATALOG C037,1 U:!BIRS t 4.1.1 Figure 1 illu:ttratos the method of identifying, by entalo; code, the 1:odol E7014 and E7024 cerios ti=ing relays. a' 4.2 ACTUAL 1;CDEL 1:U:,::ERS OF D:: VICES TESTED. l (a) E7014AC001 & E7014PC001 i (b) r7024AC001 L E7024PC001 p g_ ~ ~ ' d. colTi50TPncoucTsl mentte cearenuic.,, 00 cut' INT I40. g.,c3. /;;70;,f. civision co'*"u."cSc'c : co d
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I 3 - - ~ ~ -~ ~ o ( !,.. o. w g ~ .r y[se...ea-3. = >. E I l V IV w 1 yY gY t x-gi I.! i l si f i e 5.' g E ,d I4 >-3 4 E.3 g e Er ~ p 38y o r-eg IR;g t $r ta rg* i j or _N i ' f, / l )!l bb)lidOL Pdb~buCTSl ~~~ A'*cuet cone onmon - 000Ur2NT NO. E701!./I.7C's ...... L. DIVISIOld j CM""* I"*C M 0*'04 uu.nv u e es. i
e (. -_= - ~ g 1 l 5.'O E' w n;sm cN.c733Tsrics. 5.1 p::3cnIPTION OF OPTPATION. 5.1.1
- 4e3 UM4 (Sco Figure 2)
Applying a continuous voltn.',e to EJ cos.1 (L1-L2) starts a tico delay lasting for the preset time. During this period the nomally closed contacts (3-5, 4-6, 9-11, 10-12) remain c,losed. At ths end of the del:.y period, the nor=cil open contacts (1-5,y closed contacts breah cnd the normally 2-6, 7-11, 8-12) make. The contacts ronnin in this position until the coil is deenergi:od, at which time the suitch instantencously returns to its originsi position. will recycle; the unit within.075 second.Decnergizin the coil, eith It uill then provido a full deley period upon reonerCication regardless of how often the coil voltage is interru mitted to "ti=c-out" to it'pted before the unit has boon per-s full delay setting. I L170 Q QN L2 N7 P V e < V UP V ? v T =P V V ,Y Y i, 10TAL DEL AY SET oN DI AL I 1 l ,g ENER:12CD 11014 CCIL I g l - CEENER 12C3 l l l p g,, - CL0tto U-5)(4-6)l, i ) ,,,,9 g,g,4 3 pa, c, CL0$t3 (1-5)(2 6), 8 l I I ' N.C. ~ I >(9-11)(1o-12)l D' A I N 4 CPEN CC'dTALT5 I N.O. CLC$t0 I [(7-11)(e-12)I + a g Figuro 2. Operation of E7014, On-Dolay Rolay
- i..'
Lind,gl E7024 (Sco riguro 3) Applying a volto.,o to the coil (Yl-LTf"GF nt least.075 second still inctentenocusly trt.nr.a, r the suitch brechin't the nomally closed cont. acts (1
- 7-11, 0-12h cnd enhing the nomally open contacts (3-5, I,-32-0,
~ ' "viI401. PHODUCTS A enact c onPeaAt'0 " 00CU.'EllT i;0. 701/,/*'7%' pivisiott CON",*'..F!WC75D*'V0"
,,l. - --~~~~a. ~ 9-11 10-12e. lon,:,as the coil is energi:cd.C:nts:ts remain in thi:. tr:nsferred noci ti on ::r, The ti=o delav be.ih.n 1- :.r:i nic-ly upon d:energi:stion. At the end of the dele.y perion, th: switch returns to its normal position. Roenerb,ir.in the coil during the delcy period t.*ill i==adiatelv retu n the 'tiain. t.eh-anisa to a point uh:re it vill provid: a full delav oorica ut en subsequant doener forred position. gi:ntion. Tha switch re=ains in 'hk trcns-t h TOTAL DELAY AS Stf CN DI A;. g-g 0 l l ENERT.12CD E7o24 Colt l -DIthtAr,82tD g tt O c c o oT L2 1 I i e,t3 Ec I l - CLC5tD 73 ( f(1-5N26) cs 8 I E0 l, l 7 CD 1 75 s,0, (b5)(4-6) i e WM bW 4 a CLC$tD v v i V l l CPIN f)(7-15 8-12) ,l CLC$tD 9 ga g g I g CONTA75 l 8 N.0 g 9 5o 1o.12) -cat 8 CLCS!D l 1 Figure 3. Operation of E7024, Off-Delcy Relay i t I i 5.2 PHYSICAL C:1?>.CT ?.ISTICS. 5.2.1 p lav Dinen-inns. (See Figure 4) 5.2.2 Aepro?:innte voight. (a) Model E7014 and E7024 with (AC) collo - 2.43 lbs. (b) Model E7034 and n7024 uith (DC) coils - 2.57 lbs. NOTE Weight eny vary slightly siith i relay coil voltago specified. CONTROL PRODUCTb wtHAct connonA11oy 000 U.'.'r. N T N O, 3 7 o l f, /, 7(,,, f
- /tJ C0'dh0'o"N N J C'OisJ"CWCTS D'V' WON DIVISION
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- l l.500 i, :t O
O 5.82 f n u A MAX i l v O _h' X l = - @a n . - -- _ _..) A 2.5D REF l h _,h g 0 l I l l jMW "~ v OUALIFIC ATION TESTED FOR VERTICAL OPER ATION ONLY ' s Figuro.4 Model ::7014 and E7024 Outline and Di=ansion Drawing 5.2.3 Tar-4;2,. Stande.rd screw teminals (68-32 truss hond scre'. s 1 supplicelaro located on tho front of the unit with peruanon: schocatic enrhinr,s. Darrier isolation is dosi modate spado or ring tor.7,uo terminals with spr.;c;ned to acco=- t ing to caot industrial control specii'ications. .;.2.4' Linear Ties Rr.na;c Adinst m nt. ~~ i J l (a) !!odel E7014 relays are availablo with lotter-calibrated I dials only. Tno upper end of tho tir.:o rangos in thoso l 14odels =sy be twico the valuo specified. in Figure 1. l (b) liedel E7024 relays are furnishod with dials calibrated I in linear incre=onts covoring the rango selectod. l j i ' CONTROL PRODUCTS wcnact compon Ation 00CUf.'f.NT tio. 07014/17M /l ---.4 DIVISION cc*dmot pncoucts civision vtvon n a w:,a oc v I
- c., r, o er
4 c.. 5.3 o?rr.', Tit:G Cieu.'.CTInISTICS. 5.3.1 Envire m ntal Cenditionn. (Qualified Life) PAF. M TER MIN. NO.TML lhX. Temperature (*F) 40 70-104 156 Humidity (R.H; f.) 10 40-60 95 Pressuro Atmospheric Radiation (rads) 1---- 2.0 X 10 (gn=n3) 5 5'.3.2 om rctinc conditiene. (!!omal Environment) K02F.4L 0?2P.'$ TING SPICIFICATIONS REL4YS t!/ RF. LAYS 1;/ (DC) COILS (AC) COILS Coil Cpor ting Voltage, No=inal (Rated) As Spec As ' Spa c Pull-in (5 of rated value) 857 Min. 9 0 7. 1:i n. Drop-out (f. of rated valuo) 107. Approx. 507. Approx. Power (itatts at rated value) 8 Approx. 8 Approx. Roley Operate Ti=o (In ms) Model E7014 N/A-N/A Model E7024 75 ms Ifax. 75 us Mc.x. Relay Rolocco (Rocyclo) Ti=o (In ms) Model E7014 75 cs Mex. 75 Ms1:cx. Model E7024 N/A M/A Contact R: tings, Continuous (Resistive at 125 vde) 1.0 a=p 1.0 n=p (Rosistivo at 120 vae, 60 H:) 10.0 a p 10.0 c=p 7.nsulation Resistence (In macchas at 500 vde) 500 Min. 500 l'tu. Diolectric (v::s, 60 Hz) Ectuoan Tor =inals cnd Cround ',500 1,500 1 Batueon !!on-connected Tominals 1,000, 1,000 Repeat Accuracy (Soo definition in ~ 107 + 10% + Parecr ph 5.3.2.1) ~ 5.3.2.1 Ranent Ace"rnev Repont Accurcev at any fixed tr. 1*i~dottneu as C.!af. Icran Part ICS 2-218.07 ); "The,w:. prat rature r accuracy deviation (A ) of a ti=o dolay ralny is a u:a:urc g '"~' f$,0HTROL PRODUCTSl "o""?d"?N D.!
- c" avenicc conponraio.,
DOCU:'CNT f,0 73g,.,j;7r,, ,,,,olyision
- - ~ ~ - .~.~~~~--~s*--~~~n- ':.um deviation in the tier (,: lay that vill be w~ ~ -s..--. .r of tha m:. f cxperiencou in five cuecessivo oportmen.n at any pt:rticuln: I timo settin; of tha relay and for cny particular we rati'n. [ voltage or current." folloutng formula: Repeat Accuracy is obtained fro = the (1~ 2) Where; Ty = Maxi =um Tira Delsy AR = 100 (Ty+T) T2 = Minicum Timo Delay 2 l E7014 On Dolny on min and 3-30 cin. pull-in units with timin;; range of 1.5-15 the first delay will be approxiustely 15G longer than subsequent dolays due to coil temperaturo rico. t i NOTE Dial settability with rossect to the indicum (Marking on the rogu-lating dials) the abovo repe,1;,,yqq included in ntabij.ity value. f 5.3.2.2 Dint Adiust ent d'rn "14 Each dial is eclibrated uith the 70 lo t'cTis~'%Tiou. cedoc the lettor "A",as the startinr, point..?" vith the symbol ( A) letter are three lines for fino ed Detueen cach delay, which precodos the letter "A,justment. (A) The rottin ; I I and the tino dolcy is increase rovidos =ininus time i=um tin 2 delay is attnined nt settin,g"E".r:duall" until n=- A!'.ter edjustin the ti=c delay sotting, the relay chould be operated cloc r, trically tuo or throo ticos to choch the tima delay. i 5.3.2.3 Dirl Ad N 3 m t. J 7024 The calibration c: rhin;c as vith 5 I tr.ost tintn, ralnys, a o for convenience c:,d to reduce the E required time for notting a relay to a epocific value. llovover { procedur,e :rolo.ys c:n bo set accurately by u:in; the follouin, { (a) Titrn ret; ult. ting disi (Located on top of rainy) to i correspond with value desired. i i (b) Decord one or more time dolcys. If noro than one ti=o delay in recorded, avers;o the rocults. i I (c) Compare the value obtained with the value required. If value cbtcined is loss than tho value rsquired, turn regulatint', dial clochuico slichtly to increcco ti.2. g If value obtained is groctor then the value record:id, turn regulatin; dini countorclochnico to reduce tria tius. { d (d) Repont stops (b) cnd (c) as nococscry until required I f time delay is achieved. i i I 5.3.3 h.rf.31na coMition, (Abnornal Environnont) t 1 I-f l CONin0L PAODUCTS wruct compouvion ( DME:OM ccennot rnonucts omsios D O CU:.'E NT NO....,,,,, f..gg ', " ~ " ' ' vmcN. n.J. orm t gy, y l 3qgg7,j, y : =
p - - - - _ -.p.. ^"[EEc'!r!$5SEE NN DDE "A" D2 "D" D2 "C" D2 "D" Tc=peraturo (*F) 70-104 40 120 145 156 Hu=idity (R.H. f.) 40-60 10-95 10-95 10-95 10-95 Coil Operatin,d)Voltago ~
- (f,of Rato 1:odel E7014 (AC) 90-110 90-110 90-110 90-110 90 -110 (DC) 85-110 85-110 85 -110 85 -110 85 -110
}:odel E7024 (AC) 90-110 90-110 90-110 90 -110 90 -110 (D") 85-110 85-110 65-110 85 -110 85 -110 Sois=ic Responso ** ] NOTES i All coils =ay be operated on intermittent duty cycles at voltage: 10'/. above listed t:cxt=ums (Intor=ittent Duty = Maximum 507. duty cycle end 30 minutos "0S" time.) a For Soicnic Responso seo Figures 5. 6, 7 for Model E7014 and Figures 8, 9 and 10 for Model E7024. l 5.4 SEISMIC RESP 0:lSI. I i 5.4.1 con 4t tions of_ Snic-ie Testa. (a) Value of Da= ping Used - 5f. ] (b) Device Mounting - Vortical' Only (Ri id Test Fi::Wre) C (c) Mode of Vibration - Identical (Dan:ndent) Dinxici Inputs i (45' Thruster) -(d) Seirmic Input - Random Aultifrequone.- (Spaced at 1/3 Octavos Over a Range of 1-40 !!z). .' ' Second Duration. .4.2 Rornon_.an Sneef2 1 Figuros 5, 6 and 7 (:.iO14) cnd Figurne D. 9_c,ad j~0 (T[02 4) reprosent the actual vertical and horizont:1 ~~ test responso of the relays in th:ir throa electrical crates. Using tha Failuro Critoria epocified in Para. 5.4.4 thoco valuu:. voro derived by co=bining the lo'est test responso cpoetru: (TRS) values frca the four test orientations and multiplyin'; that composito value by 0.707 duo to the 45-degroo incif.:.ction of the tost machino. Also, suporinposed on tho grapho are tho following 1 _ = -.. I /l ' C0!4Tr[0L PRODUCTS I Ae.icnace conronatio,, 00CUMEf1T '.0. .;7(,14 /,;7 tl:. cciatuot rnonscis n vicio,4 !' --'
- L DIVISIOld ur o s e4J otets l l(t y, n ve;
- i er
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- con:sitt er as/v..ss/v.,ss/v.,rs/v. x.707 :ut To 45' meuNATscs oF TEST MA HlhE.
I t Figure 5. Model E7014, Rosponso Spoetru:3, Non-Operato Modo I 7'CONTdOL PRODUC5 A'.iCHAct conponAtton 00CUf3fJT fio.,701!./- c 2l ./ du D0VOSCO L - cuna no ancto mm m
w-odd i t -A4-5. SPECIFICATION OF VALVE LIFE: 5.2. -continued-ting replacement during the valve's installed life. The exact replacement period will depend on ambient
- of ing service conditions and postulated DBE conditions.
- ubing, Specific replacement periods for elastomeric com-11 ponents and coils will be detailed in the final n in test report.
These replacement periods will be si:0 determined by calculations using the Arrhenius ncticn Equation and the thermal aging to be included in the qualification test program. 5.3. Qualified Life Objective - In accordance with the of the o tost l definition of qualified life as the period of ' time down-during which satisfactory performance can be demon- '11 strated for the service conditions, it is the inten-tion of this program to establish the qualified life C# through of the subject valves as coinciding with a plant tho ecF design life cf 40 years. o ,rm ; 6. ONCE SPECIFICATION: cmodats; 6.1. Acceptable Limits of Operation: The acceptable limits of operation of the subject gyg e. valves, unless otherwise specified, are as follows: e 6.1.1. All AC valves and non-battery operated DC yggg valves must operate on demand at any voltage gg between 15% below and 10% above the specified lunctic: l n minal AC r DC voltage (102 volts to 132 volts for a 120 volt nominal rating). Bat-r tery operated DC valves must operate on demand at any voltage between 28% below and
- O O 12% above the specified nominal DC voltage 1 cotis-(-90 volts to 140 volts for a 125 volt nom-the inal rating).
ticn 8. 6.1.2. Valves must operate at the minimum and maxi-hCve mum operating pressure differentials as C.I stated in the Valve Design Specification pcriodit Sheets (Appendix AI). t
ATTA C H M ~ N T V to LU3-1330-83 lep3 l REVtSIONS I ECD s L.T R 1 DES CRIPTION l D ATE i APPROVEC mb b WiMAwd C E.- Ew0vnY ervito
- +.t --) 'M 1141 C, R.Ev i b E D % M E E_T l S 5 2 *il [s
- nc.e s rem ~ s Ann.cs key. Da s Dsiswa Eef n 2-nt.
gtggs E' A4Jed rear qas. -m A rg.116 o 42 M. $f; 4q. 25.,,% + a. e.a. se 2 eq is.dc.tvr.s
- Tat *, Ant te nt.o-2.4 6 0,-
b \\L rr.n was,nuru usnwu,uu.m 7 w 6 ui m io uy u o n.~ l g 1 .I 'e ~ I.nEv. ] i - [ $NEET 25;26;27 28(29 30,3132 3h 34p5 36 37,38h9;40 4142 43fr4,45r46,47j484h 9 51 SZp3 1 1 , 6tv.sTArus REY. E E E 8 6 8 8 s B 6 5 S E 6 6 E C. T, r# SHEETS SHEET I 2 5 g 5 6 7 8 9 10,il 12 13 'l4 15 16 17 18 19 20 21 W 3f4 1 j E,4",'O ~y,,",,",; Ma 4f2A97r VALCOR ENGINEERING CORPORATION i C'f),tEbe h/77~ me.=es.. KEN!!. WORTH,NEW JERSEY Ptamu remcveous assus h66 TN! i g c. W8 .GINZRAL' QUALIFICATION TEST PROCEDURE FOR CIASS IE NUCLEAR ljl "Md8,;ff,/pj/d/g '5ERVICE VALVES g size cwe ocm.m. o m -,.a. A 96487 5 Mto n 5 ) SHEET'1efif i_ SCAL.E l i g rM - - - - - - - - - - - * - ~ - - - " ~ " - ~ ' ~ ~ ~ ~ ~ - - ~ ~ ~ ~ ~ ~ ' ~ ' ' ' ~ ~ ~ ~
M /.,,)A Q ~ 2 of3 l,c y, u ....o...............,.............,..............................re...................... ...s...................... 1.O GEhTRAL This test procedure describes the qualification tests, and methods to be used to erify that the kubject valve and operator me'at the specified design and operator requirements. The tests listad harsin have been established la accordance with the puides of IEEE standard 101, IEEE 5,tandarE 323 and 2.EEE Standard 344. 2.0 " APPLICABLE to"'UMENTS Valcor_ Engineering Corporation 51602 General Acceptance Test Procedure for Nuclear Solenoid valves. IEEE 101-1972 statistical A.nalysis of The: mal Life Test Data. 323-1574 Standard for' Qualifying Class IE Iquipment l) for Nuclear Power Generating stations. 344-1975 Reecur. mended Practices for seismic Q'ualification of Class I Electric Equipment for Nuclear Powe.r Generating stations. Militarv MI::.-P-27 4 01 Propellant Pressurizing Agent, Nitrogen. M:" -C-4 5 6 62A Calibration system Requirements j I 3.0 TEST CONDITIONS AND EQUIPME 3.1 Test Conditions and Tolerances
- 3.1.1 All tests shall be performed at the following conditions, f
unless specified otherwisas Tamparature: .', 57 *r to 97'r Relative Eumidity: 90%'or less g CODC. IDENT. ND. s32K I 96487 A =152o y SCALE / YALCOM CNG. CORP. SM C ET 2 4 L 1 l s i p l
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TEST RUM ?.0 (41,322)(45.32O(60,326)(63,325)..
- COMPOSITE CF F8/v 50/V,$S/V,FB/V+ X.707 0.E TO 45' INCLINATICN 0F TEST MACHiht.
Firettre 7. Model P7014, Responso Spectrum, Transitional Mode . j]7....Colnliol OmooucTM = = r crm - - I D O C ul i fl L lio..s e m * - w
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- SEE NOTE (H.v) itsi sera t J.Op(.dQ1) (97.93)Es.76 eS3/V.55/V+ FB/V+ X.707 *:UE TO 45' In:LINATICN t
l l l Figure 8. Model E7024, Responso Spectrum, Non-Operato Modo = CONTROL PRODUCTS Ar.< Enact conronmo g m DNSnO 7 ccwp encoum c.vr.m,, _ ___.DOCUtaT NO. 701/./;7"-- . /l,
.~ f.'" FULL 5" ALE SHOOK Spt:T8tLt.*.1 Ig Peak: !a0NLS TES ID: [7024ACC01 1.0 C to D 133 % 1003"2 DAMP 1NG l S 'd II 3 u,, _. I Phape FTent d=3, C ,._....._.....-e...,.w__....,_--.3-._.. in 1. is def.ned by four poo. at ts: a. a.., :. n. t..:. r.. : :.: P., - :,,1_ :_ 6 n.r.=.c: 0.i. :.r.t:: b.. -.;,i point A = 1.0 II a sd as a::elerstica equa: to g. 25Wew of w Zl A I.S.Ei. El'.6 @ * '.} '- i - I i ! $ lt~ '. f.JJ !*:i j '"*J f.: t i l pointD = 4.011: a.34 250 percent of t'.e ZrA p _...a. _...
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- SEE tiOTE 6..v) '
TEST m a C ).12.d O_b y.,6..!O3 CCWOSI TC OF FUv.,15/v.,ts/y.,F 5/Y+ x."107 3.;I TO 4 5' Ite:L it. AT s o's OF TEST MACHINE. l Figure 9. Model E7024, Responso Spectrum, Oper..ito Mode \\ .3 00 cut :** NT t:0 ' 8 7 014' l*'*'"" CONTnot.' PRODUCTS A'.'E AA:t connon ATION ' f gi L.a - DIVISION ccufnot poouucts utvimos UtuON. I.'.I WJ REY. D SW_C1 1*tGF *.'... ee.... .nwa
l . ~ -.. i -.w... FULL SCALE SHO:M SPECTRUM la Pcul F.0DELS TESTE3: E7:2tA:031 1 E"lO2 W OD1 1 1.00 10 0 100 X 103:0 m DAMPiN3f5] ~ p.. n._. ;..,.. 1 w........ ~,. .p _..... _...,-........ _ _.. _,... he SRS shape at 5 pesecat da: - e- . ; > e,,,..:_.......... -...mi). is cer.ned by four ponts: .....p
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- sEE NOTE (H.v)
TEST N.. f.C _5 3,2.,_57. ( 152.151 ), i u 2
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CF TEST MA HiriE. ,707 Xi 10 4 $ ggg,,3 Nrig e, i P Figuro 10. Model E7024, Responso Spectrum, Transitional "cdc l IT CONTbOL PRODUCTS I wrnAct connonATION DOCUstT tJO+ E7014/:-DO:" ' I u~. ____ DIVISION _ cmot ecis cwcu UN:04. N J CTCU3 REV. D lSEET1"0F
n. - -. - -. -. ) O ( = (a) The standard resnonse spectru: (Sus) for relays per IEEE STD. 501-1970, which gives a specific nero period acceleration "G" level for cach of the relay states I (b) The*renuired resconse spectrum (nRS), which was used as a guideline and'uns artificially created by Centrol Procucts Division as a goal or caximum tect level. 5.4.3 Scir.nic Tort D'erintion. The test enchine was inclined at i F6-degrees to tne noEEontal pinne to si=ulate two-axes ex-i citation. In order to orient the test articles to their nor-cal in-sen' ice position, they were placed on a 45-degree rir.,id test fixture. This arrana.ccent gave the input notion equal vectors in the vertical plane anc in one horizontal direction. The relays were tested in four horizontal orientations. Thic was done to test for the in-phase and out-of-phase conditions of the test ite=s. This cethod of test input is recogni:cd as an acceptable alternative to true binxial excitation in Section 6.6.6 of IEEE ST3. 344-1975. i, I. 5.4.4 Eailure criteria. (Class lE functions conitored during Seis=ic Tests.) l (a) Non-Onarstinn Mode. (Relay coils deenergized) g No: tally closed contacts monitored for chatter in c:: cess of 1 millisecond with 28 vde at 1 ampere eaplied to con-i i tacts. Normally open contacts conitored for false trar.cfer of 1 millicecond or greater with 28 vde at 1 a: pere applicc to contacts. L I i (b) Onoreto Mede. -(Relay coils energized) ( Nor= ally open contact monitored for chatter in excess of -1 millisecond with 28 vde at 1 n= pere anolied to centacts. l Nor= ally closed contacts conitored for falso trancier of 1 j cillisecond or greater with 28 vde at 1 a: pero rpplied to contacts. l (c) _Trnnr.itienn1 Mode. (Relays operated for time delay) { Failure of the relays to ticcout twice. Relays cet for' approximately 10 second time. delay. L ? NOTE t No:inalratedvoltageless10h. cpplied to relay coils during operate cnd transitional code tests. t i -. l'COtJTROL PRODUCTS , DOCUMEldT NO. 3701f,fr,70 t re.ernact cont oncion ./1 :
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.. - = - .y 5.4.5 Frn'ility L el.. (Model E7024 only) 2vice frar,ility level l vas obtainec in the followin:; manner: Usin;; the Failure i Criteria described in parar,raph 5.4.4, all relays were first 'p subjected to the artificial RUS accolcration icvel. If a relay failed to =ect it's Class 15 function, the testin; was continued, but at regressive incrc=ent: (of approximately 10/- Icvels) until the malfunction ceased. The level at which faul.t free operation of the relay had been established was documenteu i as the fragility level of that relay. 5.4.6 Test Resnonse. The test responses which exceed the art'ificial RR51cyc1 (n::d are stated as such) are not the device fragility ; levels but are highest values tested to. 6.0 DESIGN LIFE. (Non-Nuclear) 4 The relays are actually designed to perform under the conditions given in the following paragraphs. 6.1 TEMPSMTURE RGCE. (a) Operating temperature range is -20*F to +165'F (b) Storage te=perature range is -67'F to +165'? i j NOTE The maximus shift in the average of three consecutive tico delays taken at +77'F is -207. at -20*F and +20, at +165'F. i l 6.2 P2 PEAT ACCURACY. l 3 6.2.1 Repeat Accuracy at cny fixed to=perature is; '(a) 1 57,for ti=e delays of 200 seconds or less. (b) 10T. for ti=o delays of 200 seconds or grestor. NOTE The first ti=o delays afforded by Model E7014 relays. with (1.5-15 min. ) and (3-30 min.) time ranges will be approximately I 15f. longer than subsequent delays due to coil temperature rise. 4 6.3 COIL VOLTACI. 6.3.1' All coils may be operated on intermittent duty cycles at vol-tages 107. abovo listed maximuss. (Intermittent duty = M.xicun i 505. duty cycle cad 30 minutos "0N" time. 16.4 COMTACT MTINCS. MONTROL PRODUCTS Autnacc connonatior "0CU'*E NT NO. 7,7 t $, r./"? !i /lj - ~. [ DIVISION conmot isosucir, n:vi:, ion j E.HE E T S C I, ;- - union. n J or:,ia rey. D
.y.... t f 6.4.1 Contnet Canneity, in A-nnres. (Resistive Loads) i i e CONTACT VOLTAGE MIN. 100,000 MI!;. 1,000,000 OPERATIO::S OP2iaTIO::S l t 30 vde 15.0 7.0 110 vde 1.0 0.5 120 vac,,60 Ha 20.0 15.0 240 vac, 60 Ha 2d.0 15.0 480 vac, 60 Ha 12.0 10.0 i I ' 6.4. 2 contnet Itetinrs UL. Contact ratings as listed under the Unden.riters Leb. cc - t ponent recognition program for 100,000 operations; i f 10 A=ps Resistivo 240 vac ] 1/4 Hors,epouar, 125 vac/240 vac ) Per Polo i l 15 A=ps, 30 vde 5 A=ps, Gonoral purpose, 600 vac j 7.0 OUALITY _AssU?.5.!:C PROVISIO::s. P l 7.1 PRO 3ECTED QUALIFIED LIFE. i 7.1.1 Ten (10) years frca date of canufacture or 25,000 coerations, whichever occurs first. (This statc=ent does not alter in c.y vay the warranty on the relay.) 7.2 KdNTE!:.0 CI SC1.rCDULE. l 7.2.1 Replace =ent of the device after 25,000 operations or 10' years fro dato of canufacture, or beforo, i l I ) 7.2.2 The date of manufacture can be found in the fir:t four dir.its of the serial nu=ber which is located on the nanoplate. me i dato code used is a four digit number reficcting year and wack of manufacture; t I I I l First two digits indicate year I Second two digits indicate wach - ' :.o: t c7024PC001 l' EXAMPLE: Dato code 7814; 78 indicates i 1978, 14 indicates uech of . cit 125VDC stmt 7: 1t**** April 3 thru 7 c year nnd 11"'I 1. 5 TO 15 SE C. vook of manufacturo. [ ti t2 I l *l* ~e t[.LC3JYnot. PRODUCTS f tlit t costricn At e;rs ' 00 CU".E N T 40.:;701.',/:, DIVISION co:ar.ct incr,vcir, t,:.":.rces
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