Disconnects for Use in High
Vibration Applications (Case 1)
APPLICATION NOTE
Applications:
Equipment that produces high vibrations or is in close proximity
to sources of high vibration such as:
Electrical motors
Air compressors
Pumps
Commercial laundry equipment
Transportation equipment
Customer Concern:
A manufacturer of commercial vacuum cleaners for coin-operated
car washes was having problems with reliability in high vibration
Standard Non-Insulated Female Disconnect on
environments. This vibration caused disconnects to slip off the
Left with High Vibration Disconnect on Right
male tabs, which caused internal arcing that damaged their
controllers, resulting in numerous service complaints for their
customers and downtime in the field.
Panduit Solution:
Insulated and Non-Insulated Vibration Resistant
Female Disconnects
Panduit developed vibration resistant female disconnect samples
for testing in this application. The solution required a higher
disconnect withdrawal force to overcome the failures caused
by the high vibration. As seen circled in the images on the right,
the samples that passed were designed without the curl slots to
increase the retention force between the curls of the female
Standard Insulated Female Disconnect on Left
disconnect and the male tab. This increased retention force
with High Vibration Disconnect on Right
directly increased the frictional force, which ultimately delivers
a higher disconnect withdrawal force. The customer evaluation
of the new design showed that none of the vibration resistant
female disconnects slipped off the male tabs. Customer downtime
as a result of disconnects vibrating off of the male tabs has been
eliminated since implementation of this product.
Application Considerations:
Additional insertion force is required to properly install the
vibration resistant female disconnect onto a male tab 12.4 pounds
force (lbf) as compared to a standard female disconnect 7.9 lbf.
Additional withdrawal force is also required to remove the vibration
resistant female disconnect from a male tab 11.3 lbf versus a
standard disconnect 9.9 lbf. Customers should determine if the
Commercial Automobile Vacuum Cleaner
additional force is acceptable in areas where the connection may
Application That Required a Female Disconnect
require removal for maintenance, repair or modifications.
with Increased Retention Force Against
High Vibration
www.panduit.comDisconnects for Use in High
Vibration Applications
Loose Piece
A
C
Disconnect
Brass
Sleeve
Max. Wire
B
Insul. Dia.
Housing
Wire Max. Wire
Dimensions
Tab Size Range Insul. Dia.
In. (mm)
In. AWG In.
2 0.03 0.02 0.02
Part Number (mm) (mm ) Color (mm) A B C Crimp Tools
Non-Insulated
D10-250C-D 0.250 x .032 12 10 0.72 0.30 0.12 CT-100A, CT-160, CT-200,
(6.4 x 0.8) (4.0) (18.29) (7.62) (3.05) CT-260, CT-570, CT-1570,
CT-2500 w/CT-2570CH
Vinyl Insulated
DV10-250C-D 0.250 x .032 12 10 Yellow 0.229 1.04 0.30 0.12
CT-100A, CT-160, CT-260,
(6.4 x 0.8) (4.0) (5.82) (26.42) (7.62) (3.1) CT-460, CT-1550, CT-1551,
CT-2500 w/CT-2550CH
Reel-Fed A
Carrier Strip
Housing
Funnel Wire
Brass
Terminal
Entry Sleeve
C
Max. Wire
B
Insul. Dia.
Tool Chart
Wire Crimp
.03 Wall
Recommended Presses:
Area
Thickness
CP-871 (UC200)
Wire Max. Wire
Dimensions
Tab Size Range Insul. Dia.
In. (mm)
In. AWG In. CA-800/CA9 Applicator
2 0.03 0.02 0.02
Part Number (mm) (mm ) Color (mm) A B C Die Inserts
DV10-250C-2K 0.250 0.032 14 10 Yellow 0.22 0.95 0.29 0.12 CD-800-3
(6.4 x 0.8) (4.0 2.5) (5.6) (24.1) (7.4) (3.1) CD9-3B
Notes: 3. UL 310 Certified
2
1. 600 V maximum voltage rating for insulated disconnects 4. Dimensions in parenthesis are in mm or mm
+1/32
194F (90C) maximum temperature rating for insulated disconnects 5. Wire strip length 9/32
302F (150C) maximum temperature rating for non-insulated 5. Package qty:
disconnects -2K = 2000 pcs./reel
-D = 500 pcs.
Stranded copper wire only
2. Material:
a. Stamping: CDA-260 brass, tin-plated
b. High withdrawal force curl design
c. Housing: Vinyl
WORLDWIDE SUBSIDIARIES AND SALES OFFICES
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Phone: 800.777.3300 Phone: 44.20.8601.7200 Phone: 65.6305.7575 Phone: 81.3.6863.6000 Phone: 52.33.3777.6000 Phone: 61.3.9794.9020
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For more information
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ALL RIGHTS RESERVED.
Visit us at www.panduit.com
TMAN15--WW-ENG
Contact Customer Service by email: cs@panduit.com
replaces WW-TMAN01
or by phone: 800.777.3300
10/2015