1、UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULJUNE 8, 20151UL 4128Outline of Investigation for Intercell and Intertier Connectors for Use inElectrochemical Battery System ApplicationsIssue Number: 1June 8, 2015Summary of TopicsThis First iss
2、ue of the Outline of Investigation for Intercell and IntertierConnectors for Use in Electrochemical Battery System Applications, UL4128, covers mating halves of intercell and intertier connectors for use inelectrochemical battery system applications.The effective date for UL LLC will be announced th
3、rough Industry File Review Announcement Letter.ULs Outlines of Investigation are copyrighted by UL. Neither a printed norelectronic copy of an Outline of Investigation should be altered in any way. All ofULs Outlines of Investigation and all copyrights, ownerships, and rights regardingthose Outlines
4、 of Investigation shall remain the sole and exclusive property of UL.COPYRIGHT 2015 UNDERWRITERS LABORATORIES INC.UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULJUNE 8, 2015UL 41282No Text on This PageUL COPYRIGHTED MATERIAL NOT AUTHORIZED FO
5、R FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULCONTENTSINTRODUCTION1 Scope .52 Components 63 Units of Measurement .64 Undated References 65 Glossary .7CONSTRUCTION6 General 77 Current Carrying Parts .88 Polymeric Materials .88.1 General .88.2 Insulating material 88.3 Environmental p
6、rotection 98.4 Gaskets, seals and O-rings .109 Spacings 1010 Accessibility of Uninsulated Live Parts .11PERFORMANCE11 Intercell / Intertier Connector Tests 1311.1 General .1311.2 Preparation of samples .1412 Dielectric Voltage Withstand Test .1513 Mold Stress Relief Test 1514 Dielectric Voltage With
7、stand Test (Repeated) 1615 Temperature Test .1616 Strain Relief Test .1617 Push-Back Relief Test .17RATINGS18 Details .17MARKINGS19 Details .1719.1 General .1719.2 Temperature rating of cables 1819.3 Multiple factories .18INSTRUCTIONS20 Assembly Instructions .1920.1 General .1920.2 Required content
8、.2020.3 Assembly procedure 2120.4 Verification 21JUNE 8, 2015 UL 4128 3UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULINSTALLATION INSTRUCTIONS21 Wiring Information 2121.1 Pressure wire and set screw type terminals .2121.2 Crimp type terminal
9、s 22APPENDIX AStandards for ComponentsA1JUNE 8, 2015UL 41284UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULINTRODUCTION1 Scope1.1 These requirements cover mating halves of intercell and intertier connectors for use inelectrochemical battery s
10、ystem applications. Intercell and intertier connectors consist of a cableconnector, cable, and mating inlet intended for use in electrochemical battery system applications. Theseconnectors are rated up to a 1000 V dc or less, and not intended for connection or disconnection underload conditions. The
11、y are intended for assembly to copper or copper alloy conductors.1.2 These devices are not intended for use in hazardous locations.1.3 These devices are intended for factory or field assembly to copper or copper alloy conductors rated90C or higher, and may be rated for use in either outdoor or indoo
12、r locations.1.4 This standard does not directly apply to the following devices, but may be used to supplement therequirements within these standards when a device is evaluated to these standards:a) Devices produced integrally with flexible cord or cable that is covered by the Standard forCord Sets a
13、nd Power-Supply Cords, UL 817;b) Devices intended for connection to the branch circuit, such as attachment plugs, cordconnectors, receptacles, inlets, and outlets that are covered by the Standard for AttachmentPlugs and Receptacles, UL 498;c) Devices solely intended for direct connection to the bran
14、ch circuit in accordance with theNational Electrical Code, NFPA 70, and that are provided with contacts of the pin and sleevetype, that are covered by the Standard for Plugs, Receptacles, and Cable Connectors of the Pinand Sleeve Type, UL 1682;d) Devices consisting of wiring terminals and supporting
15、 blocks intended for the connection ofwiring that are covered by the Standard for Terminal Blocks, UL 1059;e) Devices such as wire connectors and soldering lugs that are covered by the Standard forWire Connectors, UL 486A-486B; the Standard for Splicing Wire Connectors, UL 486C; or theStandard for E
16、quipment Wiring Terminals for Use with Aluminum and/or Copper Conductors, UL486E;f) Devices such as single pole locking-type separable connectors that are covered by theStandard for Single Pole Locking-Type Separable Connectors, UL 1691.JUNE 8, 2015 UL 4128 5UL COPYRIGHTED MATERIAL NOT AUTHORIZED FO
17、R FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL2 Components2.1 Except as indicated in 2.2, a component of a product covered by this outline shall comply with therequirements for that component. See Appendix A for a list of standards covering components generallyused in the products
18、covered by this outline.2.2 A component is not required to comply with a specific requirement that:a) Involves a feature or characteristic not needed in the application of the component in theproduct covered by this outline, orb) Is superseded by a requirement in this outline.2.3 A component shall b
19、e used in accordance with its recognized rating established for the intendedconditions of use.2.4 Specific components are recognized as being incomplete in construction features or restricted inperformance capabilities. Such components are intended for use only under limited conditions, such ascerta
20、in temperatures not exceeding specified limits, and shall be used only under those specific conditionsfor which they have been recognized.3 Units of Measurement3.1 The requirements in this outline are stated in metric units that make the requirement convenientlyuseable in countries employing the var
21、ious metric systems (practical SI and customary). In addition tobeing stated in metric units, the inch/pound units, that are customary in the USA, are also provided. Thevalues given in SI (metric) units shall be normative, except for AWG conductor sizes. Any other valuesgiven are for information pur
22、poses only.3.2 Equivalent although, not necessarily exactly identical results are to be expected from applying arequirement in USA or metric terms. Equipment calibrated in metric units is to be used when arequirement is applied in metric terms.4 Undated References4.1 Any undated reference to a code
23、or standard appearing in the requirements of this outline shall beinterpreted as referring to the latest edition of that code or standard.JUNE 8, 2015UL 41286UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL5 Glossary5.1 For the purpose of this
24、 outline, the following terms and definitions apply.5.2 ACCESSIBLE PART a part so located that it can be contacted by a person, either directly or bymeans of a probe or a tool, or that is not recessed the required distance behind an opening.5.3 ENCLOSURE that part of the connector that:a) Renders in
25、accessible all or any parts of the connector that may otherwise present a risk ofelectric shock, and/orb) Retards propagation of flame initiated by electrical disturbances occurring within.5.4 INTERCELL / INTERTIER CONNECTOR Consists of a cable connector, cable or conductive bar(bus bar) and mating
26、inlet intended to connect cells of a storage battery.CONSTRUCTION6 General6.1 The terminal of an intercell / intertier connector shall comply with the requirements in the Standard forWire Connectors, UL 486A-486B, as appropriate, and with this standard.6.2 There shall be no sharp edges or corners on
27、 the outer surface of an intercell / intertier connector thatcan result in damage to the wire insulation.6.3 A latching intercell / intertier connector shall not require the use of a tool to unlatch mated halves.Latching intercell/ intertier connectors shall incorporate a suitable latching mechanism
28、 such as a channeland rib or other latching mechanisms between the mated pair.6.4 A Locking intercell / intertier connector shall require the use of a tool to unlock the mated halves. Atool can be a specialized device provided by the manufacturer or a standard common device, (i.e.screwdriver). The t
29、ool and its operation shall be identified in the manufacturers assembly instructions, see20.2.1(d)(7).JUNE 8, 2015 UL 4128 7UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL7 Current Carrying Parts7.1 The current-carrying part of an intercell/
30、intertier connector shall be copper or copper alloy.Current-carrying parts containing more than 15 percent zinc shall comply with stress corrosion/moistammonia (NH4) test as described in the Standard for Wire Connectors, UL 486A-486B.8 Polymeric Materials8.1 General8.1.1 Polymeric materials may be u
31、sed as an enclosure or as insulating materials of an intercell / intertierconnector that are in direct contact with or in close proximity to live parts. For the purposes of theserequirements, a part that is a distance of 0.8 mm (1/32 in) or less to live parts is considered to be in closeproximity. W
32、hen the same material is used for both purposes, the more stringent requirements shall beapplied.8.1.2 A polymeric material serving as insulation or as the enclosure shall have a relative thermal index(RTI), electrical, mechanical IMP and mechanical STR, as determined in accordance with the Standard
33、for Polymeric Materials Long Term Property Evaluations, UL 746B, not less than 90C (194F).8.1.3 A polymeric material serving as the enclosure of an intercell / intertier connector that is also markedwith an enclosure type designation shall comply with the applicable requirements in the Standard forP
34、olymeric Materials Use in Electrical Equipment Evaluations, UL 746C, concerning:a) Ultraviolet light exposure, andb) Water exposure and immersion.Note: An f1 rating signifies compliance; an f2 rating requires further investigation into its suitability.8.2 Insulating material8.2.1 A polymeric materia
35、l that is in direct contact with or in close proximity less than 0.8 mm (1/32 in)to live parts shall:a) Have a flammability classification of HB, V-2, V-1, or V-0 as determined in accordance withthe Standard for Tests for Flammability of Plastic Materials for Parts in Devices and Appliances,UL 94.b)
36、 Have a High-Current Arc Ignition (HAI) performance level category (PLC) in accordance withTable 8.1;c) Have a Hot Wire Ignition (HWI) performance level category (PLC) in accordance with Table8.1;d) Have a Comparative Tracking Index (CTI) performance level category (PLC) as defined inTable 8.2;Excep
37、tion: Exception: A material not having a CTI rating may be used when the materialcomplies with the requirements for the Performance Tracking Index test (PTI) test as specified inthe Standard for Polymeric Materials Use in Electrical Equipment Evaluations, UL 746C.e) Have an Inclined Plane Tracking (
38、IPT) as defined in Table 8.2; andJUNE 8, 2015UL 41288UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULf) Comply with the requirements for exposure to ultraviolet light as determined in accordancewith the Standard for Polymeric Materials Use in
39、Electrical Equipment Evaluations, UL 746C,when exposed to light during normal operation of the product. Polymeric materials that areexposed to direct sunlight but are protected by glass, or other transparent medium, may betested with an equivalent layer of that medium attenuating the ultraviolet lig
40、ht exposure duringthe test.Table 8.1Maximum HAI and HWI PLC valuesFlammability classification High-current arc ignition Hot wire ignition(HAI) (HWI)HB 1 2V-2 2 2V-1 2 3V-0 3 4Table 8.2Determination of CTI or IPTVoltageaCreepage distance IPTbrequired CTIcrequired0 30 Any No No 30 600 30600 12.7 mm No
41、 No 600 1000 600 1000 16.0 mm No YesaVoltage is the maximum potential difference between live parts and dead metal parts that may be grounded in service orexposed to contact.bRating of 1 h using the time to track method at the higher of the rated voltage or 1000 V when the voltage rating is in thera
42、nge of 601 1000 V.cCTI PLC of 0, 1, or 2.8.3 Environmental protection8.3.1 The enclosure of an intercell/ intertier connector that is marked with an enclosure type designationshall comply with the applicable requirements for each environmental classification in accordance with theStandard for Enclos
43、ures for Electrical Equipment, Environmental Considerations, UL 50E, (Type Rating)and/or the Standard for Degrees of Protection Provided by Enclosures (IP Code), IEC 60529. An intercell/intertier connector that complies with the requirements for more than one type of enclosure shall complywith the c
44、orresponding requirements for each enclosure type designation. The enclosure type designationfor a device when unmated is not required to be the same as the enclosure type designation of that devicewhen it is fully connected to its intended mating device.JUNE 8, 2015 UL 4128 9UL COPYRIGHTED MATERIAL
45、 NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL8.4 Gaskets, seals and O-rings8.4.1 The requirements in this section apply to gaskets that are required for an electrical enclosure tomaintain a tight fit or to comply with the enclosure performance requirements when t
46、he intercell / intertierconnector are unmated or fully mated as intended.8.4.2 A gasket shall be secured with adhesive or by mechanical means, including force-fit or thecombination of the gaskets shape and elastomeric properties. The gasket and its securing means shallnot be damaged when the cover i
47、s opened.8.4.3 The gasket material shall comply with the Standard for Gaskets and Seals, UL 157.9 Spacings9.1 Intercell / intertier connector when mated (male- female pair) condition shall comply with 9.2 9.5.9.2 Spacings between uninsulated live parts of different potentials, and between a live par
48、t and anaccessible metal part (or the probe detailed in Accessibility of Uninsulated Live Parts, Section 10), shallnot be less than the values specified in Tables 9.1 and 9.2.Table 9.1Minimum spacings for field wiring terminals other than tool applied crimp type terminalsPotential involved, V Throug
49、h air and over surfacemm (in)0 50 6.4 (1/4)51 300 9.5 (3/8)301 600 12.7 (1/2)601 1000 25.4 (1)Table 9.2Minimum spacings for tool applied crimp type field wiring terminals and minimum spacings forlocations elsewhere than at wiring terminalsPotential involved, V Through air Over surfacemm (in) mm (in)0 50 1.6 (1/16) 1.6 (1/16)51 300 3.2 (1/8) 6.4 (1/4)301 600 6.4 (1/4) 9.5 (3/8)601 1000 14 (0.55) (25.4) (1)9.3 The spacings shall be measured with and without wire connected to the terminal. The wire shall beconnected as it wou
