ETCO’s Engineering Guides provide important contextual information for the manufacturing industry. Click through to find answers to your engineering questions.

UL 310 Terminal Testing Procedure Video

Ul 310 is a safety standard developed to evaluate performance of quick connect electrical terminals. ETCO engineers simulate UL 310 testing to qualify terminal performances to industry requirements. The test outlined here exposes mated sets of terminals forming a circuit to cyclical periods of energization.

TERMINAL CROSS SECTIONS -- ACCEPTABLE AND UNACCEPTABLE

Stud Hole Sizes

Cross Sections of Acceptable and Unacceptable Crimps

When it comes to wiring and providing an acceptable crimp for connectors ETCO always comes out on top. Our connectors are engineered with efficiency, safety, quality and durability in mind. There’s nothing worse than a crimp with wires jutting out causing possible fire hazards and connectivity losses. ETCO has never comprised on quality. The gallery below illustrates the differences between our crimps and competitor crimps.

The Good

The Bad and The Ugly

Reference Information for Test Currents Per UL 486 UL 486 UL 1659 UL 310

Test Current Per UL 486 for Connectors Intended for Single Conductor, Amperes

Conductor SizeAssigned maximumStatic-heating
AWG or kcmilmm2ampere ratingtest current
280.083.5
260.133.5
240.27
220.3249
200.51912
180.82317
161.3118
142.0815[20]30
123.3120[25]35
105.26130[40]50
88.3675070
613.36595
421.1585125

Static Heating & Heat-Cycling Test Currents Per UL 1659 for Conductors

Wire SizeStatic Heating TestHeat-Cycling Test
Wire Sizemm2current amperescurrent amperes
AWG
180.821020
161.31325
142.11832
123.32537
105.33045

Test Current Per UL 310 for Connectors Intended for Internal Wiring

Wire SizeTemperatureHeat-Cycling
AWGmm20.110, 0.125 inchAll others0.110, 0.125 inch terminalsAll other
(2.8mm), (3.2mm) terminals(2.8mm), (3.2mm)
220.322346
200.523468
80.8247814
161.35101020
142.11530
123.32040
105.32448

Insert / Extract Values

Male/Female Disconnect Insertion/Extraction Forces

The typical average force observed when inserting/extracting a standard NEMA DC2 male test tab into a standard ETCO disconnect while using an ETCO insertion/extraction force gauge to standard operating procedures is shown below:

Male SizeFirst InsertionFirst ExtractionSixth Extraction
Width (mm)lbs. (N)lbs. (N)Ibs. (N)
* .250″ (6.35)8.5 (37.81)7.5 (33.36)5.5 (24.47)
.187″ (4.75)6.0 (26.78)10.0 (44.64)6.0 (26.78)
.110″ (2.79)6.0 (26.98)7.0 (31.25)4.0 (17.85)

*Male test tab with recessed dimple for the detend feature, versus through hole on all others.

Wire/Crimp Ear Pullout Test Values

The minimum force required to separate the wire from the wire crimp ear with the insulation ear, if present, rendered inoperative will be as follows:

In some cases ETCO will recommend higher pullout forces to increase conductivity. ETCO will recommend crimp height to accomplish best all around crimp performance.

Size Of ConductorPullout ForcePoundsNewtons
AWGmm2
280.0828.9
260.13313.4
240.2522.3
220.324835.6
200.5071357.7
180.8232089
161.3130133.5
142.0850222.5
123.3170311.5
105.26180356
88.36790400.5
613.3100455
421.15140623

Acceptable Measurement Areas

Measuring Crimp Height: Crimp height must be measured with the spindle and anvil of a micrometer, centered against the bottom and the top of the crimp respectively and between the ribs on the bottom of the crimp, if applicable.

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