HT076xx - Kona General Testing - Harwin · Kona – Electrical, Mechanical & Environmental Testing...

harwin.com

Harwin Test Report Summary

HT07602

Kona Electrical, Mechanical & Environmental Testing

2 Issue: 2 Date: 16/06/2021 C/O: 30590

HT07602 Kona – Electrical, Mechanical & Environmental Testing

1. Introduction

1.1. Description and Purpose

Kona is a high reliability connector range, based on a single in line, 8.5mm pitch mating connector pair. These connectors are designed for higher power applications with a rugged or durable requirement. Each contact on both male and female connectors is individually shrouded and scoop-proof (to prevent accidental touch). Polarization and contact 1 identification marks are also incorporated into the housing designs. The following tests were carried out to establish and confirm the operating parameters of the Kona connectors.

1.2. Conclusion

The following data has been collated from Harwin test reports QA000027, QA000106, QA000108 and, QA000112. The results were used to create Component Specification C052XX for the Kona range. The tests indicate that the Kona range performs as required, suitable for a wide range of applications calling for high power interconnects.

2. Test Method and Requirements

2.1. Specification Parameters

Tests were carried out in general accordance with either EIA-364 standards or BS EN 60068. The list of tests covered in this summary are as follows:

Testing Standard Description of Test Section Page No.

EIA-364-06C: 2006 Contact Resistance 3.1 3 – 4

EIA-364-70A: 1998 Power Rating 3.2 4 – 8

EIA-364-09C: 1999 Durability 3.3 9

EIA-364-20C: 2004 Withstand Voltage 3.4 10 – 11

EIA-364-21C: 2000 Insulation Resistance 3.4 10 – 11

EIA-364-05B: 1998 Contact & Insert Retention 3.5 11 – 13

EIA-364-17B: 1999 Temperature Life (without load) 3.6 13

EIA-364-32C: 2000 (BS EN 60068-2-14: 2009) Thermal Shock (Temperature Cycling) 3.7 14

EIA-364-26B: 1999 (BS EN 60068-2-11: 1999) Salt Spray 3.8 15

364-31B: 1999 (BS EN 60068-2-78: 2013) Humidity 3.9 15

EIA-364-28D: 1999 (BS EN 60068-2-6: 2008) Vibration 3.10 16 - 17

EIA-364-27B: 1996 (BS EN 60068-2-27: 2009) Mechanical Shock 3.11 17 - 18

2.2. List of Connectors

The following components/connectors are used throughout the testing: • KA1-0400005 – Female Power Solder Cup Contact • KA1-1100005 – Male Power PCB Throughboard contact (piece part) • KA1-2010298F1 – Female Cable Housing 2 position, standard fixing • KA1-2010398F1 – Female Cable Housing 3 position, standard fixing • KA1-2010498F1 – Female Cable Housing 4 position, standard fixing • KA1-2010298F2 – Female Cable Housing 2 position, reverse fixing

3 Issue: 2 Date: 16/06/2021 C/O: 30590


• KA1-2010398F2 – Female Cable Housing 3 position, reverse fixing • KA1-2010498F2 – Female Cable Housing 4 position, reverse fixing • KA1-MV10205M1 – Male Vertical Throughboard 2 position, standard fixing • KA1-MV10305M1 – Male Vertical Throughboard 3 position, standard fixing • KA1-MV10405M1 – Male Vertical Throughboard 4 position, standard fixing • KA1-MV10205M2 – Male Vertical Throughboard 2 position, reverse fixing • KA1-MV10305M2 – Male Vertical Throughboard 3 position, reverse fixing • KA1-MV10405M2 – Male Vertical Throughboard 4 position, reverse fixing • HM2202-2 – Voltage Breakdown and Insulation resistance test PCB, 2 position • HM2202-3 – Voltage Breakdown and Insulation resistance test PCB, 3 position • HM2202-4 – Voltage Breakdown and Insulation resistance test PCB, 4 position • HM2197-2 – Current vs Temperature test PCB, 2 position • HM2197-3 – Current vs Temperature test PCB, 3 position • HM2197-4 – Current vs Temperature test PCB, 4 position • 8AWG Silicone Rubber Insulated Wire

3. Test Results

3.1. Contact Resistance to EIA-364-06C: 1999

Specification: 2mΩ max. per contact. Methodology: Power contacts on each connector were measured using a precision milli/micro-ohmmeter (HWN793) for resistance prior to any electrical, mechanical or environmental testing. Mated samples were then submitted to individual environmental conditions and each contact pair was measured for contact resistance. The Maximum, Minimum, and Average results are detailed below.

Contact Resistance per Contact Pair (mΩ)

Contact Pair (pre-conditioned) Max Min Average KA1-1100005 & KA1-0010005 0.39 0.34 0.36

Contact Resistance per contact (mΩ)

Condition Max Min Average Change in Max from Pre-conditioned Samples

Pre-conditioned Samples 0.39 0.34 0.36 -

Durability 0.55 0.33 0.46 0.16

Temp Life 96hrs 0.55 0.37 0.42 0.17

Temp Life 250hrs 0.55 0.39 0.46 0.16

Temp Life 1000hrs 0.55 0.41 0.48 0.16

Thermal Shock 0.44 0.38 0.42 0.06

Salt Spray 0.50 0.38 0.44 0.11

Humidity 0.48 0.36 0.42 0.10

4 Issue: 2 Date: 16/06/2021 C/O: 30590


Figure 1: Contact Resistance General Test Setup

3.2. Power Rating (Current versus Temperature Rise) to EIA-364-70A: 1998

Specification: Current Rating (when all contacts are electrically loaded) = 60.0A. Methodology: The test demonstrates the current carrying capability of the Kona connector system, both pre- and post-environmental conditioning and is carried out in accordance with EIA-364-70A, Method 2. The mated connector pairing was wired in a series circuit using 8AWG Silicone Rubber insulated wire and a custom PCB to complete the circuit. Power was supplied using Keysight N8731A (HWN 4403) and temperature monitored with TC-08 Pico Logger (HWN 549).

Current was applied in 10A increments to the connector, and the temperature rise above ambient recorded in each case. The test was performed from 0A up to 100A. The data below details the results up to 80A.

Figure 2: Current vs Temperature Example Test Setup

5 Issue: 2 Date: 16/06/2021 C/O: 30590


Figure 3: Temperature Rise vs Current for Different Contact Counts

0.00

20.00

40.00

60.00

80.00

100.00

120.00

140.00

160.00

180.00

0 10 20 30 40 50 60 70 80

Tem

pera

ture

Rise

(°C)

Current (A)

Temperature Rise vs Current - KA1 Each SizePre-conditioned

KA1-2010298F1 & KA1-MV10205M1 AVGKA1-2010398F1 & KA1-MV10305M1 AVGKA1-2010498F1 & KA1-MV10405M1 AVGPRE-CONDITIONED AVG OF ALL SIZESSINGLE CONTACT AVG

6 Issue: 2 Date: 16/06/2021 C/O: 30590


Figure 4: De-rate Curve for Different Contact Counts

-20.00

0.00

20.00

40.00

60.00

80.00

100.00

120.00

140.00

160.00

0 10 20 30 40 50 60 70 80

Tem

pera

ture

(°C)

Current (A)

Current vs Temperature De-Rating Curve - KA1 Each SizePre-Conditioned

KA1-2010298F1 & KA1-MV10205M1KA1-2010398F1 & KA1-MV10305M1KA1-2010498F1 & KA1-MV10405M1PRE-CONDITIONED AVG OF ALL SIZESSINGLE CONTACT

7 Issue: 2 Date: 16/06/2021 C/O: 30590


Figure 5: Temperature Rise vs Current Graph for Pre- and Post-Conditioned Samples

0.00

20.00

40.00

60.00

80.00

100.00

120.00

140.00

0 10 20 30 40 50 60 70 80

Tem

pera

ture

rise

(°C)

Current (A)

Temperature Rise vs Current - KA1 Averages

PRE-CONDITIONED AVG OF ALL SIZES 96 HOUR TEMP LIFE AVG OF ALL SIZES

250 HOUR TEMP LIFE AVG OF ALL SIZES THERMAL SHOCK AVG OF ALL SIZES

SALT SPRAY AVG OF ALL SIZES HUMIDITY AVG OF ALL SIZES

8 Issue: 2 Date: 16/06/2021 C/O: 30590


Figure 6: De-Rate Curve for Connectors Pre- and Post-Conditioned Samples

0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

80.00

90.00

100.00

110.00

120.00

130.00

140.00

150.00

160.00

0 10 20 30 40 50 60 70 80

Ambi

ent T

empe

ratu

re (°

C)

Current (A)

Current vs Temperature De-Rating Curve - KA1 Averages

PRE-CONDITIONED AVG OF ALL SIZES 96 HOUR TEMP LIFE AVG OF ALL SIZES250 HOUR TEMP LIFE AVG OF ALL SIZES THERMAL SHOCK AVG OF ALL SIZESSALT SPRAY AVG OF ALL SIZES HUMIDITY AVG OF ALL SIZES

9 Issue: 2 Date: 16/06/2021 C/O: 30590


3.3. Durability to EIA-364-09C: 1999

Specification: • 50N maximum contact insertion force (per Power contact, using mating contact) Pre-Conditioning • 70N maximum contact insertion force (per Power contact, using mating contact) Post-Conditioning • 5N minimum contact withdrawal force (per Power contact, using mating contact) • 250 Mechanical Operations

Methodology: For this test, both individual power contacts and fully-assembled connector pairs were mated using Mecmesin Multitest 2.5i Auto Force Gauge (HWN 4162) at a speed of 25mm/min for 250 cycles, in general accordance with EIA-364-09C. Post-conditioned samples were then cycled on the force gauge to compare the effect certain conditions have on insertion and withdrawal forces over 250 cycles.

Average Connector forces displayed are taken from multiple samples in each test set-up. Inspection of the contact plating was performed post-cycling, and little contact wear was observed.

Pre-Conditioned

Female Male Max Insertion (N) Max Withdrawal

(N) Minimum

Withdrawal (N) Average Initial Insertion (N)

Average Initial Withdrawal (N)

Full System

Per Contact

Full System

Per Contact

Full System

Per Contact

Full System

Per Contact

Full System

Per Contact

KA1-2010298F2 KA1-MV10205M2 79.76 39.88 50.21 25.11 24.30 12.15 44.03 22.01 23.50 11.75

KA1-2010398F2 KA1-MV10305M2 118.11 39.37 69.67 23.22 30.24 10.08 56.53 18.84 33.75 11.25

KA1-2010498F2 KA1-MV10405M2 135.93 33.98 85.42 21.36 44.12 11.03 63.12 15.78 46.56 11.64

KA1-0400005 KA1-1100005 - 37.22 - 26.43 - 10.08 - 16.01 - 13.60

Average per Contact - 37.61 - 24.03 - 10.84 - 18.16 - 12.06

Post-Conditioning (N)

Female Male Max Insertion

Max Withdrawal

Minimum Withdrawal

Average Initial Insertion

Average Initial Withdrawal

KA1-0400005* KA1-1100005*

Temperature Life 96hrs 34.27 19.12 5.02 23.29 5.58



Thermal Shock 47.78 24.39 10.21 23.84 10.85

Salt Spray 53.16 26.79 11.33 26.32 12.47

Humidity 69.23 29.24 8.74 37.96 10.91

*Single contact values calculated from the forces of whole contact system.

Figure 7: Typical Durability Test Setup

10 Issue: 2 Date: 16/06/2021 C/O: 30590


3.4. Withstand Voltage to EIA-364-20C: 2004 & Insulation Resistance to EIA-364-21C: 2000

Withstand Voltage:

Specification: Voltage Proof (sea level) = 3000V DC/AC for 60 seconds, Voltage Proof (70,000 feet) = 500V DC/AC for 60 seconds, Current leakage: 5mA max.

Methodology: 3000V AC (60Hz) was applied to connector pairs wired in two series cicuits for 60 seconds to determine whether breakdown or flashover occurred (3500V AC (60Hz) was applied to the samples marked with an asterix*). Samples were then put into a vaccuum chamber to simulate 70,000ft, and a 500V AC (60Hz) voltage was applied to connector pairs wired in two series to determine whether breakdown or flashover occurred. Current leakage was meaasured during the test. Samples were visually inspected following the test, with no obvious changes to the connectors occuring.

Insulation Resistance:

Specification: 10GΩ min pre- and post-conditioning (excluding salt mist conditioning) at 1000V.

Methodology: 1000V was applied to connector pairs wired in two series for two minutes to determine whether the resistance satisfies the required specifcation values of >10GΩ. Samples were visually inspected following the test, with no obvious changes to the connectors occuring.

Test Set Up Connector Assembly Part Numbers

Male Female 1 KA1-MV10298M1 KA1-2010298F1 4 KA1-MV10398M2 KA1-2010398F2 5 KA1-MV10498M1 KA1-2010498F1

Figure 8: Typical Voltage Breakdown Test Setup for Sea Level and Altitude Testing

Pre-Conditioned Samples Thermal Shock

Sample

Sea Level 70,000ft

Sample

Ambient Pressure 70,000ft Voltage

Breakdown (mA)

Insulation Resistance

(MΩ)

Voltage Breakdown

(mA)

Voltage Breakdown

(mA)


(MΩ)

Voltage Breakdown

(mA) TS1 (1) 0.030 >9999 0.002 TS1 (1)* 0.034 >9999 0.001 TS1 (2)* 0.027 >9999 0.002 TS1 (2)* 0.032 >9999 0.001 TS1 (3)* 0.035 >9999 0.001 TS4 (1)* 0.036 >9999 0.003 TS4 (1)* 0.029 >9999 0.002 TS4 (2)* 0.035 >9999 0.002 TS4 (2)* 0.043 >9999 0.003 TS5 (1)* 0.041 >9999 0.003 TS4 (3)* 0.036 >9999 0.002 TS5 (2)* 0.040 >9999 0.002 TS5 (1)* 0.030 >9999 0.002 TS5 (2)* 0.036 >9999 0.003 TS5 (3)* 0.035 >9999 0.002

11 Issue: 2 Date: 16/06/2021 C/O: 30590


Temperature Life (96 hours +150°C) Temperature Life (250 hours +150°C)

Sample

Ambient Pressure 70,000ft Sample


Breakdown (mA)


(MΩ)

Voltage Breakdown

(mA)

Voltage Breakdown

(mA)


(MΩ)

Voltage Breakdown

(mA) TS1 (1)* 0.020 >9999 0.003 TS1 (1)* 0.020 >9999 0.002 TS1 (2)* 0.020 >9999 0.003 TS1 (2)* 0.020 >9999 0.003 TS4 (1)* 0.023 >9999 0.002 TS4 (1)* 0.023 >9999 0.002 TS4 (2)* 0.024 >9999 0.002 TS4 (2)* 0.024 >9999 0.003 TS5 (1)* 0.026 >9999 0.003 TS5 (1)* 0.025 >9999 0.003 TS5 (2)* 0.026 >9999 0.003 TS5 (2)* 0.025 >9999 0.003

Salt Mist Testing 96 hours Humidity

Sample

Ambient Pressure 70,000ft Sample


Breakdown (mA)


(MΩ)

Voltage Breakdown

(mA)

Voltage Breakdown

(mA)


(MΩ)

Voltage Breakdown

(mA) TS1 (1) 0.025 4833 0.002 TS1 (1)* 0.027 >9999 0.001 TS1 (2)* 0.023 >9999 0.003 TS1 (2)* 0.026 >9999 0.002 TS4 (1)* 0.029 >9999 0.002 TS4 (1)* 0.031 >9999 0.002 TS4 (2)* 0.029 >9999 0.003 TS4 (2)* 0.030 >9999 0.002 TS5 (1) 0.026 >9999 0.002 TS5 (1)* 0.029 >9999 0.003 TS5 (2) 0.026 >9999 0.003 TS5 (2)* 0.031 >9999 0.003

*Tested at 3.5kV AC (60Hz)

3.5. Contact & Insert Retention to EIA-364-05B: 1998

Specification: • Contact Retention in Housing = 75N min. • Insert retention = 50N.

Methodology: Contact retention in the housing was tested to EIA-364-05B for both pre-conditioned and post-conditioned samples. All power contacts were removed from each assembly, measuring the force required to do so using Mecmesin Multitest 2.5i Auto Force Gauge (HWN 4162).

Insert retention was tested to EIA-364-35C for both pre and post conditioned samples. Samples were loaded into the auto force gauge where an axial load of 50.0N was applied at a rate of 69kPa, this was held for 10 seconds. Samples were then visually inspected and given a pass or fail.

Contact Retention in Housing (N) – Pre-Conditioning

Part No. Power Contact Forces (N) Max. Min. Average

KA1-2010298F1 or KA1-2010298F2 166.86 102.22 130.18 KA1-2010398F1 or KA1-2010398F2 169.91 136.67 148.39 KA1-2010498F1 or KA1-2010498F2 171.18 140.62 161.50

KA1-MV10298M1 or KA1-MV10298M2 174.91 149.71 160.40 KA1-MV10398M1 or KA1-MV10398M2 172.97 136.00 153.20 KA1-MV10498M1 or KA1-MV10498M2 155.83 105.43 132.50

Average 147.695

12 Issue: 2 Date: 16/06/2021 C/O: 30590


Insert Retention in Housing

Part No. Initial Post-Conditioning Retention Forces (Pass/Fail)

Temperature Life Thermal Shock

Salt Spray

Humidity 96hrs 250hrs 1000hrs 96hrs 1344hrs

KA1-2010298F1 Pass Pass Pass Pass Pass Pass Pass Pass KA1-MV10298M1 Pass Pass Pass Pass Pass Pass Pass Pass KA1-2010298F2 Pass Pass Pass Pass Pass Pass Pass Pass

KA1-MV10298M2 Pass Pass Pass Pass Pass Pass Pass Pass KA1-2010398F1 Pass Pass Pass Pass Pass Pass Pass Pass




KA1-MV10498M2 Pass Pass Pass Pass Pass Pass Pass Pass

Figure 9: Contact Retention Testing on a Cable Contact

Contact Retention in Housing (N) – Post-Conditioning

Part No. Power Contact Forces (N)

PCT Power Contact Forces (N)

Cable Max. Min. Average Max. Min. Average

Temperature Life – 96 hours 124.07 90.37 105.83 210.02 95.89 153.66 Temperature Life – 250 hours 109.68 79.93 92.99 192.28 107.67 154.49 Temperature Life – 1000 hours 136.07 93.95 115.27 199.06 81.73 146.45

Thermal Shock 109.23 76.73 92.08 203.83 88.21 156.22 Salt Spray 151.65 91.19 114.03 203.09 98.93 159.09

Humidity – 96 hours 150.98 83.21 107.81 200.85 84.99 142.84

13 Issue: 2 Date: 16/06/2021 C/O: 30590


Figure 10: Contact Retention Testing on a PCT Contact

3.6. Temperature Life (without load) to EIA-364-17B: 1999

Specification: Operating temperature = -65°C to +150°C.

Methodology: The test was carried out to EIA-364-17B, condition 10, method A; connectors were subjected to 96 hours, 250 hours and 1000 hours at 150±5°C using Memmert UF 160 Plus Oven (HWN 3592).

Post conditioned testing was performed for Contact Resistance (3.1), Current vs Temperature (3.2), Durability (3.3), Withstand Voltage and Insulation Resistance (3.4) and Contact & Insert Retention (3.5).

Samples were also visually inspected post-conditioning, with no significant changes observed.

Figure 11: Current vs Temperature Samples in the Temperature Life Oven

Figure 12: Durability and Contact Insert Retention Samples in the Temperature Life Oven

14 Issue: 2 Date: 16/06/2021 C/O: 30590


3.7. Thermal Shock (Temperature Cycling) to EIA-364-32C: 2000 & BS EN 60068-2-14: 2009

Specification: Operating temperature = -65°C to +150°C.

Methodology: Samples were tested in general accordance with BS EN 60068-2-14: 2009 and EIA-364-32C: 2000 Test Condition 4. This test was conducted using automated transfer between climatic chambers at the two temperature extremes (-65°C to +150°C). The connectors were measured for contact resistance, power, voltage break down, insulation resistance and durability, as well as a visual inspection after testing. The were no obvious changes as a result.


No issues were noted.

Figure 13: Chamber Response Plot for Thermal Shock Testing

Figure 14: Samples in the Thermal Shock Chamber

15 Issue: 2 Date: 16/06/2021 C/O: 30590


3.8. Salt Spray to EIA-364-26B: 1999 & BS EN 60068-2-11: 1999

Specification: 48hrs continuous salt spray, Salt Solution: 5% NaCl, Salt Mist Chamber Temp.: +35°C, Fallout rates: 0.5-3ml/hr, Ph level: 6.5-7.2 @ 35°C.

Methodology: Samples were tested in general accordance with BS EN 60068-2-11: 1999 Test Ka and EIA-364-26B Test Condition B. The samples were placed into the salt mist chamber for 48hrs and measured for contact resistance, power, voltage breakdown, insulation resistance and durability, as well as visual inspection post-testing. Some changes were noted during the visual inspection and insulation resistance testing.


Insulation resistance on one sample was affected, no other issues were noted. Visual changes were noted on the majority of samples.

Figure 15: Samples in the Salt Spray Chamber

3.9. Humidity to EIA-364-31B: 1999 & BS EN 60068-2-78: 2013

Specification: 24hrs pre-conditioning at +50°C, Humidity: 90-95%, Temperature: +40°C, Duration: 96hrs

Methodology: Samples were tested in general accordance with BS EN 60068-2-78: 2013 Test Cab and EIA-364-31B: 2000 Method 2 Test Condition A. The samples were preconditioned for 24 hours at 50°C then suspended in a humidity chamber for 96 hours at 40°C with 90-95% relative humidity. The connectors were measured for contact resistance, power and durability, as well as a visual inspection post-testing. There were no obvious changes as a result.


Figure 16: Samples in the Humidity Chamber

16 Issue: 2 Date: 16/06/2021 C/O: 30590


3.10. Vibration to EIA-364-28D: 1999 & BS EN 60068-2-6: 2008

Specification: 10Hz to 2kHz, 1.52mm pk-pk displacement or 20gn pk (whichever is less), 198m/s2 (20G), 12 cycles per axis, 20 minutes per cycle. Cables restrained > 200 mm from connector.

Methodology: Samples were tested in general accordance with BS EN 60068-2-6: 2008 Test Fc and EIA-364-28D Test Condition 4. The samples were subjected to a Swept Sine Test with continuous monitoring at ≥1 microsecond. No triggers were noted on any samples during the test process. Upon completion of testing the samples were visually inspected, no obvious changes to the samples were noted.

Samples Mounted in

Y-Axis

Samples Mounted in

X-Axis

Samples Mounted in

Z-Axis

Figure 17: Samples Mounted in the X & Y-Axis

Figure 18: Samples Mounted in the Z-Axis

17 Issue: 2 Date: 16/06/2021 C/O: 30590


3.11. Mechanical Shock to EIA-364-27B: 1996 & BS EN 60068-2-27: 2009

Specification: Acceleration: 100gn, Shock Duration: 6ms, Shock Shape: Half Sine Pulse, 3 shocks in each axis.

Methodology: Shock Test Sequence was carried out on all samples. During the test, the samples were monitored continuously for discontinuities of ≥1 microsecond. No triggers were noted on any sample during the test process. Upon completion of testing the samples were visually inspected, no obvious changes to the samples were noted.

Figure 19: Samples Mounted in the Z-Axis

Figure 20: Samples Mounted in the Positive and negative sense of the X & Y-Axis

Figure 21: Samples Mounted in the Positive and negative sense of the Z-Axis

18 Issue: 2 Date: 16/06/2021 C/O: 30590


Figure 22: Typical Plot Generated During Mechanical Shock Test in Positive & Negative Sense of Z-Axis

Figure 23: Typical Plot Generated During Mechanical Shock Test in Positive & Negative Sense of Y-Axis

Figure 24: Typical Plot Generated During Mechanical Shock Test in Positive & Negative Sense of X-Axis

HT076xx - Kona General Testing - Harwin · Kona – Electrical, Mechanical & Environmental Testing...

Documents

Transcript of HT076xx - Kona General Testing - Harwin · Kona – Electrical, Mechanical & Environmental Testing...