Summary of HALT, IPx7 & IP69K testing for AT Series connectors

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2 S Rev. A1 Corp. SINE Systems Corporation Morley Drive Clinton Twp, MI Summary of HALT, IPx7 & IP69K testing for AT Series connectors IPx7 (Submersion) PASS Requirements: Acceptance conditions per IEC Section 14.3 and the Insulation Resistance shall be greater than 20 MΩ. Results: All samples measured greater than 2 GΩ between each adjacent position during the pretest Insulation Resistance test. All samples measured greater than 2 GΩ between each adjacent position with no sign of water intrusion following the Water Immersion test. HALT (Cold Step Stress) - PASS Requirements: No discontinuity, with13 A applied, during rapid thermal cycling. Results: No loss of continuity was detected in any of the samples tested during the test. HALT (Hot Step Stress) PASS Requirements: No discontinuity, with 13 A applied, during rapid thermal cycling. Results: No loss of continuity was detected in any of the samples tested during the test. HALT (Vibration Step Stress) PASS Requirements: No discontinuity, with 13 A applied, during vibration step test. Results: No loss of continuity was detected in any of the samples tested during the test. HALT (Rapid Thermal Cycling) PASS Requirements: No discontinuity, with 13 A applied, during rapid thermal cycling. Results: No loss of continuity was detected in any of the samples tested during the test. HALT (Combined Thermal Cycling and Vibration) PASS (one exception, see Results) Requirements: No discontinuity, with 13 A applied, during combined thermal cycling and vibration. Results: Discontinuity in sample was detected during the +150 C, 50 g rms dwell. No loss of continuity was detected in any other of the samples tested during the test. IP69K (Dust & Water Spray) Dust: PASS, Water Spray: PASS Requirements (Dust): The protection is satisfactory if no deposit of dust is observable inside the enclosure at the end of the test. Results (Dust): Upon visual inspection, no ingress of dust was observed in any of the samples tested. Requirements (Water Spray): Water directed at a high pressure against the enclosure from any direction shall have no harmful effects and the Insulation Resistance shall be greater than 20 MΩ. Results (Water Spray): All samples measured greater than 2 GΩ between each adjacent position during the pre-test Insulation Resistance test. No water intrusion was detected in any of the samples tested following the Water Spray test. All samples measured greater than 2 GΩ between each adjacent position following the Water Spray test. Originator/Date Checked by Approved/Date MRF 28-Apr-09 MRF 28-Apr-09 DH 29-Apr-09 This document contains proprietary information and such information may not be disclosed to others for any purpose or used for manufacturing purposes without written permission from Sine Systems. All references to Deutsch in this document refer to the Deutsch DT Series product line, and are used for the purposes of comparison.

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4 DTL Report Number: REV 1 SAMPLE DESCRIPTION submitted one hundred forty-four (144) AT Series Connectors (and competitors) designated for Water Immersion testing. The samples were labeled by as follows: Wire Size Small Large Sine plug Sine receptacle Deutsch plug Sine receptacle Sine plug Deutsch receptacle Deutsch plug Deutsch receptacle Page 1 of 33

5 DTL Report Number: REV 1 TESTING PERFORMED WATER IMMERSION Procedure Insulation Resistance testing was performed on each sample prior to the Water Immersion test. A megohmmeter was used to measure the resistance between the adjacent positions of each connector assembly at 1000 VDC. Next, the samples were mounted to a holding fixture and submerged in one (1) meter of water for 30 minutes. Water temperature and sample temperature was maintained within a 5 C differential. Following the submergence the samples were removed from the tank and were again tested for insulation resistance. The connector assemblies were unmated and inspected internally for any signs of water intrusion. The samples were tested in eight (8) groups of eighteen (18) samples each. Requirements Acceptance conditions per IEC Section The Insulation Resistance shall be greater than 20 MΩ. Results All samples measured greater than 2 GΩ between each adjacent position during the pre-test Insulation Resistance test. All samples measured greater than 2 GΩ between each adjacent position with no sign of water intrusion following the Water Immersion test. SAMPLE DISPOSITION The test samples were returned to for further engineering evaluation. Page 2 of 33

6 DTL Report Number: REV 1 TEST EQUIPMENT s calibration system meets the requirements of ISO 17025:2005. DTL ID Description Manufacturer Model Calibration Due Thermocouple Module Fluke 80TK 04/ Digital Multimeter Fluke / Dual Timer Ultrak T-4 12/ Tape Measure Starrett D / Megohmmeter AEMC / Thermocouple Module Fluke 80TK 03/ Multimeter Fluke 73III 04/ Dual Timer Ultrak T-4 07/ Megohmmeter Biddle /10 NCR No Calibration Required APPENDICES: Appendix A: Photographs Page 3 of 33

7 DTL Report Number: REV 1 Water Immersion, Sine Plug Sine Receptacle Small Wire Water Immersion, Deutsch Plug Sine Receptacle Small Wire Page 4 of 33

8 DTL Report Number: REV 1 Water Immersion, Sine Plug Deutsch Receptacle Small Wire Water Immersion, Deutsch Plug Deutsch Receptacle Small Wire Page 5 of 33

9 DTL Report Number: REV 1 Water Immersion, Sine Plug Sine Receptacle Large Wire Water Immersion, Deutsch Plug Sine Receptacle Large Wire Page 6 of 33

10 DTL Report Number: REV 1 Water Immersion, Sine Plug Deutsch Receptacle Large Wire Water Immersion, Deutsch Plug Deutsch Receptacle Page 7 of 33

11 DTL Report Number: REV 1 Water Immersion, Large Wire Samples in Submergence Tank (Typical) Water Immersion, Small Wire Samples in Submergence Tank (Typical) Page 8 of 33

12 DTL Report Number: REV 1 Insulation Resistance, Sine Plug Sine Receptacle Insulation Resistance, Deutsch Plug Sine Receptacle Insulation Resistance, Sine Plug Deutsch Receptacle Insulation Resistance, Deutsch Plug Deutsch Receptacle Page 9 of 33

13 DTL Report Number: REV 1 Insulation Resistance, Sine Plug Sine Receptacle Insulation Resistance, Deutsch Plug Sine Receptacle Insulation Resistance, Sine Plug Deutsch Receptacle Insulation Resistance, Deutsch Plug Deutsch Receptacle Page 10 of 33

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16 DTL Report Number: REV 1 TESTING PERFORMED HALT (COLD STEP STRESS) Procedure The samples were prepared for testing by connecting all conductors from each sample in series, forming one series circuit per connector assembly (24 series circuits total for all samples in test). Each circuit was connected to a DC power source through an adjustable power resistor. Current through each circuit was set to 13 amps at room ambient temperature, measured and recorded at a rate of 1 Hz throughout the entire HALT test sequence. The samples were mounted inside the HALT chamber by clamping the wires approximately 4 inches on either side of the connector. The connector body itself was suspended in air. Testing began with a 15 minute dwell at -30 C. Chamber temperature was then lowered at -10 C intervals to -90 C, with 15 minute dwells at each interval. The lowest temperature reached without any abnormalities or failures was the minimum temperature used for the Rapid Thermal Cycling phase described later in this report. Dwell times were started when the sample temperature was within 2 C of set point. Requirements No discontinuity, with13 A applied, during rapid thermal cycling described in the procedure. Results No loss of continuity was detected in any of the samples tested during the Cold Step Stress test. The temperature of -90 C was determined to be the minimum temperature to be used for the Rapid Thermal Cycling and Combined Environment tests. Page 12 of 33

17 DTL Report Number: REV 1 TESTING PERFORMED HALT (HOT STEP STRESS) Procedure Following the Cold Stress Step test the samples began the Hot Stress Step test with a 15 minute dwell at 85 C. Chamber temperature was then increased at +10 C intervals to +150 C, with 15 minute dwells at each interval. The highest temperature reached without any abnormalities or failures was the maximum temperature used for the Rapid Thermal Cycling phase described later in this report. Dwell times were started when the sample temperature was within 2 C of set point. Requirements No discontinuity, with 13 A applied, during rapid thermal cycling described in the procedure. Results No loss of continuity was detected in any of the samples tested during the Hot Step Stress test. The temperature of +150 C was determined to be the maximum temperature to be used for the Rapid Thermal Cycling and Combined Environment tests. Page 13 of 33

18 DTL Report Number: REV 1 TESTING PERFORMED HALT (VIBRATION STEP STRESS) Procedure Following the Hot Step Stress test the samples began the Vibration Step Stress test with a 10 minute dwell at 25 C, 5 g rms. Next, the vibration level was increased by 5 g rms every 10 minutes up to the maximum of 50 g rms. Chamber temperature was maintained at +25 C throughout testing. Requirements No discontinuity, with 13 A applied, during vibration step test described in the procedure. Results No loss of continuity was detected in any of the samples tested during the Vibration Stress test. Page 14 of 33

19 DTL Report Number: REV 1 TESTING PERFORMED HALT (RAPID THERMAL CYCLING) Procedure Following the Vibration Step Stress test the samples were subjected to the following Rapid Thermal Cycle profile: 1. Ramp to -90 C using the fastest transition rate achievable by the chamber. 2. Dwell at -90 C for 15 minutes. 3. Ramp to +150 C using the fastest transition rate achievable by the chamber. 4. Dwell at +150 C for 15 minutes. 5. Repeat steps 1 through 4 for a total of five (5) cycles. Dwell times were started when the sample temperature was within 2 C of set point. Requirements No discontinuity, with 13 A applied, during the rapid thermal cycling described in the procedure. Results No loss of continuity was detected in any of the samples tested during the Rapid Thermal Cycling test. Page 15 of 33

20 DTL Report Number: REV 1 TESTING PERFORMED HALT (COMBINED THERMAL CYCLING AND VIBRATION TESTING) Procedure Following the Rapid Thermal Cycling test the samples were subjected to the following combined environment profile: 1. Ramp to -90 C, 5 g rms using the fastest transition rate achievable by the chamber. 2. Dwell at -90 C, 5 g rms for 10 minutes. 3. Ramp to +150 C, 5 g rms using the fastest transition rate achievable by the chamber. 4. Dwell at +150 C, 5 g rms for 10 minutes. 5. Repeat steps 1 through 4 nine (9) times increasing the vibration level by 5 g rms each cycle to a maximum of 50 g rms. Dwell times were started when the sample temperature was within 2 C of set point. Requirements No discontinuity, with 13 A applied, during the environmental profile described in the procedure. Results Discontinuity in sample was detected during the +150 C, 50 g rms dwell. No discontinuity was detected in any of the other samples tested during the Combined Thermal Cycling and Vibration testing. SAMPLE DISPOSITION The test samples were returned to for further engineering evaluation. Page 16 of 33

21 DTL Report Number: REV 1 TEST EQUIPMENT s calibration system meets the requirements of ISO 17025:2005. DTL ID Description Manufacturer Model Calibration Due EC120 HALT Chamber Qualmark OVS / Data Acquisition Switch Unit Agilent 34970A 07/ Channel Multiplexer Agilent 34901A 06/ Channel Multiplexer Agilent 34901A 07/ Computer Compaq EVO NCR Current Shunt Empro 50A/50mV 12/ Current Shunt Ram Meter 50A/50mV 12/ Current Shunt Ram Meter 50A/50mV 12/ Current Shunt Ram Meter 50A/50mV 12/ Current Shunt Ram Meter 50A/50mV 12/ Current Shunt Ram Meter 50A/50mV 12/ Current Shunt Ram Meter 50A/50mV 12/ Current Shunt Ram Meter 50A/50mV 12/ Current Shunt Empro 50A/50mV 12/ Current Shunt Ram Meter 50A/50mV 12/ Current Shunt Ram Meter 50A/50mV 12/ Current Shunt Empro 50A/50mV 12/ Current Shunt Ram Meter 50A/50mV 04/ Current Shunt Ram Meter 50A/50mV 11/ Current Shunt Ram Meter 50A/50mV 12/ Current Shunt Ram Meter 50A/50mV 09/ Current Shunt Empro 50A/50mV 03/ Current Shunt Ram Meter 50A/50mV 03/ Current Shunt Ram Meter 50A/50mV 12/ Current Shunt Ram Meter 50A/50mV 12/ Current Shunt Ram Meter 50A/50mV 12/ Current Shunt Empro 50A/50mV 12/ Current Shunt Ram Meter 50A/50mV 12/ Current Shunt Ram Meter 50A/50mV 12/ Power Supply Sorensen DCR A NCR NCR No Calibration Required APPENDICES: Appendix A: Photographs Page 17 of 33

22 DTL Report Number: REV 1 HALT Samples 1 to 24 in Chamber, Cold Step Stress, Hot Step Stress, Rapid Thermal Cycling HALT Samples 1 to 12 in Chamber, Vibration Step Stress, Combined Environment Page 18 of 33

23 DTL Report Number: REV 1 HALT Samples 13 to 24 in Chamber, Vibration Step Stress, Combined Environment HALT Testing Resistive Load and Data Acquisition Setup Page 19 of 33

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25 DTL Report Number: REV 1 SAMPLE DESCRIPTION submitted one hundred forty-four (144) AT Series Connectors (and competitors) designated for Dust testing. The samples were labeled by as follows: Wire Size Small Large Sine plug Sine receptacle Deutsch plug Sine receptacle Sine plug Deutsch receptacle Deutsch plug Deutsch receptacle Page 20 of 33

26 DTL Report Number: REV 1 SAMPLE DESCRIPTION (CONTINUED) submitted one hundred forty-four (144) AT Series Connectors (and competitors) designated for Water Spray testing. The samples were labeled by as follows: Wire Size Small Large Sine plug Sine receptacle Deutsch plug Sine receptacle Sine plug Deutsch receptacle Deutsch plug Deutsch receptacle Page 21 of 33

27 DTL Report Number: REV 1 TESTING PERFORMED DUST TEST Procedure The dust chamber was charged with 2 kg/m³ of talc which was agitated for 6 seconds every 15 minutes for the duration of testing (5 hours). Upon completion of testing, any excess dust was brushed off the samples. The samples were then unmated and an internal visual inspection was performed. The samples were subjected to dust testing in six (6) groups of twenty-four (24) samples each. Requirements The protection is satisfactory if no deposit of dust is observable inside the enclosure at the end of the test. Results Upon visual inspection, no ingress of dust was observed in any of the samples tested. Page 22 of 33

28 DTL Report Number: REV 1 TESTING PERFORMED WATER SPRAY TEST Procedure Insulation Resistance testing was performed on each sample prior to the Water Spray test. A mega-ohmmeter was used to measure the resistance between the adjacent positions of each connector assembly at 1000 VDC. Next, the samples were mounted to a holding fixture and placed in a water spray chamber. The samples were subjected to a high pressure cleaning test with the following parameters: Nozzle Type: Fan Jet, 35 degrees ± 5 degrees Water Pressure: 1300 psi Water Temperature: +80 C Distance from nozzle to sample: 100 mm to 150 mm Spray Time: 30 seconds per position Sample Rotation Speed: 5 RPM The samples were sprayed from four (4) positions: 0 degrees (horizontal), 30 degrees, 60 degrees and 90 degrees (vertical). The samples were tested in twenty-four (24) groups of six (6) samples each. Following the Water Spray the samples were once again tested for insulation resistance. The connector assemblies were unmated and inspected internally for any signs of water intrusion. Requirements Water directed at a high pressure against the enclosure from any direction shall have no harmful effects. The Insulation Resistance shall be greater than 20 MΩ. Results All samples measured greater than 2 GΩ between each adjacent position during the pre-test Insulation Resistance test. No water intrusion was detected in any of the samples tested following the Water Spray test. All samples measured greater than 2 GΩ between each adjacent position following the Water Spray test. Page 23 of 33

29 DTL Report Number: REV 1 SAMPLE DISPOSITION The test samples were returned to. TEST EQUIPMENT s calibration system meets the requirements of ISO 17025:2005. DTL ID Description Manufacturer Model Calibration Due Dust Cabinet DTL Per SAE J575 NCR Micromaster Western Pacific WP / Scale GSE / Pressure Gauge Ashcroft / Thermocouple Module Fluke 80TK 04/ Digital Multimeter Fluke / Dual Timer Ultrak T-4 12/ Tape Measure Starrett D / Megohmmeter AEMC / Digital Protractor Mitutoyo PRO /08 NCR No Calibration Required APPENDICES: Appendix A: Photographs Page 24 of 33

30 DTL Report Number: REV 1 Dust Testing, 2 Position Samples Dust Testing, 3 Position Samples Page 25 of 33

31 DTL Report Number: REV 1 Dust Testing, 4 Position Samples Dust Testing, 6 Position Samples Page 26 of 33

32 DTL Report Number: REV 1 Dust Testing, 8 Position Samples Dust Testing, 12 Position Samples Page 27 of 33

33 DTL Report Number: REV 1 Water Spray Testing, Sine Plug Sine Receptacle Small Wire Water Spray Testing, Deutsch Plug Sine Receptacle Small Wire Page 28 of 33

34 DTL Report Number: REV 1 Water Spray Testing, Sine Plug Deutsch Receptacle Small Wire Water Spray Testing, Deutsch Plug Deutsch Receptacle Small Wire Page 29 of 33

35 DTL Report Number: REV 1 Water Spray Testing, Sine Plug Sine Receptacle Large Wire Water Spray Testing, Deutsch Plug Sine Receptacle Large Wire Page 30 of 33

36 DTL Report Number: REV 1 Water Spray Testing, Sine Plug Deutsch Receptacle Large Wire Water Spray Testing, Deutsch Plug Deutsch Receptacle Large Wire Page 31 of 33

37 DTL Report Number: REV 1 Insulation Resistance, Sine Plug Sine Receptacle Insulation Resistance, Deutsch Plug Sine Receptacle Insulation Resistance, Sine Plug Deutsch Receptacle Insulation Resistance, Deutsch Plug Deutsch Receptacle Page 32 of 33

38 DTL Report Number: REV 1 Insulation Resistance, Sine Plug Sine Receptacle Insulation Resistance, Deutsch Plug Sine Receptacle Insulation Resistance, Sine Plug Deutsch Receptacle Insulation Resistance, Deutsch Plug Deutsch Receptacle Page 33 of 33