Working Committee Test Guideline for Motor Vehicle …c-planners.com/AK-Prufrichtlinie-en1.pdfPage 7...

VW Audi

Porsche BMW

Mercedes-Benz Working Committee Test Guideline January 1996

02 Feb 96, I/EE-2, LS

Working Committee

T e s t G u i d e l i n e

for Motor Vehicle Connectors

Edition 1 - 02/96

Audi AG

Dr. Pagel Mr. SkogmoI/EE I/EE-2

BMW AG

Dr. Thoma Mr. LubitzEE EE-65

Mercedes Benz AG

Mr. Leiber Mr. GartheEP EP/GGK

Porsche AG

Dr. Fritz Mr. KurzEG EGE 23

Volkswagen AG

Mr. Kreft Dr. WilleEE EEVB-1

(40)Test Guideline for Motor Vehicle Connectors : 1996-02

Preface

1. This test guideline has been compiled jointly by the following companies:

Audi AG,BMW AG,Mercedes Benz AG,Porsche AG,Volkswagen AG

2. This test guideline does not make any claims with respect to completeness. The manufacturer, aswell as the automobile companies, have the liberty at all times to carry out appropriate, additionaltests in accordance with the state-of-the art.

3. Should product-specific individual test sections becomes necessary in individual cases, these areto be agreed upon separately between the appropriate specialist department and the manufacturerconcerned.

General information

The standards cited below are to be taken into consideration as a basis for processing and testing:

DIN 40 050 Sheet 9 Enclosure protection ratings.DIN 41 640 Part 38 Measuring methods and testing procedures for electromechanical

components.DIN 41 640 Part 72 Measuring methods and testing procedures for electromechanical

components.DIN 46 249 Part 1 Snap-on connectors, non-insulated.DIN 50 021 Salt spray testing with various sodium chloride solutions.DIN EN 60 068 Part 2-1 Environmental tests, low temperatures.DIN EN 60 068 Part 2-2 Environmental tests, dry heat.DIN EN 60 068 Part 2-27 Environmental tests, shocking.DIN EN 60 352 Part 2 Solderless electrical connections, crimp connections.DIN EN 60 352 Part 3 Solderless electrical connections, insulating piercing connections.DIN IEC 50A (sec) 248 Fundamental environmental test procedures, oscillation, wide-band

random vibration.DIN IEC 68 Part 2-6 Fundamental environmental test procedures, sinusoidal oscillation.DIN IEC 68 Part 2-13 Fundamental environmental test procedures, low air pressure.DIN IEC 68 Part 2-14 Fundamental environmental test procedures, change of temperature.DIN IEC 68 Part 2-30 Fundamental environmental test procedures, damp heat.DIN IEC 68 Part 2-52 Fundamental environmental test procedures, salt spray.DIN IEC 512 Part 2 Electromechanical components for electronic equipment.DIN IEC 512 Part 3 Electromechanical components for electronic equipment.DIN IEC 512 Part 5 Electromechanical components for electronic equipment.DIN IEC 512 Part 7 Electromechanical components for electronic equipment.DIN IEC 512 Part 8 Electromechanical components for electronic equipment.VDA Test Sheet 621 Resistance to media


Contents

Page

Characteristic tests 5Subjection to load 7Test number structure 8Overview of lot sizes 8

A Test groups for general requirements

PG 0 Receiving inspection and testing 10PG 1 Dimensions 11PG 2 Material and surface analysis, contacts 11PG 3 Material and surface analysis, housings 12PG 4 Contact overlap 12PG 5 Load deflection curve 12PG 6 Interaction between contact and housing 13PG 7 Handling and functional reliability of the housings 13PG 8 Insertion and retention forces of the contacts 14PG 9 Skewed insertion angle 15PG 10 Protection against expansion of the contact jack 16PG 11 Insertion and extraction forces, frequency of insertion, conductor pull-out strength16PG 12 Current temperature rise, derating 17PG 13 Effect of the housing on derating 18PG 14 Thermal time constant 18PG 15 Electrical stress test 19PG 16 Frictional corrosion 20PG 17 A Dynamic stress 20PG 18 Subjection to coastal climate 22PG 19 Environmental simulation 23PG 20 A Subjection of the housings to climatic load 25PG 21 A Long-term temperature storage 26PG 22 AA Resistance to chemicals 27

A ---> Not applicable to connectors with increased requirements. These are tested according toTest Group PG xx C.

AA ---> Not applicable to connectors with requirements with respect to watertightness. Theseare tested according to Test Group PG 22 B.

B Test groups for waterproof designIncludes "A" test groups

PG 22 B Resistance to chemicals, extended testing 28PG 23 Watertightness 29

C Test groups for increased requirementsIncludes test groups "A" and "B" with intensified test requirements in the following groups

PG 17 C Dynamic stress 31PG 20 C Subjection to climatic load 32PG 21 C Long-term temperature storage 33


D Special tests Page

PG 24 Paint-related leakage 35PG 25 Shielding 35PG 26 Insertion loss 36PG 27 Oscillation 1000 h, sinusoidal 36

Appendices

Table 1, Twin-lead terminals 38Table 2, Wide-band random vibration 38

Fig. 1, Attachment to the vibration table, coupling 39Fig. 2, Attachment to the vibration table, connection to device 39

Chart 1, Temperature change cycle 40


Characteristic tests

E 0.1 Visual inspection DIN IEC 512 P.2

E 0.2 Contact resistanceE 0.2.1 Contact resistance in contact area DIN IEC 512 P.2E 0.2.2 Contact resistance in connection area DIN IEC 512 P.2E 0.2.3 Voltage drop over the entire current range DIN 46 249 P.1E 0.3 Insulation resistance DIN IEC 512 P.2

E 1.1 Dimensions DIN IEC 512 P.2

E 2.1 Material testing - contactsE 2.1.1 Material analysis of carrier material and surfaceE 2.1.2 Layer structureE 2.1.3 Layer thicknessesE 2.1.4 AdhesionE 2.1.5 Examination of the surface for defects (pores, cracks and defects)E 2.1.6 Surface roughness

E 3.1 Material testing - housingE 3.1.1 Plastic material analysisE 3.1.2 Examination of the surface for defects (pores, cracks and defects)E 3.1.3 Surface roughness

E 4.1 Contact overlap

E 5.1 Load deflection curve

E 6.1 Wobbling of the contacts in the housing chamber

E 6.2 Functioning of the primary interlock/engagement play

E 6.3 Functioning of the secondary interlock/engagement play

E 7.1 Unambiguous coding of the housings DIN IEC 512 P.7(coding/polarization)

E 7.2 Retention force of the housing catch mechanism/housing interlock DIN IEC 512 P.8

E 7.3 Latching and retention force of the secondary interlock mechanism

E 7.4 Functioning of insertion and withdrawal aids

E 8.1 Determination of contact insertion forces

E 8.2 Pull-out strength of contact from housing DIN IEC 512 P.8Test 15b

E 8.2.1 Pull-out strength of contact from housing, primary interlock onlyE 8.2.2 Pull-out strength of contact from housing, secondary interlock only

E 9.1 Contact opening dimension and pin geometry

E 9.2 Max. possible skewed insertion angle

E 10.1 Contact opening dimension


E 11.1 Slip-on and withdrawal force DIN IEC 512 P.7Test 13b

E 11.2 Conductor pull-out strength (only in association with crimp)

E 11.3 Pull-out strength out of insulation piercing connecting device DIN EN 60 352 P.3(only in association with insulation piercing connecting device)

E 12.1 Current overtemperature DIN IEC 512 P.3

E 12.2 Derating without housing DIN IEC 512 P.3

E 13.1 Derating with housing

E 14.1 Thermal time constant


E 18.1 Withdrawal and slip-on force DIN IEC 512 P.7Test 13b

E 20.1 Determining creepage distances

E 25.1 Shield damping

E 26.1 Insertion loss


Subjection to load

B 5.1 Storage under dry heat conditions, plugged-in DIN EN 60 068 P.2-2Test Ba

B 8.1 Three-fold removal of the contact from the chamber

B 10.1 Resistance of the contact jack to expanding/damage

B 11.1 Mechanical service life/frequency of insertions DIN IEC 512 P.5

B 15.1 Change of temperature/current - endurance test

B 15.2 Damp heat, cyclic DIN IEC 68 P.2-30

B 16.1 Subjection to friction

B 17.1 Oscillation, sinusoidal DIN IEC 68 P.2-6

B 17.1 C Oscillation, sinusoidal (increased stress) DIN IEC 68 P.2-6

B 17.2 Wide-band random vibration DIN IEC 50A (sec) 248

B 17.2 C Wide-band random vibration (increased stress) DIN IEC 50A (sec) 248

B 17.3 Bumping DIN EN 60 068 P.2-27

B 17.3 C Bumping (increased stress) DIN EN 60 068 P.2-27

B 18.1 Salt spray with alternating climate, cyclic DIN IEC 68 P.2-52

B 19.1 Temperature shock DIN IEC 68 P.2-14 Na

B 19.2 Change of temperature DIN IEC 68 P.2-14 Nb

B 19.3 Storage under dry heat conditions DIN EN 60 068 P.2-2Test Ba

B 19.4 Industrial climate (multiple-component climate) DIN 41 640 P.72

B 19.5 Damp heat, cyclic DIN IEC 68 P.2-30Variant 2

B 19.6 Oscillation, sinusoidal

B 19.7 Shock test (individual shocks) DIN EN 60 068 P.2-27

B 19.8 Current load


B 20.1 C Dry heat (increased stress) DIN EN 60 068 P.2-2Test Ba

B 20.2 Damp heat, constant DIN IEC 68 P.2-30

B 20.3 Storage at low temperature DIN EN 60 068 P.2-1


B 20.4 Withdrawal and insertion at -20°C


B 20.6 Impact test

B 21.1 Long-term storage under dry heat conditions DIN EN 60 068 P.2-2Test Ba

B 21.1 C Long-term storage under dry heat conditions DIN EN 60 068 P.2-2(increased stress) Test Ba

B 22.1 Resistance to media (basic requirements)

B 22.1 B Resistance to media (watertight design)

B 23.1 Enclosure rating/steam jet test DIN 40 050 Sheet 9

B 23.2 Water bath test

B 23.3 Immersion at low air pressure DIN 41 640 P.38DIN IEC 68 P.2-13

B 23.4 Thermal shock test

B 23.5 Salt spray test DIN 50 021

B 24.1 Dip painting

B 27.1 Oscillation 1000h, sinusoidal

Test number structure:

First alphabetic letter(s):

B = Subjection to stress [Beanspruchung]E = Characteristic test [Eigenschaftsprüfung]PG = Test group [Prüfgruppe]

First number:

The test group (PG) in which the test is used for the first time.

Second number:

Consecutive series number.

Last alphabetic letter(s) (optional):

A or none = test for general requirements.B = test for watertightness requirements.C = test for increased requirements.D = special test.


Overview of lot sizes

Testing withA Test groups for general requirements contacts/housings

PG 0 Receiving inspection and testing x xPG 1 Dimensions x xPG 2 Material and surface analysis, contacts 5PG 3 Material and surface analysis, housings 1PG 4 Contact overlap x 3PG 5 Load deflection curve 6PG 6 Interaction between contact and housing x 3PG 7 Handling and functional reliability of the housings x 5PG 8 Insertion and retention forces of the contacts x 8PG 9 Skewed insertion angle x 1PG 10 Protection against expansion of the contact jack x 1PG 11 Insertion and extraction forces, frequency of insertion, conductor pull-out strength

10 (x)PG 12 Current temperature rise, derating 3PG 13 Effect of the housing on derating x 3PG 14 Thermal time constant 3PG 15 Electrical stress test 10 (x)PG 16 Frictional corrosion 8PG 17 A Dynamic stress 40 xPG 18 Subjection to coastal climate x 3PG 19 Environmental simulation 20 xPG 20 A Subjection of the housings to climatic load x 10PG 21 A Long-term temperature storage x 5PG 22 AA Resistance to chemicals x x

B Test groups for watertight design

PG 22 B Resistance to chemicals, extended testing x xPG 23 Watertightness x 10

C Test groups for increased requirements

PG 17 C Dynamic stress 40 xPG 20 C Subjection to climatic load x 10PG 21 C Long-term temperature storage x 5

D Special tests

PG 24 Paint-related leakage x 10PG 25 Shielding x 5PG 26 Insertion loss x 5PG 27 Temperature vibration test, 1000h x x

Figure = Quantity of test specimens.x = Quantity of test specimens is dependent on housing, contact, number of pins, test, etc.

(x) = Quantity of test specimens to be decided on case-by-case basis. Quantity of test specimensis dependent on housing, contact, number of pins, test, etc.


"A" test groups, general requirements

PG 0 Receiving inspection and testing

The receiving inspection and testing is to be run through by all test specimens designated for thequalification test.


Contacts: all variants occurringHousings: all variants occurring

The test specimens are to be inspected for any possible manufacturing defects or changesbefore and after the individual subjections to stress.The basic mechanical functions of the connectors are to be inspected within the frameworkof the visual inspection.

E 0.2 Contact resistance

Contacts: all variants occurringCable cross-section: all variants occurring

Type of testing:

E 0.2.1 Contact resistance in contact area DIN IEC 512 P.2

E 0.2.2 Contact resistance in connection area DIN IEC 512 P.2

E 0.2.3 Voltage drop over the entire current range DIN 46 249 P.1

Requirement:

The measured values must be in accordance with the manufacturer's specification.

E 0.3 Insulation resistance DIN IEC 512 P.2

Contacts: arbitraryHousings: all variants occurring

Insulation resistance between all adjacent contacts

Requirement:

Risol > 100 MΩ at U = 500 V, t = 60 s

Risol = insulation resistanceU = test voltage DCt = reading time


PG 1 Dimensions

Test specimens:Lot size: 1 unit per tool or mold cavityContacts: all variants occurring, non-integral and integral, refer to Table 1

for permissible double crimpsHousings: all variants occurring

Type of testing:



Requirement:

The measured values must be in accordance with the release drawing and the product specification.

PG 2 Material and surface analysis, contacts

Test specimens:Lot size: 5 unitsContacts: all materials and surfaces occurring

Type of testing:


E 2.1 Material testing - contacts

E 2.1.1 Material analysis of carrier material and surface

E 2.1.2 Layer structure

E 2.1.3 Layer thicknesses

E 2.1.4 Adhesion

E 2.1.5 Examination of the surface for defects (pores, cracks and defects)

E 2.1.6 Surface roughness

Requirement:

The results of the examinations must be in accordance with the manufacturer's specifications.Irrespective thereof, crack formations or other types of damage are not permissible in the contact zone.The permissible number of pores must be in accordance with the product specification.


PG 3 Material and surface analysis, housings

Test specimens:Lot size: 1 unitHousings: all variants occurring

Type of testing:

E 0.1 Visual inspection DIN IEC 512 P.2Assessment of workmanship.

E 3.1 Material testing - housingE 3.1.1 Plastic material analysis

E 3.1.2 Examination of the surface for defects (pores, cracks and defects)

E 3.1.3 Surface roughness

Requirement:

Injection skins and parting flash shall not impair handling and function. Flash and tool offset are notpermitted on sealing surfaces.

PG 4 Contact overlap

Test specimens:Lot size: 3 housings fully fitted with componentsContacts: all variants occurringHousings: all variants occurring

Type of testing:


E 4.1 Contact overlap

Requirement:

The contact transition, as well as the determined contact overlap, must be in accordance with thedrawing.

PG 5 Load deflection curve

Test specimens:Lot size: 6 contactsContacts: contacts; all materials occurring

Type of testing:


E 5.1 Load deflection curve


Determination of the elasticity of the resilient contact, including the normal force of thecontact.

B 5.1 Storage under dry heat conditions, plugged-in DIN EN 60 068 P.2-2Test Ba

t = 96 h, T = 125 ± 2°C

t = storage timeT = storage temperature

E 5.1 Load deflection curveDetermination of the elasticity of the resilient contact, including the normal force of thecontact.

Requirement:

The characteristics must be in accordance with the product specification and the drawing entry. Theelasticity thereby must designed such that none of the permissible tolerances of the connector lead toirreversible changes in the contact opening dimension, even in the event of skewed insertion. Theinsertion and extraction forces thereby must lie within the specified range. The minimum normal forceof the contact must attain the specified value for the respective surface material.

PG 6 Interaction between contact and housing

Test specimens:Lot size: 3 housings fully fitted with componentsContacts: all variants occurringCable cross-sections: all occurring, also twin-lead terminals, refer to Table 1Housings: all variants occurring

Type of testing:

E 6.1 Wobbling of the contacts in the housing chamber

E 6.2 Functioning of the primary interlock/engagement play

E 6.3 Functioning of the secondary interlock/engagement play

Requirement:

The wobbling and engagement play of the contacts in the housing chamber, as well as properengagement of the primary and secondary interlocks, are to be tested in accordance with the releasedrawing.

PG 7 Handling and functional reliability of the housings

Test specimens:Lot size: at least 5 housings fully fitted with componentsContacts: all variants occurringHousings: all variants occurring


Type of testing:


E 7.1 Unambiguous coding of the housings DIN IEC 512 P.7(coding/polarization)

E 7.2 Retention force of the housing catch mechanism/housing interlock DIN IEC 512 P.8

E 7.3 Latching and retention force of the secondary interlock mechanism

E 7.4 Functioning of insertion and withdrawal aids

Requirement:

The characteristics must be in accordance with the product specification and the drawing entry.

PG 8 Insertion and retention forces of the contacts

Test specimens:Lot size: 4 x 2 housings fully fitted with componentsContacts: all variants occurringHousings: all variants occurring

Type of testing:


2 x 2 housings fully fitted with components:

E 8.1 Determination of contact insertion forces


E 8.2 Pull-out strength of contact from housing DIN IEC 512 P.8Test 15b

E 8.2.1 Pull-out strength of contact from housing, primary interlock only(2 housings)

E 8.2.2 Pull-out strength of contact from housing, secondary interlock only(2 housings)

2 x 2 housings fully fitted with components (new components)

B 8.1 Three-fold removal of the contact from the chamber

E 8.2.1 Pull-out strength of contact from housing, primary interlock only(2 housings)

E 8.2.2 Pull-out strength of contact from housing, secondary interlock only(2 housings)


Requirement:

The measures values must be in accordance with the product specification or the drawing entry. Theprimary and secondary interlock are to be inspected independently from one another on separatehousings. New test specimens are to be used in each case for measurements. All housing chambers andall mold cavities are to be tested!

Unless otherwise specified, the following values apply:

Test travel: s ≤ 1 mm (for required retention forces)

Primary interlock: Fprim ≥ 80 N

Secondary interlock: Fsek ≥ 60 N

Fprim = pull-out strength of primary interlock

Fsek = pull-out strength of secondary interlock

The following applies for contacts with a cable cross-section < 0.75 mm2:The minimum retention force of the primary catch mechanism must attain at least the pull-out strengthout of the cable crimp per DIN IEC 352 Part 2 in accordance with the spliced cross-section.

PG 9 Skewed insertion angle

Test specimens:Lot size: 1 housing fully fitted with componentsContacts: all variants occurringHousings: all variants occurring

Type of testing:



E 9.2 Max. possible skewed insertion angle



Requirement:

The maximum possible skewed insertion angle governed by the housing and contact parts is to bedetermined for each housing and specified by the manufacturer. The skewed insertion angle shall notexceed the permitted dimension for the contact. A permanent change of the contact opening dimensionor pin geometry is not permitted. Attention shall be paid with respect to any damage which mightoccur.


PG 10 Protection against expansion of the contact jack

Test specimens:Lot size: 1 housing fully fitted with componentsContacts: contact jack; all materials occurringHousings: all variants occurring

Type of testing:



B 10.1 Resistance of the contact jack to expanding/damageInsert test pin with maximum permitted external dimension



Requirement:

The contact opening dimension shall change only within the permissible tolerances.

PG 11 Insertion and extraction forces, frequency of insertion, conductor pull-out strength

Test specimens:Lot size: at least 10 contactsContacts: all materials and surfaces occurringCable cross-section: all variants occurring, also twin-lead terminals, refer to Table 1Housings: without/where applicable with housing to retain contacts

(low-friction, without seals, detent arms, etc.)

Type of testing:





B 11.1 Mechanical service life/frequency of insertions DIN IEC 512 P.5

Surfaces: Sn 20 insertion cycles (unless otherwise specified)Ag 50 insertion cyclesAu 100 insertion cycles






E 11.2 Conductor pull-out strength (only in association with crimp)

E 11.3 Pull-out strength out of insulation piercing connecting device DIN EN 60 352 P.3(only in association with insulation piercing connecting device)


Requirement:

The resistance, as well as the insertion and extraction force, must be in accordance with the drawing orthe product specification.Unless noted to the contrary in the drawing or product specification, the following applies:Upon conclusion of the service life test, the initially-measured contact resistance may increase by amaximum of 50% of the resistance value established in the product specification. The insertion forcemay change by a maximum of 25% of the initial value. Wearing through of the contact surface is notpermitted.

The extraction force of the cable must be in accordance with the value specified for the respectivecross-section.

PG 12 Current temperature rise, derating

Test specimens:Lot size: 3 contactsContacts: all material/surface combinations occurringCable cross-section: all variants occurringCable length: per DIN IEC 512 P.3Housings: without

Type of testing:



E 12.1 Current overtemperature DIN IEC 512 P.3

E 12.2 Derating without housing DIN IEC 512 P.3


Requirement:



PG 13 Effect of the housing on derating

Test specimens:Lot size: 3 housings fully fitted with components for each cross-sectionContacts: all materials occurringCable cross-section: all occurring, same cross-section in one test specimenCable length: per DIN IEC 512 P.3Housings: number of pins 2, 4, 8 or similar values

(to be agreed upon between manufacturer and user)

Type of testing:

E 13.1 Derating with housingDerating dependent on the number of pins at same and at stepped stress level of all contacts(to be agreed upon for the individual case at hand).

Requirement:


PG 14 Thermal time constant

Test specimens:Lot size: 3 contactsContacts: all materials occurringCable cross-section: all variants occurringCable length: per DIN IEC 512 P.3Housings: without/with housing (number of pins as agreed upon)

Type of testing:



E 14.1 Thermal time constant

Test procedure:

Subjection of a contact to load with 1/2/3/4/5/10 and 20 times the rated current andsimultaneous plotting of the temperature progression as a function of time until steady-stateoccurs or until the maximum permitted component temperature is reached.


Requirement:



PG 15 Electrical stress test

Test specimens:Lot size: at least 10 contactsContacts: all materials and surfaces occurringCable cross-section: max.Cable length: per DIN IEC 512 P.3Housings: to be decided on case-by-case basis, open housing

Type of testing:



Measurement of the insertion/extraction force following two previous insertions



B 15.1 Change of temperature/current - endurance test

Description of a test cycle:

Temperature: - 40 °C/+ 80 °C;Refer to Chart 1 for progression (appendix)

Rated current: Inom = permitted current from derating curve at 80°C

ambient temperature (during the warm phase).

Total number of cycles: 60

B 15.2 Damp heat, cyclic DIN IEC 68 P.2-30

21 days, rel. humidity 95 %, Tu = 25 °C,

To = 55 °C, 1 cycle = 1 day

Tu = lower cycle temperature

To = upper cycle temperature

B 15.1 Change of temperature/current - endurance testNumber of cycles: 60





Requirement:

During the concluding insertion and extraction force measurement, at least 75% must be attained of theinitial values.

The contact opening dimension shall only change to the extent that the normal force of the contact isstill at least 75 % of the value measured initially in accordance with the load deflection curve in PG 5.

Continuous monitoring of the contact resistance via one cycle every 96 h contact and cable terminal),whereby an increase to twice the initial value will be tolerated over the entire test duration.

PG 16 Frictional corrosion

Test specimens:Lot size: 8 contactsContacts: all material/surface combinations occurringHousings: without

Type of testing:


B 16.1 Subjection to friction

Friction travel: 50 µmCycle time: 1 HzNo. of cycles: 100 000Electr. load: max. 20 mV, 10 mA (dry circuit)

Continuous monitoring of the contact resistance.


Requirement:

The contact resistance must be in accordance with the manufacturer's specification.

PG 17 A Dynamic stressAttention: For increased requirements, testing per PG 17 C !

Test specimens: 2 groupsLot size: at least 20 contacts per group, distributed among at least two housingsContacts: all variants occurringCable cross-section: to be established on case-by-case basisHousings: sealed/not sealed, to be established by individual case

Type of testing:

Group 1:




B 17.1 Oscillation, sinusoidal DIN IEC 68 P.2-6

Severity: s = 6.2 mm, f = 15.0 - 28.6 Hza = 20.0 g, f = 28.6 -500.0 Hz

s = displacement amplitudea = accelerationf = frequency

Duration: 24 h per spatial axisSweep rate: 1 octave per minuteSuperimposition withchange of temperature: as for B 19.2

Group 2:



B 17.2 Wide-band random vibration DIN IEC 50A (sec) 248

Severity: 2 per Table 2,Duration: 168 h per spatial axis,Supplemental superimposition withchange of temperature: as for B 19.2

Groups 1 and 2:

B 17.3 Bumping DIN EN 60 068 P.2-27

a = 30 gt = 6 ms, half wave sinusoidalTotal number of shocks: 6000

a = amplitudet = individual shock duration



Remark:

Attachment of the test specimens on the vibration generator as per Fig. 1 and Fig. 2 (see appendix).

In the event of particularly critical installation conditions, special agreements shall be made between themanufacturer and the user.


Requirement:

During subjection to oscillation, the contact resistance (contact and cable terminal) shall not exceed thefollowing limiting values as compared to the initial value:

Tin surface: 3.5 x initial valueSilver surface: 3.0 x initial valueGold surface: 2.0 x initial value

No mechanical damage shall occur.

During the test, monitoring takes place for current interruption. Permissible current interruption

< 200 ns. The electric circuit is considered to be interrupted when the contact resistance exceeds a

limiting value of 150 Ω. The measurement takes place at an operating voltage of Ub = 10 V. The test

current shall be a maximum of Ip = 100 mA.

PG 18 Subjection to coastal climate

Test specimens:Lot size: 3 housings with interlock function rendered ineffectiveContacts: all materials and surfaces occurringHousings: open (not sealed), plugged-in, average number of pins

Type of testing:



Measurement following two previous insertions


B 18.1 Salt spray with alternating climate, cyclic DIN IEC 68 P.2-52Severity 1 (8 h of spraying, 16 h break)Test duration: 1 cycle


E 18.1 Withdrawal and slip-on force DIN IEC 512 P.7Test 13b

(contacts only, effect of housing ruled out, no previous insertions!)




Requirement:

The contact resistance shall not exceed the following limiting values upon conclusion of the test:


The extraction force of the connection shall increase a maximum of 50 %.

PG 19 Environmental simulation

Test specimens: 2 groupsLot size: at least 10 contacts per groupContacts: all materials and surfaces occurringCable cross-section: to be established for individual caseHousings: open (not sealed), to be established for individual case, plugged-in

For each half-group, one insertion is carried out before subjection to stress. The second half is insertedin accordance with half of the permissible number of insertion cycles.

Type of testing:



Disconnect/unplug Group 1.


Duration: 144 cyclesTemperature: -40/+130 °C for 15 min. eachChange-over time: max. 10 s

B 19.2 Change of temperature DIN IEC 68 P.2-14 Nb

Duration: 20 cyclesTemperature: -40/+120 °C for 3 h eachTime for temp. change: max. 2 h

E 0.2 Contact resistance(Group 2 only)


Duration: 120 hTemperature: 120 °C



B 19.4 Industrial climate (multiple-component climate) DIN 41 640 P.72


(0.2 ppm SO2, 0.01 ppm H2S, 0.2 ppm NO2, 0.01 ppm CI2 / 25 °C / 75 % relativehumidity / 21 d)Volume flow rate: 1 m³/h


B 19.5 Damp heat, cyclic DIN IEC 68 P.2-30Variant 2

Rel. humidity: 95 % constantDuration: 10 cycles at 24 h eachTemperatures: Tu = 25 °C, To = 55 °C

Tu = lower cycle temperature

To = upper cycle temperature



B 19.6 Oscillation, sinusoidal(Group 2 only)

f = 15 - 1000 Hz, sinusoidala = 10 gDuration: 6 h per spatial axisSweep rate: 1 octave per minute

Attach cable to test table

f = frequencya = acceleration

B 19.7 Shock test (individual shocks) DIN EN 60 068 P.2-27(Group 2 only)

a = 30 gt = 6 ms, half wave sinusoidalNo. of shocks: 50 per spatial axis

a = accelerationt = duration of individual shock

Insert Group 1.



B 19.8 Current load

Duration: 15 min.Inom : permissible current from derating curve at 20°C ambient temperature.


Requirement:

The contact resistance shall not exceed the following limiting values in any of the tests:

unplugged plugged-inTin surface: 5.0 x initial value 3.5 x initial valueSilver surface: 4.0 x initial value 2.0 x initial valueGold surface: 3.0 x initial value 2.0 x initial value

If the contacts are subsequently loaded with rated current for a duration of 15 min., the currenttemperture rise shall be a maximum of 20 °C more than in the case of a new contact.

No corrosion shall occur in the area of the contact zone.

The mechanical function of the connector shall be guaranteed.

PG 20 A Subjection of the housings to climatic loadAttention: For increased requirements, testing per PG 20 C !

Test specimens:Lot size: 10 housings fully fitted with componentsContacts: design arbitraryHousings: one housing type for each design or material group; plugged-in

Type of testing:





Duration: 120 hTemperature: 120°C


Duration: 10 daysTemperature: 40°CRel. humidity: 95 %


Upon conclusion of Test B 20.2 "Damp heat", flash off test specimens first for 0.5 h andthen measure insulation resistance.


B 20.3 Storage at low temperature DIN EN 60 068 P.2-1Duration: 48 hTemperature: -40°C






B 20.6 Impact test

One single free fall per spatial axis from a height of 1.2 m on an uncoated concrete floor atroom temperature.


Requirement:

Upon conclusion of the tests, neither functional nor dimensional changes are to have occurred which lieoutside of the permissible tolerances.The connector must allow itself to be opened and closed again even at -20°C. Upon operation, any filmhinges and latching elements which might be present shall not fracture or tear following subjection toload.

The drop test shall not lead to any damage of the test specimens which impairs function.

PG 21 A Long-term temperature storageAttention: For increased requirements, testing per PG 21 C !

Test specimens:Lot size: 5 housings or contacts molded-in with plasticContacts: as agreed uponHousings: all

Type of testing:


B 21.1 Long-term storage under dry heat conditions DIN EN 60 068 P.2-2Test Ba


Subsequent storage: 1 week at room temperature


Requirement:

Upon conclusion of the test, no functional impairments shall be detectable. Crack formations ordelaminations are not permitted.


PG 22 AA Resistance to chemicalsAttention: For watertightness requirements, testing per PG 22 B !

Test specimens:Lot size: 3 housings per test mediumContacts: design arbitraryHousings: one housing type for each material group, plugged-in

Type of testing:




B 22.1 Resistance to media (basic requirements)

The test specimens are to be exposed to the following operating agents.

Procedure:

Immerse for 5 min.; allow to drain; store in temperature chamber for 48 h at 50 °C. Uponconclusion of the test, the test specimens are to be rinsed thoroughly with water and dried.In the interest of time savings, the tests can be carried out at the same time on new testsamples in each case.

Operating agents: VDA Test Sheet 621

1. Commercially-available degreaser, undiluted2. Penetrating oil, e.g. "Caramba"3. Commercially-available washer fluid anti-freezing agent, undiluted4. Spirit, undiluted5. Lubricating grease




Requirement:

The test specimens shall not indicate any functionally-significant dimensional and structural changes.Functioning shall be maintained in its full scope.


"B" test groups, supplemental for waterproof design

PG 22 B Resistance to chemicals, extended testing

Test specimens:Lot size: 3 housings per test mediumContacts: design arbitraryHousings: one housing type for each material group, plugged-in

Type of testing:




B 22.1 B Resistance to media (watertight design)

The test specimens are to be exposed to the following operating agents:

Procedure:

Immerse for 5 min.; allow to drain; store in temperature chamber for 48 h at 50 °C. Uponconclusion of the test, the test specimens are to be rinsed thoroughly with water and dried.In the interest of time savings, the tests can be carried out at the same time on new testsamples in each case.

Operating agents: VDA Test Sheet 621

1.Commercially-available degreaser, undiluted2.Penetrating oil, e.g. "Caramba"3.Commercially-available washer fluid anti-freezing agent, undiluted4.Spirit, undiluted5.Lubricating grease6.Brake fluid, e.g. Teves ATE DOT 47.Premium-grade fuel per DIN 51 6008.Diesel fuel per DIN 51 6019.Multigrade motor oil SAE 10 W-50

10.Hypoid gear oil grade SAE 80/9011.Radiator antifreeze: 50% H2O/50% ethylene glycol12.Battery acid: diluted sulfuric acid, density 1.28 g/cm³

(Attention: only relevant for test specimens which can come into contact with acid!)




Requirement:

The test specimens shall not indicate any functionally-significant dimensional and structural changes.Functioning shall be maintained in its full scope.


PG 23 Watertightness

Test specimens:Lot size: 10 sealed housingsContacts: all cable cross-sections occurringHousings: all waterproof designsCables: insulation must withstand the test temperature

Type of testing:




Duration: 144 cyclesTemperature: -40/+130°C each for 15 min.,Change-over time: max. 10 s

B 23.1 Enclosure rating/steam jet test DIN 40 050 Sheet 9

Severity: similar to IP x9 K

Instead of the spray nozzle specified in DIN 40 050, testing is to be performed with asteam-jet cleaner as described below:

All three sides of the test specimen are to be subjected to the steam jet. The jet is to bedirected especially at the test specimen's sealing elements.

Test duration per side: 15 secDistance between nozzle and specimen: 10 - 15 cmPressure: 80 barTemperature: 80°C

The test is carried out three times.



B 23.2 Water bath test

Medium: low-surface-tension, 5% NaCl solution

5 immersion cycles; one cycle consists of immersion in hot water at 65 + 5°C and coldwater at 0 ± 3°C, duration per temperature level 1 h. The carryover of the test specimenfrom one bath to the other must take place as quickly as possible.Upon conclusion of the last cycle, the test specimens are rinsed thoroughly andsubsequently dried.



B 23.3 Immersion at low air pressure DIN 41 640 P.38DIN IEC 68 P.2-13


Air pressure in the chamber: 60 kPaStress duration: 30 min.Gradient low air pressure to normal pressure: 100 hPa/min.Storage at normal pressure: 30 min.



B 23.4 Thermal shock test

Air temperature: 120 °C Duration: 15 min. eachWater temperature: 0 °C Duration: 2 min. eachNumber of cycles: 10

Medium: low-surface-tension, 5% NaCl solution



B 23.5 Salt spray test DIN 50 021

Duration: 6 cycles; 1 cycle consists of 8 h spraying time and 16 h break



Requirement:

No medium shall penetrate into the connector.

The insulation resistance shall be > 100 MΩ.

The functioning of the latching and releasing elements must remain fully maintained.


"C" test groups, for increased requirements

PG 17 C Dynamic stress

Test specimens: 2 groupsLot size: at least 10 contacts per group, distributed among at least two housingsContacts: all occurringCable cross-section: to be established on case-by-case basisHousings: sealed/not sealed, to be established for individual case

Type of testing:

Group 1:



B 17.1 C Oscillation, sinusoidal (increased stress) DIN IEC 68 P.2-6

Severity: a = 5.00 g, f = 10 - 25 Hzs = 2.00 mm, f = 25 - 50 Hza = 20.00 g, f = 50 - 141 Hzs = 0.25 mm, f = 141 - 200 Hza = 40.00 g, f = 200 - 500 Hz

Duration: 24 h per spatial axisSweep rate: 1 octave per minuteSuperimposition withchange of temperature: as for B 19.2


Group 2:



B 17.2 C Wide-band random vibration (increased stress) DIN IEC 50A (sec) 248

Severity: 1 per Table 2,Duration: 168 h per spatial axis,Supplemental superimposition withchange of temperature: as for B 19.2

Groups 1 and 2:

B 17.3 C Bumping (increased stress) DIN EN 60 068 P.2-27


a = 30 gt = 6 ms, half wave sinusoidalTotal number of shocks: 12000

a = amplitudet = individual shock duration



Remark:

Attachment of the test specimens on the vibration generator as per Fig. 1 and Fig. 2 (see appendix).

In the event of particularly critical installation conditions, special agreements shall be made between themanufacturer and the user.

Requirement:

During subjection to oscillation, the contact resistance (contact and cable terminal) shall not exceed thefollowing limiting values as compared to the initial value:


No mechanical damage shall occur.

During the test, monitoring takes place for current interruption.

Permissible current interruption < 200 ns. The electric circuit is considered to be interrupted when the

contact resistance exceeds a limiting value of 150 Ω. The measurement takes place at an operating

voltage of Ub = 10 V. The test current shall be a maximum of Ip = 100 mA.

PG 20 C Subjection to climatic load

Test specimens:Lot size: 10 housings fully fitted with componentsContacts: design arbitraryHousings: one housing type for each connector style or material group; plugged-in

Type of testing:




B 20.1 C Dry heat (increased stress) DIN EN 60 068 P.2-2Test Ba




Duration: 10 daysTemperature: 40°CRel. humidity: 95 %


Upon conclusion of Test B 20.2 "Damp heat", flash off test specimens first for 0.5 h andthen measure insulation resistance.


B 20.3 Storage at low temperature DIN EN 60 068 P.2-1Duration: 48 hTemperature: -40°C





B 20.6 Impact test

One single free fall per spatial axis from a height of 1.2 m on an uncoated concrete floor atroom temperature.


Requirement:

Upon conclusion of the tests, neither functional nor dimensional changes are to have occurred which lieoutside of the permissible tolerances.The connector must allow itself to be opened and closed again even at -20°C. Upon operation, any filmhinges and latching elements which might be present shall not fracture or tear following subjection toload.

The drop test shall not lead to any damage of the test specimens which impairs function.

PG 21 C Long-term temperature storage

Test specimens:Lot size: 5 housings or contacts molded-in with plasticContacts: as agreed uponHousings: all

Type of testing:



B 21.1 C Long-term storage under dry heat conditions DIN EN 60 068 P.2-2(increased stress) Test Ba


Subsequent storage 1 week at room temperature.


Requirement:

Upon conclusion of the test, no functional impairments shall be detectable. Crack formations ordelaminations are not permitted.


"D" test groups, special tests

PG 24 Paint-related leakage

Test specimens:Lot size: 10 housings which have been attached and fitted with contacts on the printed

circuit board in accordance with the applicable assembly specifications.Contacts: all occurringHousings: all housing designs which come into contact with liquid dip paint during further

processing

Type of testing:


B 24.1 Dip painting

The housing components/printed circuit boards are dipped in liquid paint for 1 min. (e.g.paint supplied by Peters, type "SL 1331 N") and subsequently dried at a temperature of80 °C for 20 min.


Requirement:

The dip paint shall not penetrate into the contact space The mechanical and electrical functions shallnot be impaired.

PG 25 Shielding

Test specimens:Lot size: 5 housings fully fitted with componentsContacts: as agreed uponHousings: as agreed upon

Type of testing:


E 25.1 Shield damping

Measurement of the shielding effect of the covering of the housing and of the couplingimpedance.

Requirement:

The nominal data are to be established in coordination with the respective manufacturer.


PG 26 Insertion loss

Test specimens:Lot size: 5 housings fully fitted with componentsContacts: as agreed uponHousings: as agreed upon

Type of testing:


E 26.1 Insertion loss

Determination of insertion loss over the established frequency range

Requirement:


PG 27 Oscillation 1000 h, sinusoidal

Purpose: Overview of temperature-oscillation tests practiced for plug-in connectors.

Test specimens: one test specimen always consists of two housing halves (male/female)Lot size: as agreed uponContacts: as agreed uponHousings: as agreed upon

Type of testing:


B 27.1 Oscillation 1000h, sinusoidal

Severity: a = 40.00 ms-2, f = 20 - 71 Hzs = 0.20 mm, f = 71 - 220 Hz


(⇒ peak acceleration of approx. 39 g at 220 Hz.)

Duration: 1000 hSweep rate: 1 octave per minute; log. (≈ 3.5 min.)

Superimposition with change of temperature, 1 cycle:

Temperature: lower and upper limiting temperaturesfor operation, 1 h each

Time for temp. change: 2 h

Number of cycles: 250


All connectors of like type are supplied with the same constant current which is suited forpractical operation, and the voltage drop is monitored. The voltage drop thus represents adimension for the contact resistance. The necessary constant current, depending onrequirements, ranges from µA, mA as far as A and is to be established on a case-by-casebasis.

Monitoring:

In order for the necessary number of monitoring channels not to get out of hand, appropriate contactgroups can be formed from a certain number of like-type connectors and assigned to a monitoringchannel.Oscillation frequency and ambient temperature are monitored as well.


Requirement:



Appendix:

Table 1, Twin-lead terminals

Permitted cable cross-section combinations for twin-lead terminals

Cable [mm2] 0.35 0.50 0.75 1.0 1.5 2.5 4.00.35 X X0.50 X X X0.75 X X X1.0 X X X1.5 X X X2.5 X X X4.0 X X

Only reduced insulation leads with wire strand conductors shall be used. Solid conductors are notpermitted.

Table 2, Wide-band random vibration

Severity 1 Severity 2

Spectrum decreased by 0 dB 3 dB

[(m/s²)²/Hz] [(m/s²)²/Hz]

10.0 Hz 20.0 10.0 50.0 Hz 20.0 10.0 66.7 Hz 2.0 1.0 100.0 Hz 2.0 1.0 1000.0 Hz 0.2 0.1

Effective value ofacceleration

38.1 m/s² 26.9 m/s²


Fig. 1, Attachment to the vibration table, coupling

Fig. 2, Attachment to the vibration table, connection to device


Chart 1, Temperature change cycle

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