SAE J 2030-2015 Heavy-Duty Electrical Connector Performance Standard.pdf

1、 _ SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising ther

2、efrom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions. Copyright 2015 SAE International All rights reserved. No part of this

3、publication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-49

4、70 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/J2030_201506 SURFACE VEHICLE STANDARD J2030 JUN2015 Issued 1994-11 Revised 2015-

5、06 Superseding J2030 JUN2009 Heavy-Duty Electrical Connector Performance Standard RATIONALE Updated MIL specification reference with EIA specification. FOREWORD NOTICE: Some test procedures are potentially dangerous. SAE Technical Reports do not purport to address all of the safety problems, if any,

6、 associated with their use. It is the responsibility of the user of an SAE Technical Report to establish and employ appropriate safety practices. Tests should only be conducted by individuals who have been properly trained in the test procedure and who are aware of any hazards which might be present

7、. Appropriate safety and health precautions must be employed when conducting any test. 1. SCOPE This SAE Standard encompasses connectors between two cables or between a cable and an electrical component and focuses on the connectors external to the electrical component. This document provides enviro

8、nmental test requirements and acceptance criteria for the application of connectors for direct current electrical systems of 50 V or less in the majority of heavy-duty applications typically used in off-highway machinery. Severe applications can require higher test levels, or field-testing on the in

9、tended application. 2. REFERENCES 2.1 Applicable Documents The following publications form a part of this specification to the extent specified herein. Unless otherwise indicated, the latest issue of SAE publications shall apply. 2.1.1 SAE Publications Available from SAE International, 400 Commonwea

10、lth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org. SAE J163 Low Tension Wiring and Cable Terminals and Splice Clips SAE J726 Air Cleaner Test Code SAE INTERNATIONAL J2030 Revised JUN2015 Page 2 of 12 SAE J1455 Recommended Envir

11、onmental Practices for Electronic Equipment Design in Heavy-Duty Vehicle Applications SAE J1614 Wiring Distribution Systems for Construction, Agricultural, and Off-Road Work Machines 2.1.2 ASABE Publication Available from the American Society of Agricultural and Biological Engineers, 2950 Niles Road

12、, St. Joseph, MI 49085-9659, Tel: 269-429-0030, www.asabe.org. ASAEEP455 Environmental Considerations in Development of Mobile Agricultural Electrical/Electronic Components 2.1.3 ASTM Publications Available from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-29

13、59, Tel: 610-832-9585, www.astm.org. ASTM D 471 Standard Test Method for Rubber Property - Effect of Liquids ASTM G 153 Standard Practice for Operating Enclosed Carbon Arc Light Apparatus for Exposure of Nonmetallic Materials ASTM G 154 Standard Practice for Operating Fluorescent Light Apparatus for

14、 UV Exposure of Nonmetallic Materials 2.1.4 EIA Standard Available from the Global Documents, 15 Iverness Way East, Englewood, CO 80112-5704, USA, Tel: 303-397-7956, 800-854-7179, http:/ EIA-364-23 Low-Signal Level Contact Resistance 2.2 Related Publications The following publications are provided f

15、or information purposes only and are not a required part of this SAE Technical Report. 2.2.1 API Publication Available from API, 1220 L Street, NW, Washington, DC 20005-4070, Tel: 202-682-8000, www.api.org. API 1560 Lubricant Service Designation for Automotive Manual Transmissions and Axles 2.2.2 IS

16、O Publication Available from American National Standards Institute, 25 West 43rd Street, 4th Floor, New York, NY 10036, Tel: 212-642-4900, www.ansi.org. ISO 8092 Road Vehicles - Connections for On-Board Electrical Harnesses SAE INTERNATIONAL J2030 Revised JUN2015 Page 3 of 12 3. DEFINITIONS 3.1 CONN

17、ECTOR A coupling device, which provides an electrical junction, a mechanical junction, or both, between two cables or between one or more cables and an electrical component. Connectors can also provide for mechanical stability and geometric arrangement. 3.2 TERMINAL An electrically conductive device

18、 attached to a cable to facilitate connection to an electrical component, cable, or termination. 3.3 SEALED A system that creates a nonleaking union between mechanical elements when submerged in a water solution as defined in the tests within this document. 3.4 SIGNAL LEVEL CIRCUIT A circuit in whic

19、h open circuit voltage is typically less than 5 V and current is typically less than 0.05 A. Circuits of this energy level typically are not able to break through oxides, sulfides, or other contaminants, which can build up on the contact surfaces and prevent continuity. 3.5 POWER CIRCUIT A system us

20、ing two or more cables where current flows from the source to one or more electronic/electrical devices and back again to the source. The electrical energy is supplied at high levels of current and typical system voltage (system battery voltage). 3.6 CABLE Insulated stranded electrical conductor use

21、d to establish a single current path. 3.7 WIRING Collectively, the cables, harnesses, connectors, terminations, and supporting components used in the electrical wiring distribution system. 4. SAMPLE PREPARATION Samples shall be made on the connector manufacturers recommended tooling and checked for

22、conformance to the connector manufacturers standards. 4.1 Assembly All connector cavities shall be wired with manufacturers minimum approved cable outside diameter size except for test groups A and D which shall be be wired with manufacturers maximum approved conductor size in lengths sufficient to

23、accommodate testing. Cable diameter shall be checked and be within the connectors manufacturing specification. Crimp characteristics (i.e., height, width, etc.) shall be checked. To prevent capillary action on sealed connectors, all loose wire ends and test points (i.e., millivolt test connection) s

24、hall be sealed with alcohol-base RTV silicone or equivalent. SAE INTERNATIONAL J2030 Revised JUN2015 Page 4 of 12 5. TEST SEQUENCE For qualification testing, test samples shall be subjected to the tests in the order shown in Table 1 with a quantity of 6 for each group. The tests are to be carried ou

25、t in the numerical sequence as described in each groups column. It is permissible to use separate sample sets for Low Voltage Resistance and Insulation Resistance when both are required in the same test sequence. For those sequences requiring both Low Voltage Resistance and Insulation Resistance, tw

26、o groups of 6 may be tested, one group going through the test sequence including Insulation Resistance without Low Voltage Resistance, and the second group going through the test sequence including Low Voltage Resistance without Insulation Resistance. Group A emphasizes mechanical, fluid, and therma

27、l performance for sealed signal connectors Group B emphasizes mechanical and thermal performance for signal connectors Group C emphasizes thermal performance for all connectors Group D emphasizes mechanical performance for all connectors Group E emphasizes mechanical, fluid, and thermal performance

28、for sealed power connectors Group F emphasizes mechanical and thermal performance for power connectors TABLE 1 - TEST SEQUENCES Test Description Test Para. Group A Sequence Sealed Signal Connector Test Group B Sequence Signal Connector Test Group C Sequence Connector Test Group D Sequence Connector

29、Test Group E Sequence Sealed Power Connector Test Group F Sequence Power Connector Test Examination of Product 6.1 1 1 1 1 1 1 Low-Voltage Resistance 6.2 2,14,15 2,11,16 Insulation Resistance 6.3 3,6,8,17,19 3,14 2 2,5,7,15,18 2,13 Connection Resistance 6.4 4 4 3 3,20 3,15 Pressure Washing 6.5 5 4 M

30、aintenance Aging 6.6 2 Temperature Life 6.7 5 4 4 Ultraviolet Effects 6.8 3 Mating Forces 6.9 6 4 5 Unmating Forces 6.10 7 5 6 Durability 6.11 8 6 7 Salt Fog 6.12 7 6 Thermal Shock 6.13 9 9 5 8 8 Fluid Immersion 6.14 10 9 Vibration 6.15 12 10 11 9 Shock 6.16 13 12 12 10 Drop Test 6.17 15 6 13 Termin

31、al Retention in Connector 6.18 7 Water Immersion 6.19 16 14 Connector Retention 6.20 7 8 Mismating 6.21 9 Current Test 6.22 16 11 Dust Test 6.23 15 16 Temperature/Humidity 6.24 18 13 17 12 Current Cycling 6.25 19 14 Terminal Crimp Strength 6.26 10 Visual Examination 6.27 11,20 17 8 11 10,21 17 5.1 T

32、est Groups A, B, C, and D are for sealed signal level connectors. 5.2 Test Groups C, D, E, and F are for sealed power level connectors. 5.3 Test Groups B, C, and D are for unsealed signal level connectors. SAE INTERNATIONAL J2030 Revised JUN2015 Page 5 of 12 5.4 Test Groups C, D, and F are for unsea

33、led power level connectors. Test Sequence Example using Test Group C as follows: a. Examination of Product per 6.1. b. Insulation Resistance per 6.3. c. Connection Resistance per 6.4. d. Temperature Life per 6.7. e. Thermal Shock per 6.13. f. Drop Test per 6.17. g. Connector Retention per 6.20. h. V

34、isual Examination per 6.27. 6. TEST METHODS All tests shall be carried out at an ambient temperature of 23 3 C and a relative humidity between 20% and 90% unless otherwise stated. Not all test descriptions contained herein describe acceptance criteria. Tests may be conducted for conditioning purpose

35、s only. 6.1 Examination of Product Conduct a visual examination only for identification of product, torn seals, cracked plastic, etc. 6.2 Low-Voltage Resistance (Reference EIA-364-23) Test with applied voltage not exceeding 20 mV open circuit and the test current shall be limited to 100 mA. Utilizin

36、g Figure 1, record connection resistance per 6.4. Acceptance criteria are shown in Table 2. TABLE 2 - CONTACT RESISTANCE Cable Size mm2Maximum Resistance m 0.8 1 10.0 6.7 6.3 Insulation Resistance Using a 1000 VDC insulation resistance test measurement device or equivalent, check insulation resistan

37、ce between each contact to each adjacent contact or housing edge. If the housing edge is plastic, then a metal foil may be applied around it, to create a grounding surface for the tester return. The insulation resistance shall be greater than 20 megohms. CAUTION: A shock hazard exists with the volta

38、ges available from the insulation resistance test measurement device; always use insulation resistance test measurement device procedures when testing. SAE INTERNATIONAL J2030 Revised JUN2015 Page 6 of 12 FIGURE 1 - CONNECTION RESISTANCE, CABLE TO CABLE FIGURE 2 - CONNECTION RESISTANCE, CABLE TO DEV

39、ICE 6.4 Connection Resistance The measurement of connection resistance shall be per Figures 1 and 2. The resistance of a cable equal in length to that of the two measuring points shall be subtracted from the measured values. The cable used shall be from the same batch of cable as used for the connec

40、tor wiring. 6.4.1 Measurements at Specified Test Current Measurements shall be taken after thermal equilibrium at current levels as shown in Table 3. Voltage drops shall not exceed the levels of Table 3. SAE INTERNATIONAL J2030 Revised JUN2015 Page 7 of 12 (Reference SAE J163): TABLE 3 - MEASUREMENT

41、S AT SPECIFIED TEST CURRENT Cable Size mm2Test Current Amps Maximum Millivolt Drop (cable to device) (cable to cable) 0.8 1 2 3 5 8 13 19 10 15 20 30 40 55 70 90 100 100 100 100 100 100 100 100 COMMENT: There is a direct relationship between conductor temperature rise and the current flowing through

42、 the conductor. The effect of this temperature rise is additive to the ambient temperature conditions. The system working temperature shall not exceed the maximum applicable temperature rating of any component in the current carrying system. Consult the connector manufacturer for these material ther

43、mal limitations. NOTE: Design application currents should be obtained from SAE J1614. 6.5 Pressure Washing Test Method (Reference SAE J1455) - The mated and cabled connectors under test shall be mounted in its normal operating position with drain holes, if used, open. The test apparatus should be de

44、signed to provide 100% coverage of the exposed surface of the mated and cabled connectors using flat fan spray nozzles located 20 cm to 30 cm (7.9 in to 11.8 in) away. This apparatus should provide a source pressure of approximately 7000 kPa gage (1020 lbf/in2gage) with a flow rate of approximately

45、9460 cm3/min (150 gal/h). The test item should be exposed to the spray for 3 s of a 6 s period for a total of 375 cycles. The test should be run at 40 C (104 F) with water/detergent. An Insulation Resistance test (see 6.3) shall be conducted after this test. A sample test device is illustrated in Fi

46、gure 3. FIGURE 3 - PRESSURE WASH CHAMBER SAE INTERNATIONAL J2030 Revised JUN2015 Page 8 of 12 6.6 Maintenance Aging Subject at least 10% of the cavities to ten cycles of inserting and removing its respective contact. The ten cycles shall also include any disassembly required to remove the contacts.

47、The connectors shall be mated and unmated during each cycle. Insertion and removal shall be performed using manufacturers recommended practice. 6.7 Temperature Life The cabled-mated connectors shall be subject to 1000 h at 125 3 C without current flowing. There shall be no evidence of cracking, dist

48、ortion, or detrimental damage. 6.8 Ultraviolet Effects Test the mated connectors for 1000 h per ASTM G 155 with extended UV filter or ASTM G 154 using an unfiltered UVA 340 lamp with 20 h UV and 4 h of condensation for each cycle. 6.9 Mating Forces For connectors without mechanical assist, test the

49、maximum required force to mate the plug and receptacle pair and engage the latching mechanism. The force is not to exceed 135 N. 6.10 Un-mating Forces For connectors without mechanical assist, test the maximum force required to separate the plug and receptacle with the latch mechanism fully disengaged. The force is not to exceed 135 N. 6.11 Durability The conne