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What are the test items for waterproof connectors?

2025-08-28

To ensure the quality and reliability of waterproof connectors, a series of performance tests must be conducted to evaluate their electrical, mechanical, and environmental durability. Below are the key test items and requirements:

1. Dielectric Withstanding Voltage

Standard: GJB1217-1991, Method 1005
Condition: Room temperature and pressure
Test: Apply AC 1500V/50Hz between conductors and insulation for 1 minute.
Requirement: No breakdown or arcing; leakage current < 2mA.

2. Insulation Resistance

Standard: GJB1217-1991, Method 1005
Condition: Room temperature and pressure
Test: Apply DC 500V between conductors and insulation.
Requirement: Insulation resistance > 1000 MΩ.

3. Contact Resistance

Condition: Room temperature and pressure, connectors mated
Requirement: Contact resistance ≤ 10 mΩ.

4. Salt Spray Test

Standard: GJB1217-1991, Method 1001
Test: Expose unmated connectors to a 5% NaCl solution at 35±2°C for 48 hours.
Requirement: No corrosion affecting performance.

5. Waterproof Performance

Condition: Room temperature and pressure
Test: Immerse mated connectors with tightened nuts in 1m deep water for 4 hours.
Requirement: No water leakage internally. After air-drying for 30 minutes, dielectric strength, insulation resistance, and contact resistance must meet specifications.

6. Contact Separation Force

Requirement: Single-pin separation force: 1.0–4.0 N.

7. Mechanical Life

Standard: GJB1217-1991, Method 2016
Test: Mate and unmate connectors 3000 times.
Requirement: Slight wear on plating allowed without exposing base metal. No mechanical damage affecting performance. Contact resistance must remain compliant after testing.

8. Temperature Endurance

Test: Apply current gradually up to the rated maximum. Increase temperature to the specified maximum and maintain for 250 hours.
Requirement: Connectors must function normally.

9. Intermateability

Requirement: Free and fixed connectors of the same model must mate and separate fully without issues.

This article outlines the critical tests ensuring the reliability of waterproof connectors in demanding applications. For further details or custom testing requirements, feel free to contact us at Shenzhen Cablein Tech Co., Ltd.

Bruce
Shenzhen Cablein Tech Co., Ltd.

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What are the test items for waterproof connectors?

2025-08-28

1. Dielectric Withstanding Voltage

Standard: GJB1217-1991, Method 1005
Condition: Room temperature and pressure
Test: Apply AC 1500V/50Hz between conductors and insulation for 1 minute.
Requirement: No breakdown or arcing; leakage current < 2mA.

2. Insulation Resistance

Standard: GJB1217-1991, Method 1005
Condition: Room temperature and pressure
Test: Apply DC 500V between conductors and insulation.
Requirement: Insulation resistance > 1000 MΩ.

3. Contact Resistance

Condition: Room temperature and pressure, connectors mated
Requirement: Contact resistance ≤ 10 mΩ.

4. Salt Spray Test

Standard: GJB1217-1991, Method 1001
Test: Expose unmated connectors to a 5% NaCl solution at 35±2°C for 48 hours.
Requirement: No corrosion affecting performance.

5. Waterproof Performance

Condition: Room temperature and pressure
Test: Immerse mated connectors with tightened nuts in 1m deep water for 4 hours.
Requirement: No water leakage internally. After air-drying for 30 minutes, dielectric strength, insulation resistance, and contact resistance must meet specifications.

6. Contact Separation Force

Requirement: Single-pin separation force: 1.0–4.0 N.

7. Mechanical Life

Standard: GJB1217-1991, Method 2016
Test: Mate and unmate connectors 3000 times.
Requirement: Slight wear on plating allowed without exposing base metal. No mechanical damage affecting performance. Contact resistance must remain compliant after testing.

8. Temperature Endurance

Test: Apply current gradually up to the rated maximum. Increase temperature to the specified maximum and maintain for 250 hours.
Requirement: Connectors must function normally.

9. Intermateability

Requirement: Free and fixed connectors of the same model must mate and separate fully without issues.

Bruce
Shenzhen Cablein Tech Co., Ltd.

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What are the test items for waterproof connectors?

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What are the test items for waterproof connectors?