Product Specification
108-137045
Sep 10th, 2015 Rev. B
HA Insert Series
Table of contents
1. SCOPE .......................................................................................................................................2
1.1. Content ............................................................................................................................. 2
1.2. Qualification ..................................................................................................................... 2
2. APPLICABLE DOCUMENTS ..................................................................................................... 2
2.1. TE Connectivity Documents ...........................................................................................2
2.2. Other Documents ............................................................................................................. 2
3. REQUIREMENTS .......................................................................................................................3
3.1. Design and Construction ................................................................................................3
3.2. Materials ...........................................................................................................................3
3.3. Rated .................................................................................................................................3
3.4. Performance and Test Description .................................................................................3
3.5. Test Requirements and Procedures Summary.............................................................. 3
3.6. Test Sequences ................................................................................................................7
4. QUALITY ASSURANCE PROVISIONS......................................................................................8
4.1. Qualification Testing........................................................................................................8
4.2. Requalification Testing.................................................................................................... 8
4.3. Acceptance .......................................................................................................................8
4.4. Quality Conformance Inspection .................................................................................... 8
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Product Specification
108-137045
Sep 10th, 2015 Rev. B
1. SCOPE
1.1. Content
This specification covers the performance, tests and quality standards for the contact inserts of
heavy duty connector series HA-003/ HA-004/ HA-010/ HA-016/ HA-032(2x 16)/ HA-048(3x 16)/
HA-064(4x 16). The contact inserts are available for positions number 3/4/10/16/32/48/64.
The termination conductor-contact insert is affected via:
1).a crimp contact which is fitted into the contact insert. The contact insert is designed for
conductors of 0.14 mm² up to 4.0 mm².
2). a screw contact which is integrate into the contact insert. The contact insert is designed for
conductors 0.5 mm² up to 2.5 mm².
3).a spring clamp contact which is integrate into the contact insert. The contact insert is designed
for conductors 0.5 mm² up to 2.5mm².
1.2. Qualification
When tests are performed, the following specified specifications and standards shall be used. All
inspections shall be performed using the applicable inspection plan and product drawing.
2. APPLICABLE DOCUMENTS
The following documents form part of this specification to the extent specified herein. In the case
of a conflict between the requirements of this specification and the product drawing or of conflicts
between the requirements of this specification and the referenced documents, this specification
shall take precedence.
2.1. TE Connectivity Documents
A. Customer drawing and name
HA insert series
2.2. Other Documents
EN 61984: Connectors - Safety requirements and tests
IEC 60068: Environmental testing
IEC 60512: Connectors for electronic equipment -Test and measurements
IEC 60529: Degrees of Protection Provided by Enclosures (IP Code)
IEC 60664-1: Insulation coordination for equipment within low-voltage systems (Part 1)
EN 61373: Railway application - Rolling stock equipment - Shock and vibration test
ISO 6988: Metallic and other non-organic coatings - Sulfur dioxide test with general
condensation of moisture
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Product Specification
108-137045
Sep 10th, 2015 Rev. B
3. REQUIREMENTS
3.1. Design and Construction
Product shall be of the design, construction and physical dimensions specified on the applicable
product drawing.
3.2. Materials
Materials used in the construction of this product shall be as specified on the applicable product
drawing.
3.3. Rated
Rated Current / Voltage / Impulse Voltage / Pollution Degree
16A 250V 4KV 3
Except for the below:
HA-003-M/ F (Screw type.): 10A 250V 4KV 3
HA-004-M/ F (Screw type.): 10A 250V 2.5KV 3
HA-003-MS/ FS (Spring type.): 10A 400V 6KV 3
HA-004-MS/ FS (Spring type.): 10A 400V 4KV 3
Operation Temperature
-40°C ~+125°C
Degree of Protection
IP20
Protection Class
II
Overvoltage Category
III
3.4. Performance and Test Description
Product shall be designed to meet the electrical, mechanical and environmental performance
requirements specified in Paragraph 3.5. Unless otherwise specified, all tests shall be performed
at ambient environmental conditions per IEC 60512 / EN 61984.
3.5. Test Requirements and Procedures Summary
General
No.
Test Items
Requirements
Condition according to
3.5.1
Visual and dimensional
examination
Meets requirements of product
drawing
Visual and dimensional examination
IEC 60512-1-1/-2, Test 1a and 1b
6.2 of EN 61984
Marking shall be still readable
according to 6.2 of EN61984
(If marking made by impression,
molding, pressing or engraving or
the like are not subjected to this test)
Test piston: No. 1
Wet test with liquid: water
Duration: 10 cycles
Force:5N
IEC 60068-2-70 Test Xb
7.3.2 of EN61984
Mechanical
3.5.2
Durability of marking
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Product Specification
108-137045
Sep 10th, 2015 Rev. B
Polarisation and coding
For unenclosed connector (internal
For multi-pole connector, require
connections) 20N
provision against incorrect mating
For enclosed connector (external
according to 6.3 & 6.9.1 of EN 61984
connections) 1.5 x Mating force, but
No damage likely to impair function
not higher than 80N
Test 13e of IEC 60512-13-5
Pull out force of
terminations
See 6.6 of EN 61984
See 6.6 of EN 61984
The conductor shall not slip out of
crimp barrel and pull out force as
specified in Table 1 of EN 60352-2
Visual tests on the crimp barrel and
tensile strength test of the crimp
connection as specified in IEC
60352-2.
The conductor of the smallest and
largest cross-sectional area shall not
slip out of the clamping unit, and pull
out force as specified in Table 3, and
torque force as specified in Table 4
IEC 60999-1 or IEC 60999-2
Mechanical tests on the conductor
connection as specified in
9.3~9.6 of IEC 60999-1 or IEC
60999-2
Only for spring clamp
connection
The conductor of the smallest and
largest cross-sectional area shall not
slip out of the clamping unit, and pull
out force as specified in Table 3
IEC 60999-1 or IEC 60999-2
Mechanical tests on the conductor
connection as specified in
9.3~9.5 of IEC 60999-1 or IEC
60999-2 or IEC 60352-7
Contact retention force in
insert
No axial displacement likely to impair
normal operation, min 50N force for
each pin or socket
6.18.2 of EN 61984
Test load applied in axial direction,
test speed:20mm/min, permissible
shift contacts of 1.0mm,
Test 15a of IEC 60512-15-1
Connector and internal insulation
shall no damage to impair normal
use. A reduction of clearance and
creepage distance is not allowed.
6.18.1 & 6.18.3 of EN 61984
Dropping height:
- 750mm for specimens of mass≤
250g
- 500mm for specimens of
mass>250g
Dropping cycles:8
positions in 45°step, one cycles
per position
IEC 60512-7-2 Test 7b
3.5.7
Mechanical Operation
(Durability)
500 operation cycles without load
No damage likely to impair normal
use
6.14.1 of EN 61984
Shall be engaged and disengaged
by means of
A) a device simulating normal
operating conditions at the speed of
approximately 50mm/min
B) manual mating/un-mating 300
Max. cycle per hour
IEC 60512-9-1 Test 9a
7.3.9 of EN 61984
3.5.8
Vibration, Random
No damage likely to impair function
No discontinuities greater than t>1µs
Frequency:5~150Hz
Per EN 61373, Category 1, Class B
(IEC60068-2-6 Test Fc)
No damage likely to impair function
No discontinuities greater than t>1µs
Acceleration:50m/s2
Duration:30ms
Total 18 shocks(three positive and
three negative in each of the three
orthogonal axes)
Per EN 61373
3.5.3
a
3.5.4
Only for crimp contact
connection
a
Only for screw contact
connection
a
3.5.5
3.5.6
3.5.9
Mechanical strength impact
Shock
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Product Specification
108-137045
Sep 10th, 2015 Rev. B
Electrical
3.5.10
Contact Resistance
Initial
Max.5mΩ
Final
The change of contact
resistance shall be no
more than 50 % of the
reference value or
≤5 mΩ.
The higher value is
permissible
Test current: 1A
Measure pointsb at the end of the
termination
Max three contacts per specimen
plus protective earthing, if any
IEC 60512-2-2 Test 2b
Temperature Rise Test
The sum of the ambient temperature
and the temperature rise (△T ) of a
connector shall not exceed the upper
limiting temperature
6.16 of EN 61984
Length of test cable see table 7 of
7.3.8 of EN 61984
Carry its rated current
Upper limiting temperature:125℃
(Table 5b)
IEC 60512-5-1 Test 5a
3.5.12
Dielectric Voltage
Withstand Test
No flashover or breakdown of
voltage
6.13 of EN 61984
Impulse test voltage according to
Table 8, applied three impulses of
each polarity and interval of at least
1s between impulses.
7.3.12 of EN 61984
3.5.13
Insulation Resistance
Not less than 400MΩ
Test voltage 1000V DC
Time:60s
IEC 60512-3-1 Test 3a Method B
No damage likely to impair function
Subject mated specimen to
-40℃ Duration time:16h, Test Ab
Per IEC 60512-11-10 Test 11j
(IEC 60068-2-1)
No damage likely to impair function
Subject mated specimen to
+125℃ Duration time:168h Test Bb
Per IEC 60512-11-9 Test 11i
(IEC 60068-2-2)
3.5.11
Environmental
3.5.14
3.5.15
3.5.16
3.5.17
Cold
Dry Heat
Damp Heat, cyclic
Rapid Change of
temperature (Temperature
Cycle)
No damage likely to impair function
No damage likely to impair function
Subject mated specimen to
Min ambient temperature: 25±2℃
Max ambient temperature: 40±2℃
Number of cycles:21
Duration time:12h+12h
Variant 1
IEC 60512-11-12 Test 11m
Subject mated specimen to
Ta=-40±2℃ to Tb=+125±2℃,
duration t1: 1h each extreme,
100 cycles
IEC 60512-11-4 Test 11d
(IEC 60068-2-14 Test Na)
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Product Specification
108-137045
Sep 10th, 2015 Rev. B
3.5.18
3.5.19
Corrosion
(Alternative)
No damage likely to impair function
Per 6.21 of EN 61984
no live parts shall be accessible by
test finger, 6.4.2.2 or 6.4.2.3 of EN
61984
Protection against electric
shock
Test 1: Flowing mixed gas corrosion
according to test 11g, method 1 or
method 4 (Table 1)
Duration time: 4day (96h)
IEC 60512-11-7 Test 11g
7.3.14 of EN 61984
Test 2: Sulphur dioxide test with
general condensation of moisture
according to EN ISO 6988
Duration time:24h (1 test cycle)
7.3.14 of EN 61984
Unenclosed connector. Test finger
or 50mm sphere pressed with 20N
against the surface as specified by
the manufacture
Mated specimen and socket
connector (if application)
7.3.6.1 of EN 61984
a test
items are for themselves separate tests and are performed on new specimens.
point: at the conductors as close as possible to the termination, if this is not possible, the conductor
resistance shall be recalculated.
b measuring
Number of Specimen as below table:
Table 1 - Number of Specimen
Test
Group A
Description
Numbers & consist of
3 pairs connectors
Mechanical Test
Group B
Service life Test
3 pairs connectors
Group C
Temperature rise Test, Mated
3 pairs connectors
Group D
Climatic Test, Mated
3 pairs connectors
Group E
Degree of protection Test
3 pairs connectors
Group F
Temperature Cycle Test
3 pairs connectors
Group G
Vibration and Shock Test
3 pairs connectors (assemble with Hood & Housing)
Note: For connector family of the same design and comparable size, test may be made only on that member of the family
which represents the worse case for that test.
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Product Specification
108-137045
Sep 10th, 2015 Rev. B
3.6. Test Sequences
Test Group
Test or Examination
A
B
C
D
E
F
G
1,3
1,8
1,6
2,8
2,5
3
4
2,5
3,9
4,10
5
6
6
7
Test Sequence
Visual and dimensional examination
Durability of marking
Polarisation and coding (If application)
Pull out force of terminations
Only for Crimped connections
Only for Screw contact connections
Contact retention force in insert
Mechanical strength impact
Mechanical Operation (Durability)
Vibration, Random
Shock
Contact Resistance
Temperature Rise Test
Dielectric Voltage Withstand Test
Insulation Resistance
Cold
Dry Heat
Damp Heat, cyclic
Rapid Change of temperature (Temperature Cycle)
Corrosion
Protection against electric shock
1,6
2
3
1,5
1,3
1,11
7a
4
5
3
2,4
2
4
3
7
2
Notes:
1) Numbers indicate the sequence in which the tests are performed.
2) a test items are for themselves separate tests and are performed on new specimens.
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Product Specification
108-137045
Sep 10th, 2015 Rev. B
4. QUALITY ASSURANCE PROVISIONS
4.1. Qualification Testing
A. Specimen Selection
Specimens shall be prepared in accordance with product drawing and shall be selected
at random from current production.
B. Test Sequence
The samples shall be prepared in accordance with product drawings. They shall be
selected at random from current production.
4.2. Requalification Testing
If changes significantly affecting form, fit or functions are made to the product or manufacturing
process, product assurance shall coordinate requalification testing, consisting of all or part of the
original testing sequence as determined by development/product, quality and reliability
engineering.
4.3. Acceptance
Acceptance is based on verification that the product meets the requirements of paragraph 3.5.
Failures attributed to equipment, test setup or operator deficiencies shall not disqualify the
product. If product failure occurs, corrective action shall be taken and specimens resubmitted for
qualification. Testing to confirm corrective action is required before re-submittal.
4.4. Quality Conformance Inspection
The applicable quality inspection plan shall specify the sampling acceptable quality level to be
used. Dimensional and functional requirements shall be in accordance with the applicable product
drawing and this specification. Bulk wire resistance shall be subtracted from resistance readings.
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