Device Under Test: 90HBW08PT, 90HBW10PT, 90B08ST, 90B05ST, 90B10ST Environmental Test: Thermal Shock, Moisture resistance, Thermal aging, Resistance to Reflow Physical Test: Mechanical Life, Mechanical shock, Vibration Resistance, Terminal Strength Flammability, Solderability, Process seal Test Report Number: SM04-17 Test Start Date: December 3, 2013 Test Completion Date: March 14, 2014 Test Facility: Grayhill, Inc. Test Requested By: Gary Dreher Test Performed By: Lakeiah Johnson Laboratory Technician Report Written By: Lakeiah Johnson Laboratory Technician Report Approved By: Nicole Jachna Quality Lab Manager TABLE OF CONTENTS SUBJECT PAGE # 1.0 SUMMARY ................................................................................................................................................................... 4 1.1. PURPOSE .................................................................................................................................................................................... 4 1.2. REQUIREMENTS & METHODS..................................................................................................................................................... 4 1.3. TEST SUMMARY ......................................................................................................................................................................... 5 2.0 FLOW CHART ............................................................................................................................................................. 6 3.0 CONTACT RESISTANCE............................................................................................................................................ 7 3.1. PURPOSE .................................................................................................................................................................................... 7 3.2. TEST SETUP DETAILS ................................................................................................................................................................... 7 3.3. TEST SETUP PHOTOS .................................................................................................................................................................. 8 3.4. ACCEPTANCE CRITERIA ............................................................................................................................................................... 8 3.5. TEST RESULTS ............................................................................................................................................................................. 8 4.0 INSULATION RESISTANCE ....................................................................................................................................... 9 4.1. PURPOSE .................................................................................................................................................................................... 9 4.2. TEST SETUP DETAILS ................................................................................................................................................................... 9 4.3. TEST SETUP PHOTOS ................................................................................................................................................................ 10 4.4. ACCEPTANCE CRITERIA ............................................................................................................................................................. 10 4.5. TEST RESULTS ........................................................................................................................................................................... 10 5.0 FLAMMABILITY ........................................................................................................................................................ 11 5.1. PURPOSE .................................................................................................................................................................................. 11 5.2. TEST SETUP DETAILS ................................................................................................................................................................. 11 5.3. TEST SETUP PHOTOS ................................................................................................................................................................ 12 5.4. ACCEPTANCE CRITERIA ............................................................................................................................................................. 12 5.5. TEST RESULTS. .......................................................................................................................................................................... 12 6.0 SOLDERABILITY ...................................................................................................................................................... 13 6.1. PURPOSE .................................................................................................................................................................................. 13 6.2. TEST SETUP DETAILS ................................................................................................................................................................. 13 6.3. TEST SETUP PHOTOS ................................................................................................................................................................ 14 7.0 DIELECTRIC WITHSTAND TEST ............................................................................................................................. 16 7.1 PURPOSE .................................................................................................................................................................................. 16 7.2 TEST SETUP DETAILS ................................................................................................................................................................. 16 7.1. TEST SETUP PHOTOS ................................................................................................................................................................ 17 7.2. ACCEPTANCE CRITERIA ............................................................................................................................................................. 17 7.3. TEST RESULTS ........................................................................................................................................................................... 17 8.0 MECHANICAL LIFE TEST ........................................................................................................................................ 18 8.1. PURPOSE .................................................................................................................................................................................. 18 8.2. TEST SETUP DETAILS ................................................................................................................................................................. 18 8.3. TEST SETUP PHOTOS ................................................................................................................................................................ 19 8.4. ACCEPTANCE CRITERIA ............................................................................................................................................................. 19 8.5. TEST RESULTS ........................................................................................................................................................................... 19 9.0 OPERATING FORCE ................................................................................................................................................ 20 9.1. 9.2. 9.3. 9.4. 9.5. PURPOSE .................................................................................................................................................................................. 20 TEST SETUP DETAILS ................................................................................................................................................................. 20 TEST SETUP PHOTOS ................................................................................................................................................................ 21 ACCEPTANCE CRITERIA ............................................................................................................................................................. 21 TEST RESULTS ........................................................................................................................................................................... 21 2 of 37 OPS Form #333, Rev A 11/12/12 Report SM04-17 Rev. A 10.0 MOISTURE RESISTANCE..................................................................................................................................... 22 10.1. PURPOSE .............................................................................................................................................................................. 22 10.2. TEST SETUP DETAILS ............................................................................................................................................................. 22 10.3. TEST SETUP PHOTOS ............................................................................................................................................................ 23 10.4. ACCEPTANCE CRITERIA ......................................................................................................................................................... 23 10.5. TEST RESULTS ....................................................................................................................................................................... 23 11.0 RESISTANCE TO REFLOW SOLDER PROCESSING ......................................................................................... 24 11.1. PURPOSE .............................................................................................................................................................................. 24 11.2. TEST SETUP DETAILS ............................................................................................................................................................. 24 11.3. TEST SETUP PHOTOS ............................................................................................................................................................ 25 11.4. ACCEPTANCE CRITERIA ......................................................................................................................................................... 25 11.5. TEST RESULTS ....................................................................................................................................................................... 25 12.0 PROCESS SEAL .................................................................................................................................................... 27 12.1. PURPOSE .............................................................................................................................................................................. 27 12.2. TEST SETUP DETAILS ............................................................................................................................................................. 27 12.3. TEST SETUP PHOTOS ............................................................................................................................................................ 28 12.4. ACCEPTANCE CRITERIA ......................................................................................................................................................... 28 12.5. TEST RESULTS ....................................................................................................................................................................... 28 13.0 MECHANICAL SHOCK .......................................................................................................................................... 29 13.1. PURPOSE .............................................................................................................................................................................. 29 13.2. TEST SETUP DETAILS ............................................................................................................................................................. 29 13.3. TEST SETUP PHOTOS ............................................................................................................................................................ 30 13.4. ACCEPTANCE CRITERIA ......................................................................................................................................................... 30 13.5. TEST RESULTS ....................................................................................................................................................................... 30 14.0 VIBRATION RESISTANCE .................................................................................................................................... 31 14.1. PURPOSE .............................................................................................................................................................................. 31 14.2. TEST SETUP DETAILS ............................................................................................................................................................. 31 14.3. TEST SETUP PHOTOS ............................................................................................................................................................ 32 14.4. ACCEPTANCE CRITERIA ......................................................................................................................................................... 32 14.5. TEST RESULTS ....................................................................................................................................................................... 33 15.0 TERMINAL STRENGTH ........................................................................................................................................ 34 15.1. PURPOSE .............................................................................................................................................................................. 34 15.2. TEST SETUP DETAILS ............................................................................................................................................................. 34 15.3. TEST SETUP PHOTOS ............................................................................................................................................................ 35 15.4. ACCEPTANCE CRITERIA ......................................................................................................................................................... 35 15.5. TEST RESULTS ....................................................................................................................................................................... 35 16.0 THERMAL AGING TEST ....................................................................................................................................... 36 16.1. 16.2. 16.3. 16.4. 16.5. PURPOSE .............................................................................................................................................................................. 36 TEST SETUP DETAILS ............................................................................................................................................................. 36 TEST SETUP PHOTOS ............................................................................................................................................................ 37 ACCEPTANCE CRITERIA ......................................................................................................................................................... 37 TEST RESULTS ....................................................................................................................................................................... 37 3 of 37 OPS Form #333, Rev A 11/12/12 Report SM04-17 Rev. A 1.0 SUMMARY 1.1. PURPOSE To test and verify a change in the plastic resin material used for the 90 Series switch body and cover to a halogenfree grade of Amodel in place of the Stanyl material that is currently used. 1.2. REQUIREMENTS & METHODS PS90 MIL-STD-202G MIL-STD-83504 UL-94 SVV1747 IEC 695-11-5 IPC J-STD-002 4 of 37 OPS Form #333, Rev A 11/12/12 Report SM04-17 Rev. A 1.3. TEST SUMMARY Table 1 – Test Summary Test Description Thermal shock Mechanical Life Dielectric Withstand Voltage Contact Resistance Moisture Resistance Insulation Resistance Resistance to Reflow Solder Processing Process Seal Mechanical Shock Vibration Resistance Terminal Strength Thermal Aging Solderability Flammability Operating Force Basic Standard MIL-STD-202 Method 107G, PS90 – 90 Series Product Specification MIL-STD-83504/12, PS90 – 90 Series Product Specification MIL-STD-202 Method 301, PS90 – 90 Series Product Specification MIL-STD-202 Method 307, PS90 – 90 Series Product Specification MIL-STD-202 Method 106, PS90 – 90 Series Product Specification MIL-STD-202 Method 302, PS90 – 90 Series Product Specification PS90 – 90 Series Product Specification MIL-STD-202 Method 112, PS90 – 90 Series Product Specification MIL-STD-202 Method 213, PS90 – 90 Series Product Specification MIL-STD-202 Method 204 PS90 – 90 Series Product Specification MIL-STD-202 Method 211A, PS90 – 90 Series Product Specification MIL-STD-202 Method 108A , PS90 – 90 Series Product Specification MIL-STD-202 Method 208, PS90 – Series Product Specification IEC Standard 60695-11-5 UL-94, PS90 – 90 Series Product Specification PS90 – 90 Series Product Specification Test Results PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS Test Date 01/30/2014 To 02/24/2014 01/30/2014 To 02/24/2014 01/30/2014 To 02/24/2014 01/30/2014 To 02/24/2014 01/30/2014 To 02/24/2014 01/30/2014 To 02/24/2014 01/30/2014 To 02/24/2014 01/30/2014 To 02/24/2014 01/30/2014 To 02/24/2014 01/30/2014 To 02/24/2014 01/30/2014 To 02/24/2014 01/30/2014 To 02/24/2014 01/30/2014 To 02/24/2014 01/30/2014 To 02/24/2014 01/30/2014 To 02/24/2014 Test Location Grayhill, Inc. Grayhill, Inc. Grayhill, Inc. Grayhill, Inc. Grayhill, Inc. Grayhill, Inc. Grayhill, Inc. Grayhill, Inc. Grayhill, Inc. Grayhill, Inc. Grayhill, Inc. Grayhill, Inc. Grayhill, Inc. Grayhill, Inc. Grayhill, Inc. 5 of 37 OPS Form #333, Rev A 11/12/12 Report SM04-17 Rev. A 2.0 FLOW CHART Subgroup V 5 samples 90 series 125 units Subgroup VI 10 samples Flammability soldetability Subgroup I 20 samples subgroup II 20 samples Subgroup III 40 Samples Subgroup IV 10 samples Thermal shock Moisture Reistance Resistance to Reflow solder Processing Mechanical Shock Mechanical Life Insulation Resistance Contact Resistance (20) Vibration resistance Contact Resistance Process Seal (20) Contact Resistance Dielectric withstanding contact resistance Subgroup VII 10 samples Subgroup VIII 10 samples Process Seal Thermal Aging Terminal Strength Contact Resistance Insulation Resistance Operating Force 6 of 37 OPS Form #333, Rev A 11/12/12 Report SM04-17 Rev. A 3.0 CONTACT RESISTANCE Test Specification Contact Resistance PS90, MIL-STD-202 Method 307 3.1. DUT Part Number DUT Serial Number Test Location 90B08ST 1-30 90HBW08PT, 90B08ST, 90B05ST 1-30 Grayhill Inc. 90B05ST, 90B10ST 90B10ST 1-20 90HBW08PT 1-98 Test Date 12/3/2013 to 03/03/2014 PURPOSE The purpose of the contact resistance test is to determine the resistance offered to a flow of current during its passage between the electrical contacting surfaces of connecting components, such as plugs, jacks, connectors, and sockets, or between the electrical contacts of current controlling components, such as switches and relays. For practical reasons, lead and terminal resistances may be included in the actual measurement, as well as the contact resistance proper. In many applications it is required that the contact resistance be low and stable, so that the voltage drop across the contacts does not affect the accuracy of the general circuit conditions. If large currents are passed through high resistance contacts, excessive energy losses and dangerous overheating of the contacts may occur. 3.2. TEST SETUP DETAILS 1. Set DC power supply to test voltage 1V and 10 milliamperes. 2. Connect the affixed 4 wire test probes to DUT leads by clips 3. Take one measurement for each actuation. 4. Record data Table 2 – Equipment List Equipment ID GT — 534 GT — 13 GT— 507 Equipment Type DC Power supply Multimeter Multimeter Model Number GPS-4251 87 III 34401A Manufacturer GWINSTEK Fluke Agilent Calibration Due Date Verified with GT-13 05-2014 03-2014 7 of 37 OPS Form #333, Rev A 11/12/12 Report SM04-17 Rev. A 3.3. TEST SETUP PHOTOS Figure 1 – Test setup 3.4. ACCEPTANCE CRITERIA When switches are tested as specified, the contact resistance shall not exceed 20 milliohms initially or 100 milliohms after mechanical life 3.5. TEST RESULTS After testing all switches contact resistance did not exceed 20milliohms initially of 100 milliohms after mechanical life. Table 3 – Test Results DUT 1-30 Part Number 90B08ST Test Specification Pass Test Location CR MIL-STD-202, Method 307 PASS Grayhill Inc. 1-30 90B05ST CR MIL-STD-202, Method 307 PASS Grayhill Inc. 1-20 90B10ST CR MIL-STD-202, Method 307 PASS Grayhill Inc. 1-98 90HBW08PT CR MIL-STD-202, Method 307 PASS Grayhill Inc. Test Date 12/03/2013 To 03/03/2014 12/03/2013 To 03/03/2014 12/03/2013 To 03/03/2014 12/03/2013 To 03/03/2014 8 of 37 OPS Form #333, Rev A 11/12/12 Report SM04-17 Rev. A 4.0 INSULATION RESISTANCE Test Specification Insulation Resistance PS90 MIL-STD 202, Method 302 4.1. DUT Part Number DUT Serial Number Test Location 90B08ST 1-30 90HBW08PT, 90B05ST 1-30 90B08ST, Grayhill Inc. 90B10ST 1-20 90B05ST, 90B10ST 90HBW08PT 1-98 Test Date 12/4/2013 To 03/03/2014 PURPOSE This test is performed to verify the resistance offered by the insulating members of a component part to an impressed direct voltage tending to produce a leakage of current. Typical environmental effects of this test are changes in physical properties of materials resulting in: Intermittent operation Unit failure Increased leakage currents 4.2. 1. 2. 3. 4. TEST SETUP DETAILS Visual Inspection of the unit is to be performed before and after testing. Apply the voltage level for the specified time to the points of application Measure and document resistance value after the specified electrification time. Repeat 2-3 for all points of application. Table 4 – Equipment List Equipment ID GT-76 Equipment Type Megaohm-Meter Model Number 1865 Megaohm-Meter Manufacturer Quad Tech Calibration Due Date 10-2014 Table 5 – Test Conditions Test Condition Quantity Operational Mode Temperature Humidity Units DUT Parameters All Unpowered °C 24.4 %h 16.9 Across open contacts and between Points of Application adjacent closed contacts Note: Due to all contact being sealed a measurement between only adjacent close contacts can be done. 9 of 37 OPS Form #333, Rev A 11/12/12 Report SM04-17 Rev. A 4.3. TEST SETUP PHOTOS Figure 2 – Test setup photo 4.4. ACCEPTANCE CRITERIA The insulation resistance shall not be less than 5,000 Megaohms initially or 1,000 Megaohms after mechanical life. 4.5. TEST RESULTS All DUT were not less than 5,000 Megaohm initially or less than 1,000 Megaohm after mechanical life testing Table 6 – Test Results DUT 1-30 Part Number Test Specification Pass Test Location 90B08ST Insulation Resistance MIL-STD-202, Method 302 PASS Grayhill Inc. 1-30 90B05ST Insulation Resistance MIL-STD-202, Method 302 PASS Grayhill Inc. 1-20 90B10ST Insulation Resistance MIL-STD-202, Method 302 PASS Grayhill Inc. 1-98 90HBW08PT Insulation Resistance MIL-STD-202, Method 302 PASS Grayhill Inc. Test Date 12/03/13 To 02/24/2014 12/03/13 To 02/24/2014 12/03/13 To 02/24/2014 12/03/13 To 02/24/2014 10 of 37 OPS Form #333, Rev A 11/12/12 Report SM04-17 Rev. A 5.0 FLAMMABILITY Test Specification DUT Part Number IEC Standard 60695-11-5 Flammability 90HBW08PT UL-94 5.1. DUT Serial Number Test Location Test Date 42,64,65,66,67 Grayhill Inc. 12/27/2013 PURPOSE This test is performed to determine the flammability of a part exposed to an external flame. Flammability can be determined by the time it takes a part to become self-extinguishing after exposure to an external flame. Typical environmental effects of this test are changes in physical properties of materials resulting in: Fire Explosive type fire Continued self-ignition of material 5.2. 1. 2. 3. 4. 5. 6. TEST SETUP DETAILS Visual Inspection of the unit is to be performed before and after testing. Place and setup the torch in the chamber. See table below for flame length. Expose the unit under test to the flame impingement point in the orientation specified below. Expose the unit for the specified exposure time. Remove the unit form the flame and document results. Perform the Visual Check after exposure. Table 7 – Test Conditions Test Condition Quantity Chamber Flame orientation Exposure time Fuel type Nozzle type Allowable burn time Mating Connector Attached Operational Mode Temperature Humidity Units Parameters seconds 5 Chemical Fume hood Vertical 30 Propane See UL-94 &IEC 60695 3 seconds No °C RH% Non-Operating 24.1 15.5 11 of 37 OPS Form #333, Rev A 11/12/12 Report SM04-17 Rev. A 5.3. TEST SETUP PHOTOS Figure 3 – Flammability Test Setup 5.4. Figure 4 – Flammability Test Setup ACCEPTANCE CRITERIA There shall be less than 3 seconds of continuous flaming after removal of burner, and falling burning drops shall not ignite the cheese cloth underneath. 5.5. TEST RESULTS. All switches had a continuous flame after removing the burner for less than 3 seconds and the burning drops did not ignite the cheese cloth underneath. Table 8 – Test Results DUT Test 42 Flammability 64 Flammability 65 Flammability 66 Flammability 67 Flammability Specification MIL STD 202G Method 111A MIL STD 202G Method 111A MIL STD 202G Method 111A MIL STD 202G Method 111A MIL STD 202G Method 111A Pass/Fail Test Location Test Date PASS Grayhill Validation Lab 12/27/2013 PASS Grayhill Validation Lab PASS Grayhill Validation Lab PASS Grayhill Validation Lab PASS Grayhill Validation Lab 12/27/2013 12/27/2013 12/27/2013 12/27/2013 12 of 37 OPS Form #333, Rev A 11/12/12 Report SM04-17 Rev. A 6.0 SOLDERABILITY Test Solderability 6.1. Specification MIL-DTL-9419G Method 4.7.19 DUT Part Number DUT Serial Number Test Location Test Date 90HBW08PT 32-41 Grayhill Inc. 2/06/2013 PURPOSE The purpose of this test method is to determine the solderability of all terminations, which are normally joined by a soldering operation. This determination is made on the basis of the ability of these terminations to be wetted by solder and predictability of a suitable fillet resulting from solder application. These procedures will verify will verify that the pre-assembly lead finish provides a solder able surface of sufficient quality to enable satisfactory soldering. 6.2. TEST SETUP DETAILS 1. 2. 3. 4. 5. 6. 7. 8. While running this test specimen should follow MIL-STD-202G and condition table. Visual inspection of the unit is to be performed before and after testing. All terminals of the DUT are to be tested Dipping device: Need not be used. Examination of terminations: Method for evaluation of lugs and tabs shall apply. Preparation of terminations and aging shall be as specified in ANSI/J-STD-002 Flux shall be applied by a suitable method (e.g., brush) and allowed to drain for 5 to 20 seconds. Solder in shall be applied to the terminal along with the clean solder coated tip of an iron (unless otherwise specified in the individual specification, iron temperature shall be 350°C) to a point ¼ inch from the nearest insulating material or ½ the exposed length of the terminal. 9. The termination shall be positioned so that the iron can be applied to the test surface in a horizontal position. 10. Prior to examination, flux residue shall be removed from the terminations by cleaning in a suitable solvent. 11. Terminations shall be examined as specified in ANSI/J-STD-002. Table 9 – Equipment List Equipment ID Equipment Type Model Number GT-530 Steamage N/A GT-302 Solder Iron FM-202 Manufacturer Mountian gate Engineering Hakko Calibration Due Date 01-2015 09-2014 Table 10 – Test Conditions Test Condition Units Parameters Quantity 8 Hours Steamage Water Type for Steamage Solder Solder Pot Temperature Time on Solder Iron Temperature Humidity Flux DUT NA 10 Yes Ionized NA 63% Sn / 37%Pb °C 250 Sec °C RH% 5-20 24.1 15.5 182 13 of 37 OPS Form #333, Rev A 11/12/12 Report SM04-17 Rev. A 6.3. TEST SETUP PHOTOS Figure 5 – Test Setup Figure 6 – Test Setup Figure 7 – Test setup 14 of 37 OPS Form #333, Rev A 11/12/12 Report SM04-17 Rev. A 6.4 ACCEPTANCE CRITERIA All terminations shall exhibit a continuous solder coating free from defects for a minimum of 95% of the critical area of any individual termination. Anomalies other than dewetting, nonwetting, and pin holes are not cause for rejection 6.5 TEST RESULTS After testing all terminations showed a continuous solder coating free from defects for a minimum of 95% of the critical area. Table 11 – Test Results DUT Test 32-41 Solderability Specification MIL-DTL-9419G Method 4.7.19 Pass Test Location Test Date PASS Grayhill, Inc 2/06/2013 15 of 37 OPS Form #333, Rev A 11/12/12 Report SM04-17 Rev. A 7.0 DIELECTRIC WITHSTAND TEST Test Specification DUT Serial Number 90B08ST 1-30 90HBW08PT, PS90- 90 series 90B05ST 1-30 90B08ST, 90B05ST, product specification 90B10ST 1-20 90B10ST 90HBW08PT 1-98 Dielectric Withstand Test DUT Part Number Test Location Test Date Grayhill Inc. 12/05/2013 To 03/03/2014 7.1 PURPOSE This test is performed to verify that the unit under test can withstand the effects of temporary over voltage conditions resulting from switching, surges, and other similar phenomenon. Typical environmental effects of this test are changes in physical properties of materials resulting in: Intermittent operation Unit failure Increased leakage currents 7.2 TEST SETUP DETAILS 1. Visual Inspection of the unit is to be performed before and after testing. 2. Apply specified AC voltage and current level (if specified) for the specified duration time between terminals. 3. Monitor faults indicator and record reading. Table 12 – Equipment List Equipment ID Equipment Type Model Number Manufacturer Calibration Due Date GT - 63 Dielectric Withstand Tester Hypot III Associated Research, Inc. 12-2014 Table 13 – Test Conditions Test Condition Units Parameters Quantity Assemblies All Voltage Level VAC 500 Period of Application Seconds 5 Maximum Leakage Current µA 100 Points of Application between adjacent closed contacts Note: Only measurement between adjacent close contacts were measured due to contacts being sealed in closed position 16 of 37 OPS Form #333, Rev A 11/12/12 Report SM04-17 Rev. A 7.1. TEST SETUP PHOTOS Figure 8 – Test setup 7.2. ACCEPTANCE CRITERIA There shall be no arcing, flashover, breakdown of insulation, or damage, and the leakage current shall be no greater than 100 micro amperes. 7.3. TEST RESULTS All DUT passed Dielectric Withstanding. Table 14 – Test results DUT 1-30 Part Number 90B08ST Test Specification Pass Test Location Dielectric Withstanding MIL-STD-202, Method 301 PASS Grayhill Inc. 1-30 90B05ST Dielectric Withstanding MIL-STD-202, Method 301 PASS Grayhill Inc. 1-20 90B10ST Dielectric Withstanding MIL-STD-202, Method 301 PASS Grayhill Inc. 1-98 90HBW08PT Dielectric Withstanding MIL-STD-202, Method 301 PASS Grayhill Inc. Test Date 12/03/13 To 02/24/2014 12/03/13 To 02/24/2014 12/03/13 To 02/24/2014 12/03/13 To 02/24/2014 17 of 37 OPS Form #333, Rev A 11/12/12 Report SM04-17 Rev. A 8.0 MECHANICAL LIFE TEST Test Specification Mechanical Life Test MIL-STD-83504/12 8.1. DUT Part Number 90B08ST 90B05ST 90B10ST DUT Serial Number 1-20 1-20 1-20 Test Location Grayhill Inc. Test Date 01/31/2014 To 02/07/2014 PURPOSE The purpose of this test is to validate the manufacturing process in its ability to produce a product capable of withstanding the effects of shipping, handling, installation, and operational shock. The potential product issue modes and effects detected in this test are: • • • 8.2. Housing cracks Product/component breakage Inadvertent activation TEST SETUP DETAILS 1. 2. 3. 4. 5. Perform initial Functional Test. Visual Inspection of DUTs is to be performed before and after testing. Mount DUT on test fixture. Set Tester speed to achieve 10 cycles per minute for a total of 2000 cycles. Perform dielectric and contact resistance testing. Table 15 – Equipment List Equipment ID GT-532 GT-141 GT-554 GT-13 Equipment Type Accelerometer Mechanical Shock Table Power supply Multimeter Model Number M-350A04 M-RAD 1616(100)PA-MP GWinstek 87III Manufacturer PCB Piezotronics MRAD GPS-3030DD Fluke Calibration Due Date 04-2014 verified by controller’s software & GT-534 Verified with GT-13 5-2014 Table 16 – Test Conditions Test Condition Quantity Test Voltage Test current Total Actuations Actuator Speed Temperature Relative Humidity Units DUT Vdc mA Actuations CPM °C % Parameters 60 5 10 2000 10 24.5 27.9 18 of 37 OPS Form #333, Rev A 11/12/12 Report SM04-17 Rev. A 8.3. TEST SETUP PHOTOS Figure 9 – Mechanical Life Test Setup 8.4. ACCEPTANCE CRITERIA DUT should be electrically and mechanically operative with no evidence of broken, deformed, displaced, or loosened parts. The contact resistance shall not exceed 100 milliohms. The dielectric withstand voltage shall be no arcing, flashover, breakdown of insulation, or damage, and the leakage current shall be no greater than 100 microamps. 8.5. TEST RESULTS After completing testing there was no sign of broken, deformed, displaced or loosened parts. The contact resistance did not exceed 100 milliohms and the leakage current was not greater than 100 micro amps. Table 17 – Test Results DUT 1-20 1-20 1-20 Part Number 90B08ST 90B05ST 90B10ST Test Mechanical Life Mechanical Life Mechanical Life Specification MIL-STD-83504/12 MIL-STD-83504/12 MIL-STD-83504/12 Pass PASS PASS PASS Test Date 01/31/2014 02/07/2014 02/07/2014 19 of 37 OPS Form #333, Rev A 11/12/12 Report SM04-17 Rev. A 9.0 OPERATING FORCE Test Specification Operating Force PS90 9.1. DUT Part Number 90B08ST 90B05ST 90B10ST DUT Serial Number 1-20 1-20 1-20 Test Location Test Date Grayhill Inc. 02/27/2014 PURPOSE To verify the value of force needed to actuate the DUT from open to close and close to open. 9.2. TEST SETUP DETAILS 1. Mount DUT onto test fixture 2. At approximately a 45° angle apply compressive force to switch to activate from open to close and close to open. 3. Record data Table 18 – Equipment List Equipment ID LT-05 PAL- 13 Equipment Type Dip switch holder Digital Force Gauge Model Number NA 143986 Manufacturer Grayhill IMADA Calibration Due Date N/A 11-2014 Table 19 – Test Conditions Test Condition Units Parameters Quantity Points of measurements Temperature Min force Max. force Humidity DUT 60 close to open/ open to close 27.2 1 32 12.6 °C oz oz %RH 20 of 37 OPS Form #333, Rev A 11/12/12 Report SM04-17 Rev. A 9.3. TEST SETUP PHOTOS Figure 10 – Test setup 9.4. ACCEPTANCE CRITERIA When switches are tested using a suitable means, the value of force to actuate the switch from open to close and close to open shall be 1 ounces minimum and 32 ounces maximum after mechanical life . 9.5. TEST RESULTS All Switches actuation force did not exceed the maximum of 32 ounces. Table 20 – Test Results DUT 1-20 1-20 1-20 Part Number 90B08ST 90B05ST 90B10ST Specification PS90 PS90 PS90 Pass PASS PASS PASS Test Location Grayhill Inc. Grayhill Inc. Grayhill Inc. Test Date 02/27/2014 02/27/2014 02/27/2014 21 of 37 OPS Form #333, Rev A 11/12/12 Report SM04-17 Rev. A 10.0 MOISTURE RESISTANCE Test Specification Moisture Resistance MIL-STD-202, METHOD 106G DUT Part Number DUT Serial Number Test Location Test Date 02/19/2014 90HBW08PT 68-87 Grayhill Inc. To 03/02/2014 10.1. PURPOSE The moisture resistance test is performed for the purpose of evaluating, in an accelerated manner, the resistance of component parts and constituent materials to the deteriorative effects of the high-humidity and heat conditions typical of tropical environments. Most tropical degradation results directly or indirectly from absorption of moisture vapor and films by vulnerable insulating materials, and from surface wetting of metals and insulation. These phenomena produce many types of deterioration, including corrosion of metals, physical distortion and decomposition of organic materials, leaching out and spending of constituents of materials; and detrimental changes in electrical properties. This test has proven reliable for indicating those parts, which are unsuited for tropical field use. 10.2. TEST SETUP DETAILS 1. While running the test specimen should follow MIL-STD-202G and test condition table. 2. Visual inspection of the unit is to be performed before and after testing. 3. Mounting: Switches shall be mounted on a corrosion-resistant metal panel with the shaft in a horizontal position. 4. At the end of the drying period, dielectric-withstanding voltage shall again be measured as specified in 4.8.12, unless otherwise specified. 5. Examinations during final measurement and after test: Switches shall be examined for evidence of corrosion, breaking, cracking, or spalling. 6. Within 24 hours after the test, switches shall be examined for evidence of corrosion, breaking, cracking, spalling, or loosening of terminals. 7. Perform Insulation Resistance and Dielectric Withstanding Voltage after completion of test. Table 21 – Equipment List Equipment ID Equipment Type Model Number Manufacturer Calibration Due Date GT-1006 Temperature Chamber SMS-8-3800 Thermotron 07-2014 Table 22 – Test Conditions Test Condition Quantity Duration Cycles Operational Mode Temperature Humidity Units Parameters DUT Hours 20 24 11 unpowered 26.6 28.5 °C %RH 22 of 37 OPS Form #333, Rev A 11/12/12 Report SM04-17 Rev. A 10.3. TEST SETUP PHOTOS Figure 11 – Test setup 10.4. ACCEPTANCE CRITERIA There shall be no evidence of corrosion and the insulation resistance shall be no less than 10 Megaohms. At the end of the drying period the insulation resistance shall no less than 5,000 megaohms 10.5. TEST RESULTS After testing there was no signs of corrosion and the insulation resistance were greater than 10 Megaohms and after drying period IR was not less than 5000 Megaohm Table 23 – Test Results DUT Specification Pass Test Location 68-87 MIL-STD-202, METHOD 106G PASS Grayhill Inc. Test Date 02/19/2014 To 03/03/2014 23 of 37 OPS Form #333, Rev A 11/12/12 Report SM04-17 Rev. A 11.0 RESISTANCE TO REFLOW SOLDER PROCESSING Test Resistance to Reflow Solder Processing Specification PS90—90 series product specification DUT Part Number DUT Serial Number Test Location Test Date 90HBW08PT 90HBW10PT 11-31, 43-63,98-107 1-10 Grayhill Inc. 12/10/2013 11.1. PURPOSE To determine whether wires and other components can withstand the effects of heat which they will be subjected during the soldering process, (solder iron, solder wave, solder reflow or solder dip). 11.2. TEST SETUP DETAILS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Visual inspection DUT should be mounted on mounting board Set oven to test setup profile shown in figure 12 Allow oven to stabilize to temperature profile Place DUT onto conveyor belt DUT should be visually examined after process Take (20) twenty DUT and record CR Take the other (20) DUT and take them for process seal testing Allow DUT to soak in process seal for a minimum of 20 seconds. Record data Table 24 – Equipment List Equipment ID 16-1749-62H Equipment Type Solder Reflow Oven Model Number Isotherm 500 Manufacturer Vitronics Calibration Due Date 08-2014 Table 25 – Test Conditions Test Condition Units Parameters Quantity Duration Solder Temperature Temperature Humidity DUT Min °C °C %RH 40 7 270 23.7 17.3 24 of 37 OPS Form #333, Rev A 11/12/12 Report SM04-17 Rev. A 11.3. TEST SETUP PHOTOS Figure 12 – Profile 11.4. ACCEPTANCE CRITERIA There should be no evidence of physical or electrical damage. Contact Resistance shall not be more than 50% of initial. When tested for process there shall not be no continuous streams of large bubbles for more than 20 seconds. 11.5. TEST RESULTS All DUT showed no evidence of physical or electrical damage, with the exception of DUT 26 & 27 which failed reflow testing due to lifting of seal on one end of switch after Reflow testing. A retest was done due to failures on an additional twenty (20) switches which all passed and showed no evidence of physical or electrical damage. Table 26 – Test Results DUT Test Specification Pass Test Location Test Date 11 - 63 Retest Reflow Oven Reflow Oven PS90 PS90 (2) failed PASS Grayhill Inc. Grayhill Inc 12/10/2013 03/11/2014 Note: DUT 26 & 27 had lifting of seals after oven reflow testing 25 of 37 OPS Form #333, Rev A 11/12/12 Report SM04-17 Rev. A Figure 13 – Test results Figure 14 – Retest Results 26 of 37 OPS Form #333, Rev A 11/12/12 Report SM04-17 Rev. A 12.0 PROCESS SEAL Test Specification Process Seal MIL-STD-202, Method 112 DUT Part Number DUT Serial Number Test Location 90HBW08PT 90B08ST 11-43 21-30 Grayhill Inc. Test Date 12/10/2013 To 01/13/2014 12.1. PURPOSE The purpose of this test is to determine the effectiveness of the seal in a component part which has an internal cavity which is either evacuated or contains air or gas. A defeat in any portion of the surface area of a seal part can permit entrance of damaging containments which will reduce its effective life. 12.2. TEST SETUP DETAILS 1. 2. 3. 4. 5. 6. 7. 8. Visual inspection Mount DUT onto to fixture to hold them in fluid Allow fluid to reach a temperature of 125 °C ± 5°C Immerse DUT into fluid to a minimum depth of 2 inches below the surface Observe the DUT against a dull non-reflective black background through a magnifier Observe DUT from instant of immersion until 30 seconds after immersion Leakers are identified by a stream of large bubbles or a single bubble Record results Table 27 – Equipment List Equipment ID Equipment Type Model Number GT- Heat fluid container NA Manufacturer Trio Tech International Calibration Due Date N/A Table 28 – Test Conditions Test Condition Quantity Duration Temperature Humidity Units Parameters DUT seconds °C %RH 25 30 27.2 12.6 27 of 37 OPS Form #333, Rev A 11/12/12 Report SM04-17 Rev. A 12.3. TEST SETUP PHOTOS Figure 15 – Test setup 12.4. ACCEPTANCE CRITERIA When DUT are tested as specified in MIL-STD-202, Method 112, there shall be no steady stream of large bubbles continuously coming from the switch. 12.5. TEST RESULTS All DUT passed process seal testing acceptance criteria. Table 29 – Test Results DUT Part Number 11-43 90HBW08PT 21-30 90B08ST Specification PS90 MIL-STD-202, Method112 PS90 MIL-STD-202, Method112 Pass Test Location Test Date PASS Grayhill Inc. 12/10/2013 PASS Grayhill Inc. 01/13/2014 28 of 37 OPS Form #333, Rev A 11/12/12 Report SM04-17 Rev. A 13.0 MECHANICAL SHOCK Test Specification DUT Part Number DUT Serial Number Test Location MIL-STD-202, Method 202 90HBW08PT 88-97 Grayhill Inc. MIL-STD-202, Method 313 Mechanical Shock Test Date 02/25/2014 13.1. PURPOSE The purpose of this test is to validate the manufacturing process in its ability to produce a product capable of withstanding the effects of shipping, handling, installation, and operational shock. The potential product issue modes and effects detected in this test are: • • • Housing cracks Product/component breakage Inadvertent activation 13.2. TEST SETUP DETAILS 1. 2. 3. 4. 5. 6. 7. 8. Visual Inspection of the DUT is to be performed before and after testing. Verify specified test conditions table with test fixture on test table. Place product in a holding fixture in specified orientation. Attach connector(s) and tie down wire harness at appropriate lengths, if required. Monitor DUT outputs, using GT-68 chatter box. Test product for specified shocks/axis. Repeat until all DUT have completed their total shocks/unit. Perform the Visual Examination and Functional Check after the test. Table 30 – Equipment List Equipment ID GT-532 Equipment Type Accelerometer Model Number M-350A04 Manufacturer PCB Piezotronics GT-141 Mechanical Shock Table Chatter box M-RAD 1616(100)PAMP NA MRAD GT-68 NA Calibration Due Date 04-2014 Calibration at use (verified by controller’s software & Accelerometer GT-534) 6-2014 Table 31 – Test Conditions Test Condition Quantity Operational Mode Pulse Type Acceleration Pulse duration Direction Units DUT G msec. Parameters 10 Unpowered Half Sine 1000 0.5 3 Orthogonal Planes and Upside down 29 of 37 OPS Form #333, Rev A 11/12/12 Report SM04-17 Rev. A 13.3. TEST SETUP PHOTOS Figure 16 – Test Profile Figure 17 – Test setup 13.4. ACCEPTANCE CRITERIA When switches are tested as specified in MIL-STD-202, Method 213, with all contacts continuously monitored in accordance with method 310 of MIL-STd-202. There shall be no opening of closed contacts or closing of open contacts in excess of 10 microseconds. Contact resistance shall be 100 milliohms maximum after life testing. 13.5. TEST RESULTS After Mechanical shock testing there were no openings of closed contacts or closed contacts in excess of 10 microseconds and contact resistance did not exceed 100 milliohms Table 32 – Test Results DUT 88-97 Test Mechanical Shock Specification MIL-STD-202, Method 213 Pass PASS Test Location Grayhill Inc. Test Date 02/24/2014 30 of 37 OPS Form #333, Rev A 11/12/12 Report SM04-17 Rev. A 14.0 VIBRATION RESISTANCE Test Specification DUT Part Number DUT Serial Number Test Location Test Date Vibration Resistance MIL-STD-202, Method 204 MIL-STD-202, Method 310 90HBW08PT 88-97 Grayhill Inc. 03/03/2014 To 03/06/2014 14.1. PURPOSE The vibration test is performed for the purpose of determining the effect on component parts of vibration in the frequency ranges of 10 to 500 hertz (Hz), 10 to 2,000 Hz or 10 to 3,000 Hz, as may be encountered in aircraft, missiles, and tanks. The choice of test condition A, B, C, D, E, F, G, or H should be based on the frequency range and the vibration amplitude dictated by the applications of the component under consideration, and the state of the component part in relation to resistance-to-vibration damage. 14.2. TEST SETUP DETAILS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Visual Inspection of the DUT is to be performed before and after testing Attach characterization sample(s) to the test fixture on the test table in specified orientation. Characterize set-up conditions. Attach DUT in specified orientation. Attach connector(s) and tie down wire harness(es) at appropriate lengths, if required. Power and monitor DUT output. Apply vibration, temperature and voltage per specified levels and verify operation, if required. Vibrate the DUT for specified duration. Subject DUT to conditions in Test Checkpoint Table. Repeat steps D thru I until all DUT have been tested for their total duration. Perform the Visual Examination and Functional Check after the test. Table 33 – Equipment List Equipment ID Equipment Type Model Number Manufacturer Calibration Due Date GT-354 GT-353 Shaker Amp Shaker Table SA-30 US-11000VH/17-50 Dynamic Solutions Dynamic Solutions Not Required Not Required Table 34 – Test Conditions Test Condition Quantity Duration Operational Mode Applicable Axes Acceleration Level(s) Lower Limit Frequency Upper Limit Frequency Mating Connector / Harness Attached Pass/Fail Criteria Units Parameters DUT Hours 10 4 Unpowered Longitudinal, Transverse, and Vertical 15 10 2000 Yes See below 3 G Hz Hz Y/N 31 of 37 OPS Form #333, Rev A 11/12/12 Report SM04-17 Rev. A 14.3. TEST SETUP PHOTOS FIGURE 18 – TEST SETUP Figure 19 – Test profile 14.4. ACCEPTANCE CRITERIA When switches are tested as specified in MIL-STD-202 Method 204, there should be no opening of closed contacts or closing of open contacts in excess of 10 microseconds and there shall be no evidence of broken, loose, deformed or displaced parts. 32 of 37 OPS Form #333, Rev A 11/12/12 Report SM04-17 Rev. A 14.5. TEST RESULTS After completing testing there weren’t any closing of open contacts or opening of closed contacts and no evidence was found of broken, loose or displaced parts. Table 35 – Test Results DUT Test Specification Pass Test Location 88-97 Resistance to vibration MIL-STD-202, Method 204B PASS Grayhill Inc. Test Date 03/03/2014 To 03/06/2014 33 of 37 OPS Form #333, Rev A 11/12/12 Report SM04-17 Rev. A 15.0 TERMINAL STRENGTH Test Terminal Strength Specification MIL-STD-202G Method 211A DUT Part Number DUT Serial Number Test Location Test Date 90B08ST 21-30 Grayhill Inc. 01/13/2014 15.1. PURPOSE This test is performed to determine whether the design of the terminals and their method of attachment can withstand one or more of the applicable mechanical stresses to which they will be subjected during installation or disassembly in equipment. These stresses must be withstood by the component part without sustaining damage, which would affect either the utility of the terminals or the operation of the component part itself. The forces applied consist of direct axial, radial or tension pulls, twist, bending torsion, and the torque exerted by the application of nuts or screws on threaded terminals. 15.2. TEST SETUP DETAILS 1. 2. 3. 4. 5. After completing Process seal Mount DUT in a metal plate using the specified maximum mounting torque. Apply a tensile force (5Lbs) in the direction of the axis of the cable or terminal. Perform visual check. Repeat steps until all DUT are tested Table 36 – Equipment List Equipment ID Equipment Type Model Number Manufacturer Calibration Due Date GT-230 GT-132 Push / Pull Tester Force Gauge UTSM MG 500 Chatillon MARK - 10 NA Table 37 – Test Conditions Test Condition Quantity Operational Mode Temperature Humidity Units Parameters DUT 10 unpowered 25.6 19.5 °C %RH 34 of 37 OPS Form #333, Rev A 11/12/12 Report SM04-17 Rev. A 15.3. TEST SETUP PHOTOS Figure 20 – Test setup 15.4. ACCEPTANCE CRITERIA There shall be no evidence of mechanical distortion, cracking of the switch body, breaking of the seal or changes in the electrical characteristics 15.5. TEST RESULTS All DUT showed no sign of distortion, cracking of the switch body or breaking of the seal after 5lbs of tensile force was applied. Table 38 – Test Results DUT 21-30 Test Terminal Strength Specification MIL-STD-202G Pass PASS Test Location Grayhill Inc. Test Date 01/13/2014 35 of 37 OPS Form #333, Rev A 11/12/12 Report SM04-17 Rev. A 16.0 THERMAL AGING TEST Test Specification Thermal Aging MIL-STD-202, METHOD 108A DUT Part Number DUT Serial Number 90HBW08PT Test Location 1 — 10 Grayhill Inc. Test Date 12/2/2013 To 12/27/2013 16.1. PURPOSE This is conducted for the purposes of determining the effects on electrical and mechanical characteristics of a part, resulting from exposure of the part to an elevated ambient temperature for a specified length of time, while the part is performing its operational function. Evidence of deterioration resulting from this test can at times be determined by visual examination; however, the effects may be more readily ascertained by measurements or test prior to, during, or after exposure. 16.2. TEST SETUP DETAILS 1. Visual examination of the DUT with special attention to stress areas such as corners of molded housing and document the results. 2. Take picture of the DUT. 3. Set Temperature Chamber as specified in the test conditions. 4. Maintain the test temperature for a period as specified in the test plan. 5. Adjust Temperature Chamber to maintain standard ambient, until the DUT has achieved temperature stabilization. 6. Conduct a complete visual examination of the DUT and document the results. 7. Compare these data with the initial visual examination. 8. Perform contact resistance after 500hrs and 100hrs. Table 39 – Equipment List Equipment ID GT-92 Equipment Type Temperature chamber Model Number 752-02-10V Manufacturer Tenny Environmental Calibration Due Date 07-2014 Table 40 – Test Conditions Test Condition Quantity Duration Operational Mode Test Temperature Temperature Humidity Units Parameters DUT Hours 10 1000 Unpowered 125 26.1 17.4 °C °C %RH 36 of 37 OPS Form #333, Rev A 11/12/12 Report SM04-17 Rev. A 16.3. TEST SETUP PHOTOS Figure 21 – Test Setup 16.4. ACCEPTANCE CRITERIA DUT should be electrically and mechanically operative and the contact resistance shall not change by more than 50% over the duration of the test. 16.5. TEST RESULTS Contact Resistance did not change by more than 50% and all switches were electrically and mechanically operative. Table 41 – Test Results DUT Test 1—10 Thermal Aging Specification MIL-STD-202, METHOD 108A Pass Test Location Test Date PASS Grayhill Inc. 12/27/2013 37 of 37 OPS Form #333, Rev A 11/12/12 Report SM04-17 Rev. A