Project Number: Design Qualification Test Report Requested by: Travis Newton Tracking Code: 125343_Report_Rev_1 Date: 5/18/2012 Part #: RCU-G-02.00-AMS-BC\ RPBU-01-S-A-VT-LC Product Rev: N/A Lot #: N/A Tech: Aaron Mckim Part description: RCU\RPBU Test Start: 07/18/2011 Eng: Eric Mings Qty to test: 30 Test Completed: 08/15/2011 DESIGN QUALIFICATION TEST REPORT RCU\RPBU RCU-G-02.00-AMS-BC\ RPBU-01-S-A-VT-LC Page 1 of 35 Tracking Code: 125343_Report_Rev_1 Part #: RCU-G-02.00-AMS-BC\ RPBU-01-S-A-VT-LC Part description: RCU\RPBU CERTIFICATION All instruments and measuring equipment were calibrated to National Institute for Standards and Technology (NIST) traceable standards according to IS0 10012-l and ANSI/NCSL 2540-1, as applicable. All contents contained herein are the property of Samtec. No portion of this report, in part or in full shall be reproduced without prior written approval of Samtec. SCOPE To perform the following tests: Design Qualification test. Please see test plan. APPLICABLE DOCUMENTS Standards: EIA Publication 364 TEST SAMPLES AND PREPARATION 1) All materials were manufactured in accordance with the applicable product specification. 2) All test samples were identified and encoded to maintain traceability throughout the test sequences. 3) After soldering, the parts to be used for LLCR and DWV/IR testing were cleaned according to TLWI-0001. 4) Either an automated cleaning procedure or an ultrasonic cleaning procedure may be used. 5) The automated procedure is used with aqueous compatible soldering materials. 6) Parts not intended for testing LLCR and DWV/IR are visually inspected and cleaned if necessary. 7) Any additional preparation will be noted in the individual test sequences. 8) Solder Information: Lead Free 9) Re-Flow Time/Temp: See accompanying profile. 10) Samtec Test PCBs used: PCB-102608-TST-XX\ PCB-102609-TST-XX Page 2 of 35 Tracking Code: 125343_Report_Rev_1 Part #: RCU-G-02.00-AMS-BC\ RPBU-01-S-A-VT-LC Part description: RCU\RPBU TYPICAL OVEN PROFILE (Soldering Parts to Test Boards) Page 3 of 35 Tracking Code: 125343_Report_Rev_1 Part #: RCU-G-02.00-AMS-BC\ RPBU-01-S-A-VT-LC Part description: RCU\RPBU FLOWCHARTS Gas Tight TEST STEP 01 02 03 GROUP A1 64 Points LLCR-1 Gas Tight LLCR-2 Gas Tight = EIA-364-36A LLCR = EIA-364-23, LLCR 20 mV Max, 100 mA Max Use Keithley 580 or 3706 in 4 wire dry circuit mode Page 4 of 35 Tracking Code: 125343_Report_Rev_1 Part #: RCU-G-02.00-AMS-BC\ RPBU-01-S-A-VT-LC Part description: RCU\RPBU FLOWCHARTS Continued Durability/Mating/Unmating/Gaps TEST GROUP B1 STEP 8 Boards (largest position submitted) 01 Contact Gaps 02 LLCR-1 03 Forces - Mating / Unmating 04 25 Cycles 05 Forces - Mating / Unmating 06 25 Cycles (50 Total) 07 Forces - Mating / Unmating 08 25 Cycles (75 Total) 09 Forces - Mating / Unmating 10 25 Cycles (100 Total) 11 Forces - Mating / Unmating 12 Clean w/Compressed Air 13 Contact Gaps 14 LLCR-2 15 Thermal Shock (Mated and Undisturbed) 16 LLCR-3 17 Cyclic Humidity (Mated and Undisturbed) 18 LLCR-4 19 Forces - Mating / Unmating Thermal Shock = EIA-364-32, Table II, Test Condition I: o o -55 C to +80 C 1/2 hour dwell, 100 cycles Humidity = EIA-364-31, Test Condition B (240 Hours) and Method III (+25°C to +65°C @ 90% RH to 98% RH) ambient pre-condition and delete steps 7a and 7b Mating / Unmating Forces = EIA-364-13 Contact Gaps / Height - No standard method. Usually measured optically. Gaps to be taken on a minimum of 20% of each part tested LLCR = EIA-364-23, LLCR 20 mV Max, 100 mA Max Use Keithley 580 or 3706 in 4 wire dry circuit mode Page 5 of 35 Tracking Code: 125343_Report_Rev_1 Part #: RCU-G-02.00-AMS-BC\ RPBU-01-S-A-VT-LC Part description: RCU\RPBU FLOWCHARTS Continued IR & DWV TEST GROUP A1 STEP 2 Mated Sets 01 GROUP A2 2 Unmated of Part # Being Tested GROUP A3 GROUP B1 2 Unmated of Mating Part # 2 Mated Sets Break Down Pin-to-Pin Break Down Pin-to-Pin Break Down Pin-to-Pin Pin-to-Pin DWV/Break Down Voltage DWV/Break Down Voltage DWV/Break Down Voltage IR & DWV at test voltage (on both mated sets and on each connector unmated) 02 Thermal Shock (Mated and Undisturbed) 03 IR & DWV at test voltage (on both mated sets and on each connector unmated) 04 Cyclic Humidity (Mated and Undisturbed) 05 IR & DWV at test voltage (on both mated sets and on each connector unmated) TEST GROUP A1 STEP 2 Mated Sets 01 GROUP A2 2 Unmated of Part # Being Tested GROUP A3 GROUP B1 2 Unmated of Mating Part # 2 Mated Sets Break Down Pin-to-Ground Break Down Pin-to-Ground Break Down Pin-to-Ground Pin-to-Ground DWV/Break Down Voltage DWV/Break Down Voltage DWV/Break Down Voltage IR & DWV at test voltage (on both mated sets and on each connector unmated) 02 Thermal Shock (Mated and Undisturbed) 03 IR & DWV at test voltage (on both mated sets and on each connector unmated) 04 Cyclic Humidity (Mated and Undisturbed) 05 IR & DWV at test voltage (on both mated sets and on each connector unmated) DWV on Group B1 to be performed at Test Voltage DWV test voltage is equal to 75% of the lowest break down voltage from Groups A1, A2 or A3 Thermal Shock = EIA-364-32, Table II, Test Condition I: -55oC to +85oC 1/2 hour dwell, 100 cycles Humidity = EIA-364-31, Test Condition B (240 Hours) and Method III (+25°C to +65°C @ 90% RH to 98% RH) ambient pre-condition and delete steps 7a and 7b IR = EIA-364-21 DWV = EIA-364-20, Test Condition 1 Page 6 of 35 Tracking Code: 125343_Report_Rev_1 Part #: RCU-G-02.00-AMS-BC\ RPBU-01-S-A-VT-LC Part description: RCU\RPBU FLOWCHARTS Continued Current Carrying Capacity - USB 3.0 TEST STEP GROUP A1 3 Mated Assemblies All Contacts Powered 01 * CCC * A current of 1.8 A shall be applied to VBU pins and its corresponding GND pin (pin 1 and pin 4 of the USB 3.0 Standard –A and Standard -B connectors). Additionally, a minimum of 0.25 A shall be applied to all the other contacts. When the current is applied to the contacts, the delta temperature shall not exceed +30 degree Celsius at any point on the USB 3.0 connectors under test, when measured at ambient temperature of 25 degree Celsius. IP67 Dust & Water TEST STEP GROUP A1 6 Mated Connectors 01 02 Dust Test Check for Dust GROUP B1 6 Connectors (Cable Dust Cover) Dust Test Check for Dust Dust/Water Testing = Per CEI/IEC 60529 Code IP67 Page 7 of 35 GROUP C1 6 Connectors (Mating Part Dust Cover) Dust Test Check for Dust Tracking Code: 125343_Report_Rev_1 Part #: RCU-G-02.00-AMS-BC\ RPBU-01-S-A-VT-LC Part description: RCU\RPBU IP68 Dust & Water TEST STEP 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 GROUP G1 3 Mated Connectors For Each Depth Tested (27 Total Mated Connectors) 2M for 30 Minutes Check for Water 3M for 30 Minutes Check for Water 4M for 30 Minutes Check for Water 5M for 30 Minutes Check for Water 6M for 30 Minutes Check for Water 7M for 30 Minutes Check for Water 8M for 30 Minutes Check for Water 9M for 30 Minutes Check for Water 10M for 30 Minutes Check for Water Dust/Water Testing = Per CEI/IEC 60529 Code IP68 For this test you have to use the pressure chamber New parts should be used for each depth tested Stop testing once parts fail * It is not necessary to perform the dust portion of this test if IP67 testing has been performed Page 8 of 35 Tracking Code: 125343_Report_Rev_1 Part #: RCU-G-02.00-AMS-BC\ RPBU-01-S-A-VT-LC Part description: RCU\RPBU ATTRIBUTE DEFINITIONS The following is a brief, simplified description of attributes. THERMAL SHOCK: 1) 2) 3) 4) 5) 6) EIA-364-32, Thermal Shock (Temperature Cycling) Test Procedure for Electrical Connectors. Test Condition 1: -55°C to +85°C Test Time: ½ hour dwell at each temperature extreme Number of Cycles: 100 All test samples are pre-conditioned at ambient. All test samples are exposed to environmental stressing in the mated condition. HUMIDITY: 1) 2) 3) 4) 5) Reference document: EIA-364-31, Humidity Test Procedure for Electrical Connectors. Test Condition B, 240 Hours. Method III, +25° C to + 65° C, 90% to 98% Relative Humidity excluding sub-cycles 7a and 7b. All samples are pre-conditioned at ambient. All test samples are exposed to environmental stressing in the mated condition. MATING/UNMATING: 1) Reference document: EIA-364-13, Mating and Unmating Forces Test Procedure for Electrical Connectors. 2) The full insertion position was to within 0.003” to 0.004” of the plug bottoming out in the receptacle to prevent damage to the system under test. 3) One of the mating parts is secured to a floating X-Y table to prevent damage during cycling. LLCR: 1) EIA-364-23, Low Level Contact Resistance Test Procedure for Electrical Connectors and Sockets. 2) A computer program, LLCR 221.exe, ensures repeatability for data acquisition. 3) The following guidelines are used to categorize the changes in LLCR as a result from stressing a. <= +5.0 mOhms: ----------------------------- Stable b. +5.1 to +10.0 mOhms: ---------------------- Minor c. +10.1 to +15.0 mOhms: -------------------- Acceptable d. +15.1 to +50.0 mOhms: -------------------- Marginal e. +50.1 to +2000 mOhms: ------------------- Unstable f. >+2000 mOhms: ----------------------------- Open Failure Page 9 of 35 Tracking Code: 125343_Report_Rev_1 Part #: RCU-G-02.00-AMS-BC\ RPBU-01-S-A-VT-LC Part description: RCU\RPBU ATTRIBUTE DEFINITIONS Continued The following is a brief, simplified description of attributes GAS TIGHT: 1) 2) 3) 4) To provide method for evaluating the ability of the contacting surfaces in preventing penetration of harsh vapors which might lead to oxide formation that may degrade the electrical performance of the contact system. EIA-364-23, Low Level Contact Resistance Test Procedure for Electrical Connectors and Sockets. A computer program, LLCR 221.exe, ensures repeatability for data acquisition. The following guidelines are used to categorize the changes in LLCR as a result from stressing a. <= +5.0 mOhms: ----------------------------- Stable b. +5.1 to +10.0 mOhms: ---------------------- Minor c. +10.1 to +15.0 mOhms: -------------------- Acceptable d. +15.1 to +50.0 mOhms: -------------------- Marginal e. +50.1 to +2000 mOhms: ------------------- Unstable f. >+2000 mOhms: ----------------------------- Open Failure Procedure: a. Reference document: EIA-364-36, Test Procedure for Determination of Gas-Tight Characteristics for Electrical Connectors, Sockets and/or Contact Systems. b. Test Conditions: i. Class II--- Mated pairs of contacts assembled to their plastic housings. ii. Reagent grade Nitric Acid shall be used of sufficient volume to saturate the test chamber iii. The ratio of the volume of the test chamber to the surface area of the acid shall be 10:1. iv. The chamber shall be saturated with the vapor for at least 15 minutes before samples are added. v. Exposure time, 55 to 65 minutes. vi. The samples shall be no closer to the chamber walls than 1 inches and no closer to the surface of the acid than 3 inches. vii. The samples shall be dried after exposure for a minimum of 1 hour. о viii. Drying temperature 50 C ix. The final LLCR shall be conducted within 1 hour after drying. INSULATION RESISTANCE (IR): To determine the resistance of insulation materials to leakage of current through or on the surface of these materials when a DC potential is applied. 1) PROCEDURE: a. Reference document: EIA-364-21, Insulation Resistance Test Procedure for Electrical Connectors. b. Test Conditions: i. Between Adjacent Contacts or Signal-to-Ground ii. Electrification Time 2.0 minutes iii. Test Voltage (500 VDC) corresponds to calibration settings for measuring resistances. 2) MEASUREMENTS: 3) When the specified test voltage is applied (VDC), the insulation resistance shall not be less than 1000 megohms. Page 10 of 35 Tracking Code: 125343_Report_Rev_1 Part #: RCU-G-02.00-AMS-BC\ RPBU-01-S-A-VT-LC Part description: RCU\RPBU ATTRIBUTE DEFINITIONS Continued The following is a brief, simplified description of attributes DIELECTRIC WITHSTANDING VOLTAGE (DWV): To determine if the sockets can operate at its rated voltage and withstand momentary over potentials due to switching, surges, and other similar phenomenon. Separate samples are used to evaluate the effect of environmental stresses so not to influence the readings from arcing that occurs during the measurement process. 1) PROCEDURE: a. Reference document: EIA-364-20, Withstanding Voltage Test Procedure for Electrical Connectors. b. Test Conditions: i. Between Adjacent Contacts or Signal-to-Ground ii. Barometric Test Condition 1 iii. Rate of Application 500 V/Sec iv. Test Voltage (VAC) until breakdown occurs 2) MEASUREMENTS/CALCULATIONS a. The breakdown voltage shall be measured and recorded. b. The dielectric withstanding voltage shall be recorded as 75% of the minimum breakdown voltage. c. The working voltage shall be recorded as one-third (1/3) of the dielectric withstanding voltage (onefourth of the breakdown voltage). TEMPERATURE RISE (Current Carrying Capacity, CCC): 1) EIA-364-70, Temperature Rise versus Current Test Procedure for Electrical Connectors and Sockets. And the Universal Serial Bus 3.0 Specifications 2 2) When current passes through a contact, the temperature of the contact increases as a result of I R (resistive) heating. 3) The number of contacts being investigated plays a significant part in power dissipation and therefore temperature rise. 4) The size of the temperature probe can affect the measured temperature. 5) Copper traces on PC boards will contribute to temperature rise: a. Self heating (resistive) b. Reduction in heat sink capacity affecting the heated contacts 6) Typically, neighboring contacts (in close proximity to maximize heat build up) are energized. 7) The thermocouple (or temperature measuring probe) will be positioned at a location to sense the maximum temperature in the vicinity of the heat generation area. 8) A computer program, TR 803.exe, ensures accurate stability for data acquisition. 9) Hook-up wire cross section is larger than the cross section of any connector leads/PC board traces, jumpers, etc. 10) Hook-up wire length is longer than the minimum specified in the referencing standard. Page 11 of 35 Tracking Code: 125343_Report_Rev_1 Part #: RCU-G-02.00-AMS-BC\ RPBU-01-S-A-VT-LC Part description: RCU\RPBU ATTRIBUTE DEFINITIONS Continued The following is a brief, simplified description of attributes WATER TESTING: 1) Reference document: CEI/IEC 60529 Code IP67 2) SCRES torque specification for SPN-17-01 is 12 IN-LB 3) SCPE torque specification for SCN-17-01 is 12 IN-LB DUST TESTING: 1) Reference document: CEI/IEC 60529 Code IP67 2) SCRES torque specification for SPN-17-01 is 12 IN-LB 3) SCPE torque specification for SCN-17-01 is 12 IN-LB Page 12 of 35 Tracking Code: 125343_Report_Rev_1 Part #: RCU-G-02.00-AMS-BC\ RPBU-01-S-A-VT-LC Part description: RCU\RPBU RESULTS CCC CCC Signal Pins…………………………When tested per the USB 3.0 spec we observed a 2.0 ° temp rise at 1.8 Amps CCC Power Pins…………………………When tested per the USB 3.0 spec we observed an 2.2° temp rise at 1.8 Amps Mating – Unmating Forces Initial o Mating Min --------------------------------------- 9.25 Lbs Max--------------------------------------14.10 Lbs o Unmating Min --------------------------------------- 4.46 Lbs Max--------------------------------------- 5.92 Lbs After 25 Cycles o Mating Min --------------------------------------- 7.92 Lbs Max--------------------------------------13.14 Lbs o Unmating Min --------------------------------------- 4.22 Lbs Max--------------------------------------- 5.29 Lbs After 50 Cycles o Mating Min --------------------------------------- 8.20 Lbs Max--------------------------------------13.24 Lbs o Unmating Min --------------------------------------- 4.22 Lbs Max--------------------------------------- 5.38 Lbs After 75 Cycles o Mating Min --------------------------------------- 8.67 Lbs Max--------------------------------------13.55 Lbs o Unmating Min --------------------------------------- 4.31 Lbs Max--------------------------------------- 5.75 Lbs After 100 Cycles o Mating Min --------------------------------------- 9.11 Lbs Max--------------------------------------13.93 Lbs o Unmating Min --------------------------------------- 4.42 Lbs Max--------------------------------------- 5.96 Lbs After Humidity o Mating Min --------------------------------------- 8.51 Lbs Max--------------------------------------13.45 Lbs o Unmating Min --------------------------------------- 3.72 Lbs Max--------------------------------------- 5.57 Lbs Page 13 of 35 Tracking Code: 125343_Report_Rev_1 Part #: RCU-G-02.00-AMS-BC\ RPBU-01-S-A-VT-LC Part description: RCU\RPBU RESULTS Continued Insulation Resistance minimums, IR Pin to Pin Initial o Mated ---------------------------------------------- 100000Meg Ω ------------------------- Pass o Unmated ------------------------------------------ 100000Meg Ω ------------------------ Pass Thermal o Mated ---------------------------------------------- 100000Meg Ω ------------------------ Pass o Unmated ------------------------------------------ 100000Meg Ω ------------------------ Pass Humidity o Mated ------------------------------------------------- 2000Meg Ω ------------------------ Pass o Unmated --------------------------------------------- 2600Meg Ω ------------------------ Pass Pin to Ground Initial o Mated ---------------------------------------------- 100000Meg Ω ------------------------- Pass o Unmated ------------------------------------------ 100000Meg Ω ------------------------ Pass Thermal o Mated ---------------------------------------------- 100000Meg Ω ------------------------ Pass o Unmated ------------------------------------------ 100000Meg Ω ------------------------ Pass Humidity o Mated ------------------------------------------------- 1700Meg Ω ------------------------ Pass o Unmated -------------------------------------------- 15000Meg Ω ------------------------ Pass Dielectric Withstanding Voltage minimums, DWV Minimums o Breakdown Voltage -------------------------------- 1200 VAC o Test Voltage ------------------------------------------- 900 VAC o Working Voltage ------------------------------------- 300 VAC Pin to Pin Initial DWV -------------------------------------------------- Passed Thermal DWV ----------------------------------------------- Passed Humidity DWV ---------------------------------------------- Passed Pin to Ground Initial DWV -------------------------------------------------- Passed Thermal DWV ----------------------------------------------- Passed Humidity DWV ---------------------------------------------- Passed Page 14 of 35 Tracking Code: 125343_Report_Rev_1 Part #: RCU-G-02.00-AMS-BC\ RPBU-01-S-A-VT-LC Part description: RCU\RPBU RESULTS Continued LLCR: Mating\Unmating Durability Group (24 points 20 AWG and 24 points 25 AWG LLCR test points) 20 AWG Initial --------------------------------------------------------------- 19.3mOhms Max Durability, 100 Cycles o <= +5.0 mOhms ------------------------------------ 24 Points ------------------------- Stable o +5.1 to +10.0 mOhms ----------------------------------- 0 Points ------------------------- Minor o +10.1 to +15.0 mOhms --------------------------------- 0 Points ------------------------- Acceptable o +15.1 to +50.0 mOhms --------------------------------- 0 Points ------------------------- Marginal o +50.1 to +2000 mOhms --------------------------------- 0 Points ------------------------- Unstable o >+2000 mOhms ------------------------------------------ 0 Points ------------------------- Open Failure Thermal o <= +5.0 mOhms ------------------------------------ 24 Points ------------------------- Stable o +5.1 to +10.0 mOhms ----------------------------------- 0 Points ------------------------- Minor o +10.1 to +15.0 mOhms --------------------------------- 0 Points ------------------------- Acceptable o +15.1 to +50.0 mOhms --------------------------------- 0 Points ------------------------- Marginal o +50.1 to +2000 mOhms --------------------------------- 0 Points ------------------------- Unstable o >+2000 mOhms ------------------------------------------ 0 Points ------------------------- Open Failure Humidity o <= +5.0 mOhms ------------------------------------ 24 Points ------------------------- Stable o +5.1 to +10.0 mOhms ----------------------------------- 0 Points ------------------------- Minor o +10.1 to +15.0 mOhms --------------------------------- 0 Points ------------------------- Acceptable o +15.1 to +50.0 mOhms --------------------------------- 0 Points ------------------------- Marginal o +50.1 to +2000 mOhms --------------------------------- 0 Points ------------------------- Unstable o >+2000 mOhms ------------------------------------------ 0 Points ------------------------- Open Failure 25 AWG Initial --------------------------------------------------------------- 30.5mOhms Max Durability, 100 Cycles o <= +5.0 mOhms ------------------------------------ 24 Points ------------------------- Stable o +5.1 to +10.0 mOhms ----------------------------------- 0 Points ------------------------- Minor o +10.1 to +15.0 mOhms --------------------------------- 0 Points ------------------------- Acceptable o +15.1 to +50.0 mOhms --------------------------------- 0 Points ------------------------- Marginal o +50.1 to +2000 mOhms --------------------------------- 0 Points ------------------------- Unstable o >+2000 mOhms ------------------------------------------ 0 Points ------------------------- Open Failure Thermal o <= +5.0 mOhms ------------------------------------ 24 Points ------------------------- Stable o +5.1 to +10.0 mOhms ----------------------------------- 0 Points ------------------------- Minor o +10.1 to +15.0 mOhms --------------------------------- 0 Points ------------------------- Acceptable o +15.1 to +50.0 mOhms --------------------------------- 0 Points ------------------------- Marginal o +50.1 to +2000 mOhms --------------------------------- 0 Points ------------------------- Unstable o >+2000 mOhms ------------------------------------------ 0 Points ------------------------- Open Failure Humidity o <= +5.0 mOhms ------------------------------------ 23 Points ------------------------- Stable o +5.1 to +10.0 mOhms ----------------------------------- 1 Points ------------------------- Minor o +10.1 to +15.0 mOhms --------------------------------- 0 Points ------------------------- Acceptable o +15.1 to +50.0 mOhms --------------------------------- 0 Points ------------------------- Marginal o +50.1 to +2000 mOhms --------------------------------- 0 Points ------------------------- Unstable o >+2000 mOhms ------------------------------------------ 0 Points ------------------------- Open Failure Page 15 of 35 Tracking Code: 125343_Report_Rev_1 Part #: RCU-G-02.00-AMS-BC\ RPBU-01-S-A-VT-LC Part description: RCU\RPBU RESULTS Continued LLCR: Gas Tight Group (48 signal and 16 ground LLCR test points) Signal Pin Initial --------------------------------------------------------------- 21.5 mOhms Max Gas-Tight o <= +5.0 mOhms ------------------------------------ 48 Points ------------------------- Stable o +5.1 to +10.0 mOhms ----------------------------------- 0 Points ------------------------- Minor o +10.1 to +15.0 mOhms --------------------------------- 0 Points ------------------------- Acceptable o +15.1 to +50.0 mOhms --------------------------------- 0 Points ------------------------- Marginal o +50.1 to +2000 mOhms --------------------------------- 0 Points ------------------------- Unstable o >+2000 mOhms ------------------------------------------ 0 Points ------------------------- Open Failure Ground Pin Initial --------------------------------------------------------------- 12.7 mOhms Max Gas-Tight o <= +5.0 mOhms ------------------------------------ 16 Points ------------------------- Stable o +5.1 to +10.0 mOhms ----------------------------------- 0 Points ------------------------- Minor o +10.1 to +15.0 mOhms --------------------------------- 0 Points ------------------------- Acceptable o +15.1 to +50.0 mOhms --------------------------------- 0 Points ------------------------- Marginal o +50.1 to +2000 mOhms --------------------------------- 0 Points ------------------------- Unstable o >+2000 mOhms ------------------------------------------ 0 Points ------------------------- Open Failure IP67 Testing (Dust) Group A1 Dust Initial (Before Exposure) No Dust Present After Exposure No Dust Present Initial (Before Exposure) No Dust Present After Exposure No Dust Present Initial (Before Exposure) No Dust Present After Exposure No Dust Present Initial (Before Exposure) No Water Present After Exposure No Water Present Group B1 Dust Group C1 Dust IPX8 Testing (Water) Group A1 (10 m) Water Page 16 of 35 Tracking Code: 125343_Report_Rev_1 Part #: RCU-G-02.00-AMS-BC\ RPBU-01-S-A-VT-LC Part description: RCU\RPBU DATA SUMMARIES MATING/UNMATING FORCE: Initial Mating Minimum Maximum Average St Dev Count After 25 cycles Unmating Mating Force (Lbs) Newtons Force (Lbs) Newtons Force (Lbs) Newtons Force (Lbs) 41.14 62.72 49.71 6.67 8 9.25 14.10 11.18 1.50 8 19.84 26.33 23.80 1.94 8 4.46 5.92 5.35 0.44 8 35.23 58.45 45.89 6.68 8 7.92 13.14 10.32 1.50 8 18.77 23.53 21.91 1.48 8 4.22 5.29 4.93 0.33 8 After 50 cycles Mating Minimum Maximum Average St Dev Count After 75 cycles Unmating Mating Force (Lbs) Newtons Force (Lbs) Newtons Force (Lbs) Newtons Force (Lbs) 36.47 58.89 48.13 6.47 8 8.20 13.24 10.82 1.46 8 18.77 23.93 22.49 1.68 8 4.22 5.38 5.06 0.38 8 38.56 60.27 50.26 6.46 8 8.67 13.55 11.30 1.45 8 19.17 25.58 23.16 1.81 8 4.31 5.75 5.21 0.41 8 After 100 cycles Maximum Average St Dev Count Unmating Newtons Mating Minimum Unmating Newtons After Humidity Unmating Mating Unmating Newtons Force (Lbs) Newtons Force (Lbs) Newtons Force (Lbs) Newtons Force (Lbs) 40.52 61.96 52.36 6.27 8 9.11 13.93 11.77 1.41 8 19.66 26.51 24.01 2.03 8 4.42 5.96 5.40 0.46 8 37.85 59.83 49.13 7.30 8 8.51 13.45 11.05 1.64 8 16.55 24.78 21.90 2.68 8 3.72 5.57 4.92 0.60 8 Page 17 of 35 Tracking Code: 125343_Report_Rev_1 Part #: RCU-G-02.00-AMS-BC\ RPBU-01-S-A-VT-LC Part description: RCU\RPBU DATA SUMMARIES Continued INSULATION RESISTANCE (IR): Pin to Pin Minimum Initial Thermal Humidity Mated RCU/RPBU 100000 100000 2000 Unmated RCU 100000 100000 2600 Unmated RPBU 100000 100000 100000 Pin to Ground Minimum Initial Thermal Humidity Mated RCU/RPBU 100000 100000 1700 Unmated RCU 100000 100000 15000 DIELECTRIC WITHSTANDING VOLTAGE (DWV): Voltage Rating Summary Minimum RCU/RPBU 1200 900 300 Break Down Voltage Test Voltage Working Voltage Pin to Pin Initial Test Voltage After Thermal Test Voltage After Humidity Test Voltage Passed Passed Passed Pin to Ground Initial Test Voltage After Thermal Test Voltage After Humidity Test Voltage Passed Passed Passed Page 18 of 35 Unmated RPBU 100000 100000 100000 Tracking Code: 125343_Report_Rev_1 Part #: RCU-G-02.00-AMS-BC\ RPBU-01-S-A-VT-LC Part description: RCU\RPBU DATA SUMMARIES Continued LLCR: Mating\Unmating Durability Group: 1) 2) 3) 4) A total of 24 points 20 AWG and 24 points 25 AWG were measured. EIA-364-23, Low Level Contact Resistance Test Procedure for Electrical Connectors and Sockets. A computer program, LLCR 221.exe, ensures repeatability for data acquisition. The following guidelines are used to categorize the changes in LLCR as a result from stressing. a. <= +5.0 mOhms: ---------------------------- Stable b. +5.1 to +10.0 mOhms: --------------------- Minor c. +10.1 to +15.0 mOhms: ------------------- Acceptable d. +15.1 to +50.0 mOhms: ------------------- Marginal e. +50.1 to +2000 mOhms ------------------- Unstable f. >+2000 mOhms: ---------------------------- Open Failure 20 AWG Date 2011-7-18 2011-7-20 2011-8-3 2011-8-15 Room Temp C 23 25 22 22 RH 39% 39% 50% 48% Name Aaron McKim Aaron McKim Aaron McKim Aaron McKim mOhm values Actual Delta Delta Delta Initial 100 Cycles Thermal Humidity Average 18.8 0.1 0.0 0.1 St. Dev. 0.3 0.2 0.2 0.2 Min 18.3 -0.3 -0.4 -0.5 Max 19.3 0.3 0.2 0.3 Count 24 24 24 24 How many samples are being tested? How many contacts are on each board? 100 Cycles Thermal Humidity Stable 24 24 24 Minor 0 0 0 Acceptable Marginal 0 0 0 0 0 0 Page 19 of 35 8 3 Unstable 0 0 0 Open 0 0 0 Tracking Code: 125343_Report_Rev_1 Part #: RCU-G-02.00-AMS-BC\ RPBU-01-S-A-VT-LC Part description: RCU\RPBU DATA SUMMARIES Continued 25 AWG Date 2011-7-18 2011-7-20 2011-8-3 2011-8-15 Room Temp C 23 25 22 22 RH 39% 39% 50% 48% Name Aaron McKim Aaron McKim Aaron McKim Aaron McKim mOhm values Actual Delta Delta Delta Initial 100 Cycles Thermal Humidity Average 28.8 0.3 -0.2 1.4 St. Dev. 0.6 0.7 0.4 1.4 Min 27.7 -2.1 -1.3 -0.9 Max 30.5 1.3 0.4 5.2 Count 24 24 24 24 How many samples are being tested? How many contacts are on each board? 100 Cycles Thermal Humidity Stable 24 24 23 Minor 0 0 1 Acceptable Marginal 0 0 0 0 0 0 Page 20 of 35 8 3 Unstable 0 0 0 Open 0 0 0 Tracking Code: 125343_Report_Rev_1 Part #: RCU-G-02.00-AMS-BC\ RPBU-01-S-A-VT-LC Part description: RCU\RPBU DATA SUMMARIES Continued GAS TIGHT: 1) 2) 3) 4) A total of 48 signal and 16 ground points were measured. EIA-364-23, Low Level Contact Resistance Test Procedure for Electrical Connectors and Sockets. A computer program, LLCR 221.exe, ensures repeatability for data acquisition. The following guidelines are used to categorize the changes in LLCR as a result from stressing. a. <= +5.0 mOhms: ----------------------------- Stable b. +5.1 to +10.0 mOhms: ---------------------- Minor c. +10.1 to +15.0 mOhms: -------------------- Acceptable d. +15.1 to +50.0 mOhms: -------------------- Marginal e. +50.1 to +2000 mOhms: ------------------- Unstable f. >+2000 mOhms: ----------------------------- Open Failure Signal Pin Date Room Temp C RH Name mOhm values Average St. Dev. Min Max Count 2011-3-21 23 48% Troy Cook Actual Initial 18.2 2.7 15.0 21.5 48 2011-3-22 23 44% Troy Cook Delta Gas Tight -0.1 0.6 -2.4 1.3 48 How many samples are being tested? How many contacts are on each board? Gas Tight Stable 48 Minor 0 Acceptable 0 Page 21 of 35 Marginal 0 8 24 Unstable 0 Open 0 Tracking Code: 125343_Report_Rev_1 Part #: RCU-G-02.00-AMS-BC\ RPBU-01-S-A-VT-LC Part description: RCU\RPBU DATA SUMMARIES Continued Ground Pin Date Room Temp C RH Name mOhm values Average St. Dev. Min Max Count 2011-3-21 23 48% Troy Cook Actual Initial 11.2 1.2 9.3 12.7 16 2011-3-22 23 44% Troy Cook Delta Gas Tight 0.1 0.8 -1.8 1.7 16 How many samples are being tested? How many contacts are on each board? Gas Tight Stable 16 Minor 0 Acceptable 0 Page 22 of 35 Marginal 0 8 24 Unstable 0 Open 0 Tracking Code: 125343_Report_Rev_1 Part #: RCU-G-02.00-AMS-BC\ RPBU-01-S-A-VT-LC Part description: RCU\RPBU DATA INSULATION RESISTANCE (IR): Initial Insulation Resistance Measured In Meg Ohms Mated X RCU/RPBU 100000 100000 Pin to Pin A Unmated B X X RCU RPBU 100000 100000 100000 100000 Mated X RCU/RPBU 100000 100000 Pin to Ground A Unmated B X X RCU RPBU 100000 100000 100000 100000 Thermal Insulation Resistance Measured In Meg Ohms Mated X RCU/RPBU 100000 100000 Pin to Pin A Unmated B X X RCU RPBU 100000 100000 100000 100000 Mated X RCU/RPBU 100000 100000 Pin to Ground A Unmated B X X RCU RPBU 100000 100000 100000 100000 Page 23 of 35 Tracking Code: 125343_Report_Rev_1 Part #: RCU-G-02.00-AMS-BC\ RPBU-01-S-A-VT-LC Part description: RCU\RPBU DATA Continued Humidity Insulation Resistance Measured In Meg Ohms Mated X RCU/RPBU 25000 2000 Pin to Pin A Unmated B X X RCU RPBU 50000 100000 2600 100000 Mated X RCU/RPBU 2500 1700 Pin to Ground A Unmated B X X RCU RPBU 50000 100000 15000 100000 Page 24 of 35 Tracking Code: 125343_Report_Rev_1 Part #: RCU-G-02.00-AMS-BC\ RPBU-01-S-A-VT-LC Part description: RCU\RPBU DATA Continued DIELECTRIC WITHSTANDING VOLTAGE (DWV): Initial Breakdown Voltage Test Voltage Until Breakdown Occurs Mated RCU/RPBU 1300 1400 Pin to Pin A Unmated B X RCU RPBU 1300 1500 1400 1700 Pin to Ground Mated A Unmated B X RCU/RPBU RCU RPBU 1300 1200 2000 1400 1400 2100 Initial DWV Test Voltage= 900 Mated RCU/RPBU 900 900 Pin to Pin A Unmated B RCU RPBU 900 900 900 900 Mated RCU/RPBU 900 900 Pin to Ground A Unmated B RCU RPBU 900 900 900 900 Page 25 of 35 Tracking Code: 125343_Report_Rev_1 Part #: RCU-G-02.00-AMS-BC\ RPBU-01-S-A-VT-LC Part description: RCU\RPBU DATA Continued DIELECTRIC WITHSTANDING VOLTAGE (DWV): Thermal Test Voltage Test Voltage= 900 Mated RCU/RPBU 900 900 Pin to Pin A Unmated B RCU RPBU 900 900 900 900 Mated RCU/RPBU 900 900 Pin to Ground A Unmated B RCU RPBU 900 900 900 900 Humidity Test Voltage Test Voltage= 900 Mated RCU/RPBU 900 900 Pin to Pin A Unmated B RCU RPBU 900 900 900 900 Mated RCU/RPBU 900 900 Pin to Ground A Unmated B RCU RPBU 900 900 900 900 Page 26 of 35 Tracking Code: 125343_Report_Rev_1 Part #: RCU-G-02.00-AMS-BC\ RPBU-01-S-A-VT-LC Part description: RCU\RPBU DATA Continued MATING/UNMATING: Mating\Unmating Durability Group Sample# Initial 25 Cycles 50 Cycles 75 Cycles 100 Cycles After Humidity Mating Unmating Mating Unmating Mating Unmating Mating Unmating Mating Unmating Mating Unmating 1 14.10 5.49 13.14 4.92 13.24 5.08 13.55 5.29 13.93 5.42 9.86 5.57 2 11.46 5.33 10.68 5.03 11.24 5.32 11.56 5.34 11.95 5.61 12.82 5.24 3 9.25 5.06 9.26 5.11 9.97 5.38 10.65 5.75 11.28 5.96 8.51 4.56 4 11.52 5.36 11.09 4.94 11.69 5.17 12.50 5.40 12.92 5.71 10.59 5.12 5 9.38 5.56 7.92 4.72 8.20 4.95 8.67 5.19 9.11 5.44 10.97 5.50 6 11.30 4.46 10.38 4.22 10.96 4.22 11.31 4.31 11.70 4.42 12.05 5.02 7 11.10 5.62 9.83 5.17 10.21 4.97 10.47 5.15 11.12 5.21 10.11 4.66 8 11.30 5.92 10.24 5.29 11.06 5.36 11.68 5.23 12.16 5.42 13.45 3.72 Page 27 of 35 Tracking Code: 125343_Report_Rev_1 Part #: RCU-G-02.00-AMS-BC\ RPBU-01-S-A-VT-LC Part description: RCU\RPBU DATA Continued LLCR: Mating\Unmating Durability Group 20 AWG 1 1 1 2 2 2 3 3 3 4 4 4 5 5 5 6 6 6 7 7 7 8 8 8 mOhm values Position P2 P5 P7 P2 P5 P7 P2 P5 P7 P2 P5 P7 P2 P5 P7 P2 P5 P7 P2 P5 P7 P2 P5 P7 Actual Initial 18.9 18.8 19.2 19.2 18.8 18.6 19.1 18.8 18.8 19.1 19.2 18.9 18.5 18.9 18.4 18.3 19.0 18.4 18.3 18.7 19.2 18.9 19.3 19.0 Delta 100 Cycles 0.3 0.2 0.3 0.3 0.0 0.2 0.2 0.3 0.3 0.1 0.2 0.1 0.0 -0.2 0.1 0.2 0.1 0.3 0.1 0.1 -0.3 -0.1 -0.3 -0.1 Delta Thermal -0.1 0.0 0.0 0.1 0.1 0.1 0.0 0.1 0.1 0.0 0.1 -0.1 -0.1 -0.4 0.1 0.1 -0.3 0.1 0.1 0.2 -0.4 -0.2 -0.3 -0.1 Delta Humidity 0.3 0.3 -0.2 0.3 0.3 0.2 0.1 0.3 0.3 0.2 0.1 0.2 0.2 -0.3 0.2 0.1 -0.2 0.3 0.1 0.0 -0.4 -0.2 -0.5 0.1 1 1 1 2 2 2 3 3 3 4 4 4 mOhm values Position P3 P4 P8 P3 P4 P8 P3 P4 P8 P3 P4 P8 Actual Initial 28.3 29.1 28.5 28.7 29.4 29.2 28.2 28.3 28.9 29.8 28.9 29.0 Delta 100 Cycles 0.1 0.4 0.3 0.1 0.4 1.3 0.4 0.4 0.7 0.7 0.4 1.3 Delta Thermal -0.3 -0.1 -0.1 -0.6 -0.2 -0.2 -0.1 0.1 -0.2 -0.8 -0.2 0.1 Delta Humidity 0.2 1.6 0.4 2.2 0.8 1.3 0.8 0.9 2.6 2.8 0.2 5.2 Board 25 AWG Board Page 28 of 35 Tracking Code: 125343_Report_Rev_1 5 5 5 6 6 6 7 7 7 8 8 8 P3 P4 P8 P3 P4 P8 P3 P4 P8 P3 P4 P8 Part #: RCU-G-02.00-AMS-BC\ RPBU-01-S-A-VT-LC Part description: RCU\RPBU 28.6 29.8 28.5 27.7 28.6 28.7 28.2 28.4 30.5 28.6 29.1 28.3 0.1 0.8 0.6 0.3 0.1 0.1 0.2 0.3 -0.9 -0.1 -2.1 0.1 Page 29 of 35 0.0 -1.1 0.2 -0.1 -0.1 0.0 0.3 0.3 -1.3 -0.1 -1.0 0.4 3.2 -0.4 2.7 0.9 0.3 0.8 1.7 2.0 1.1 0.0 -0.9 2.7 Tracking Code: 125343_Report_Rev_1 Part #: RCU-G-02.00-AMS-BC\ RPBU-01-S-A-VT-LC Part description: RCU\RPBU DATA Continued Gas Tight Group Signal Pin Board 1 1 1 1 1 1 2 2 2 2 2 2 3 3 3 3 3 3 4 4 4 4 4 4 5 5 5 5 5 5 6 6 6 6 6 6 7 7 7 7 7 7 8 mOhm values Position P2 P3 P4 P5 P7 P8 P2 P3 P4 P5 P7 P8 P2 P3 P4 P5 P7 P8 P2 P3 P4 P5 P7 P8 P2 P3 P4 P5 P7 P8 P2 P3 P4 P5 P7 P8 P2 P3 P4 P5 P7 P8 P2 Actual Initial 15.5 20.4 20.5 15.1 15.6 20.5 16.0 21.5 21.3 16.5 15.3 20.8 15.6 20.7 20.8 15.6 15.2 20.5 15.7 20.7 20.7 15.7 15.3 20.2 15.6 21.4 21.5 15.8 15.0 20.4 15.2 21.1 21.2 15.4 15.2 20.8 15.5 20.6 21.0 15.1 15.2 20.4 15.8 Page 30 of 35 Delta Gas Tight 0.3 0.2 0.2 0.3 -0.1 0.0 -0.2 -0.4 -0.2 -0.1 0.0 0.1 1.2 1.1 1.2 1.3 0.0 0.0 -1.1 -2.4 -1.3 -1.1 -0.5 -1.1 0.1 0.1 0.1 0.2 -0.1 0.0 -0.2 -0.1 -0.4 -0.2 -0.1 0.0 -0.1 0.0 -0.2 0.0 -0.1 -0.1 0.0 Tracking Code: 125343_Report_Rev_1 Part #: RCU-G-02.00-AMS-BC\ RPBU-01-S-A-VT-LC Part description: RCU\RPBU 8 8 8 8 8 P3 P4 P5 P7 P8 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 mOhm values Position P1 P6 P1 P6 P1 P6 P1 P6 P1 P6 P1 P6 P1 P6 P1 P6 21.2 21.3 15.9 15.2 20.4 0.4 0.4 -0.2 -0.3 -0.3 Actual Initial 10.1 10.7 10.9 10.4 12.2 12.3 12.6 9.6 12.7 11.1 12.0 12.3 9.6 9.3 12.5 11.1 Delta Gas Tight 0.2 0.2 -0.1 0.2 1.7 0.0 -1.8 -1.3 0.2 0.9 0.2 0.3 0.0 0.0 0.2 0.3 Ground Pin Board Page 31 of 35 Tracking Code: 125343_Report_Rev_1 Part #: RCU-G-02.00-AMS-BC\ RPBU-01-S-A-VT-LC Part description: RCU\RPBU DATA Continued IP67 Testing (Dust) Group A1 (Dust mated) Sample # 21 22 23 24 25 26 Visual Inspection PASS PASS PASS PASS PASS PASS Group B1 (Cable dust cover) Sample # 33 34 35 36 37 38 Visual Inspection PASS PASS PASS PASS PASS PASS Group B2 (Mating part dust cover) Sample # 45 46 47 48 49 50 Visual Inspection PASS PASS PASS PASS PASS PASS Page 32 of 35 Tracking Code: 125343_Report_Rev_1 Part #: RCU-G-02.00-AMS-BC\ RPBU-01-S-A-VT-LC Part description: RCU\RPBU DATA Continued IPX8 Testing (Water) Sample # 57 58 59 Visual Inspection at 9 Meters PASS PASS PASS Sample # 57 58 59 Visual Inspection at 10 Meters PASS PASS PASS Page 33 of 35 Tracking Code: 125343_Report_Rev_1 Part #: RCU-G-02.00-AMS-BC\ RPBU-01-S-A-VT-LC Part description: RCU\RPBU EQUIPMENT AND CALIBRATION SCHEDULES Equipment #: MO-04 Description: Multimeter /Data Acquisition System Manufacturer: Keithley Model: 2700 Serial #: 0798688 Accuracy: See Manual … Last Cal: 04/30/2011, Next Cal: 04/30/2012 Equipment #: PS-07 Description: Power Supply Manufacturer: Agilent Model: AT-6031A Serial #: 2721A00648 Accuracy: See Manual See Manual … Last Cal: 08/21/2011, Next Cal: 08/21/2012 Equipment #: TCT-04 Description: Dillon Quantrol TC2 Test Stand Manufacturer: Dillon Quantrol Model: TC2 Serial #: 04-1041-04 Accuracy: Speed Accuracy: +/- 5% of indicated speed; Displacement: +/- 5 micrometers. … Last Cal: 05/21/2011, Next Cal: 05/21/2012 Equipment #: THC-02 Description: Temperature/Humidity Chamber Manufacturer: Thermotron Model: SE-1000-6-6 Serial #: 31808 Accuracy: See Manual … Last Cal: 02/16/2011, Next Cal: 02/16/2012 Equipment #: HPM-01 Description: Hipot Megommeter Manufacturer: Hipotronics Model: H306B-A Serial #: M9905004 Accuracy: 2 % Full Scale Accuracy … Last Cal: 11/30/2010, Next Cal: 11/30/2011 Equipment #: TSC-01 Description: Vertical Thermal Shock Chamber Manufacturer: Cincinnatti Sub Zero Model: VTS-3-6-6-SC/AC Serial #: 10-VT14993 Accuracy: See Manual … Last Cal: 05/18/2011, Next Cal: 05/18/2012 Page 34 of 35 Tracking Code: «TC» Part #: «Part_Number» Part description: «Part_Name» EQUIPMENT AND CALIBRATION SCHEDULES Continued Equipment #: IPX8-01 Description: IP-X8 Water Pressure test Chamber Manufacturer: Samtec Machine Model: N/A Serial #: N/A Accuracy: No Calibration Required Equipment #: DUST-01 Description: IP-X6 Dust Tester Manufacturer: Samtec Machine Model: N/A Serial #: N/A Accuracy: No Calibration Required Page 35 of 35