1 245 Lynnfield Street Peabody, MA 01960-5099, USA Tel. 978.532.0775 Fax 978.531.6993 www.trucorporation.com 1-5/8 EIA Mating Durability Test Report Objective Test & characterize the mating durability of a TRU manufactured 1-5/8 EIA interface using phosphor bronze contact over an extended number of mating cycles to simulate a lifetime of performance. The test will measure and monitor the following parameters: VSWR, insertion loss, flare diameter of contact, to determine their impact on electrical/ mechanical performance. Test Sample A cable assembly described below was subjected to the test. 1-5/8 Cable Assembly: 41.50” length, LMR-1200 FR cable, Fig.1 Connector 1: 1-5/8 EIA (m) Plug, (TRU-9751-SNX) Connector 2: 1-5/8 EIA (m) Plug, (TRU-9751-SNX) Test & Inspection Conditions: All individual tests and inspections performed under the following conditions unless otherwise specified in the detail procedure(s): Environment: Temperature: Relative Humidity: Barometric Pressure: Room Ambient, 59 to 86 deg F (15 to 30 deg C) 20% to 80% Sea Level (650 to 800mm Hg) Configuration: Tests and inspections will be performed on a clean flat surface (bench or equivalent) in a clean well-lighted area, free of debris and foreign objects, unless otherwise specified. Test & Inspection Equipment: The following test equipment / tools / fixtures or equivalent were used to perform the test & inspections. Electrical: Vector Network Analyzer (HP 8753E) used on all electrical measurements Applicable test port cables / adapters for each assembly, set up as applicable per figure 1. 7-16 Calibration Kit (p/n: Maury Microwave 2750B) Full 2 Port Calibration: 401 data points 30 Hz BW S11 measurement = End 1 of cable assembly S22 measurement = End 2 of cable assembly 2 Electrical Test Set-Up Network Analyzer S22 S11 Device Under Test Figure 1 Mechanical: Mitutoya 5210-540-2973 micrometer: used to measure contact diameter. Test Procedure: • Baseline electrical / mechanical measurements were performed on the sample assembly: o VSWR, Insertion Loss (Frequency range: 10 MHz to 1000 MHz) o Contact diameter, Visual Examination of Product • Subject sample to 500 mating cycles or until a failure occurs. o A failure would consist of: assembly loses contact, or contact flare diameter does not meet spec (∅.598±.002). o Note: a cycle consists of 1 complete electro-mechanical mating onto its corresponding mating adapter or mating contact and 1 complete un-mating from its corresponding adapter or mating contact. • After every 10 cycles (up to 100), then every 25 (up to 200), then every 50 (up to 500) all-electrical / mechanical test & inspections performed at baseline were repeated on each sample. See figures 2-3 for mating configurations. • A separate test to simulate extended mating to be performed following 500 mating cycles. Assembly mated with applicable adapters for a duration of one week. All electrical/ mechanical test & inspections performed at baseline performed. See Results/ Conclusion portion of report for results. Results / Conclusions: • TRU 1-5/8 EIA meet /exceed 500 mating cycles, without any significant degradation to electrical / mechanical performance parameters. The test results were summarized and recorded per the following data: See figures 4-8. • The VSWR and contact flare diameter following the extended mate test revealed little to no change. • There was significant plating wear on the contact (see figures 9-11), but this did not affect electrical performance. The first signs of plating wear noticed after 60 cycles. 3 Figure 2 Figure 3 Mated configuration Unmated configuration TEST DATA Contact Flare diameter measurements Figure 4 Figure 5 Contact Flare Diameter End 2 Number of Cycles 50 0 40 0 30 0 20 0 15 0 10 0 80 60 40 20 0.601 0.600 0.599 0.598 0.597 0.596 0.595 0 50 0 Dameter (inches) Number of Cycles 40 0 30 0 20 0 15 0 10 0 80 60 40 0 0.601 0.600 0.599 0.598 0.597 0.596 0.595 20 Diameter (inches) Contact Flare Diameter End 1 4 VSWR measurements Figure 6 Figure 7 VSWR S22 Figure 8 0.000 -0.005 -0.010 -0.015 -0.020 -0.025 Number of Cycles 50 0 40 0 30 0 20 0 15 0 10 0 80 60 40 20 Insertion Loss S21 50 0 40 0 30 0 20 0 Number of Cycles Insertion loss measurements 0 15 0 10 0 80 60 40 20 0 0 0 0 0 0 50 40 30 20 15 10 80 1.010 1.009 1.008 1.007 1.006 1.005 1.004 1.003 1.002 1.001 1.000 Number of Cycles Insertion Loss (dB) 60 40 VSWR 1.010 1.009 1.008 1.007 1.006 1.005 1.004 1.003 1.002 1.001 1.000 20 VSWR VSWR S11 5 Figure 9 Baseline Figure 10 Wear marks Figure 11 Wear marks