Solar Connectors are transmitters of energy and carriers of electricity. When power is transmitted, there is bound to be a loss. For connector manufacturers, the biggest test is how to achieve safe and stable transmission with minimal energy loss. The reliability of the connector considers the following factors:
1. Materials for connector product design and product manufacturing;
2. Operating environment;
3. Functional requirements The application environment, especially temperature, humidity, corrosiveness, etc., determines which failure mechanisms will work, and the functional requirements of the connector decide which degree of failure is allowed.
To understand the reliability of the connector, various tests are generally carried out on the connector. The test typically involves the following items: plug-in force test, durability test, insulation resistance test, vibration test, mechanical shock test, thermal shock test, Mixed gas corrosion test, etc. The specific test items are as follows:
1. Plug force test
Reference Standard: IEC62852 /UL6703
Purpose: to verify whether the plug-in force of the connector meets the product specification requirements;
Principle: Fully insert or pull out the connector at a specified rate and record the corresponding force value.
2. Durability test
Reference Standard: IEC62852 /UL6703
Purpose: To evaluate the influence of repeated plugging and unplugging on the connector and simulate the plugging and unplugging status of the connector in actual use.
Principle: Continuously plug and unplug the connector at the specified rate until the specified number of times is reached.
3. Insulation resistance test
Reference Standard: IEC62852 /UL6703
Purpose: To verify whether the connector's insulation performance meets the circuit design's requirements or whether its resistance value meets the needs of the relevant technical conditions when it is subjected to environmental stress such as high temperature and humidity.
Principle: The resistance value is presented by applying a voltage to the insulating part of the connector so that leakage current occurs on the surface or inside the insulating region.
4. Withstand voltage test
Reference Standard: IEC62852 /UL6703
Purpose: To verify whether the connector can work safely under rated voltage and withstand over-potential to evaluate whether the insulation material or insulation gap of the connector is suitable. Principle: Between the connector contacts and the contacts, the contacts and the Apply a specified voltage between the shells and keep it for a specified time to observe whether the sample has breakdown or discharge.
5. Contact resistance test
Reference standard: IEC62852 /UL6703
Purpose: To verify the resistance value generated when the current flows through the contact surface of the contact piece Principle: Bypassing a specified current to the connector, measure the voltage drop across the connector to obtain the resistance value
6. Vibration test:
Reference Standard: IEC62852 /UL6703
Purpose: To verify the effect of vibration on the performance of electrical connectors and their components.
Vibration type: random vibration, sinusoidal vibration
7. Mechanical impact test
Reference Standard: IEC62852 /UL6703
Purpose: To verify the impact resistance of the connector and its components or to assess the firmness of its structure;
Test waveform: half-sine wave, square wave.
8. Thermal shock test
Reference Standard: IEC62852 /UL6703
Purpose: To evaluate the influence of the connector on its functional quality under the immediate and significant temperature difference.
9. Temperature and humidity combined cycle test
Reference Standard: IEC62852 /UL6703
Objective: To evaluate the influence of connectors on the performance of connectors after being stored in a high temperature and high humidity environment.
10. High-temperature test
Reference Standard: IEC62852 /UL6703
Purpose: To evaluate whether the performance of terminals and insulators changes after a connector is exposed to high temperatures for a specified period.
11. Salt spray test
Reference Standard: IEC62852 /UL6703
Purpose: To evaluate the resistance to salt spray corrosion of connectors, terminals, and coatings
12. Mixed gas corrosion test
Reference Standard: IEC62852 /UL6703
Objective: To evaluate the corrosion resistance of connectors exposed to mixed gases of different concentrations and the effect on their performance.
1. Materials for connector product design and product manufacturing;
2. Operating environment;
3. Functional requirements The application environment, especially temperature, humidity, corrosiveness, etc., determines which failure mechanisms will work, and the functional requirements of the connector decide which degree of failure is allowed.
To understand the reliability of the connector, various tests are generally carried out on the connector. The test typically involves the following items: plug-in force test, durability test, insulation resistance test, vibration test, mechanical shock test, thermal shock test, Mixed gas corrosion test, etc. The specific test items are as follows:
1. Plug force test
Reference Standard: IEC62852 /UL6703
Purpose: to verify whether the plug-in force of the connector meets the product specification requirements;
Principle: Fully insert or pull out the connector at a specified rate and record the corresponding force value.
2. Durability test
Reference Standard: IEC62852 /UL6703
Purpose: To evaluate the influence of repeated plugging and unplugging on the connector and simulate the plugging and unplugging status of the connector in actual use.
Principle: Continuously plug and unplug the connector at the specified rate until the specified number of times is reached.
3. Insulation resistance test
Reference Standard: IEC62852 /UL6703
Purpose: To verify whether the connector's insulation performance meets the circuit design's requirements or whether its resistance value meets the needs of the relevant technical conditions when it is subjected to environmental stress such as high temperature and humidity.
Principle: The resistance value is presented by applying a voltage to the insulating part of the connector so that leakage current occurs on the surface or inside the insulating region.
4. Withstand voltage test
Reference Standard: IEC62852 /UL6703
Purpose: To verify whether the connector can work safely under rated voltage and withstand over-potential to evaluate whether the insulation material or insulation gap of the connector is suitable. Principle: Between the connector contacts and the contacts, the contacts and the Apply a specified voltage between the shells and keep it for a specified time to observe whether the sample has breakdown or discharge.
5. Contact resistance test
Reference standard: IEC62852 /UL6703
Purpose: To verify the resistance value generated when the current flows through the contact surface of the contact piece Principle: Bypassing a specified current to the connector, measure the voltage drop across the connector to obtain the resistance value
6. Vibration test:
Reference Standard: IEC62852 /UL6703
Purpose: To verify the effect of vibration on the performance of electrical connectors and their components.
Vibration type: random vibration, sinusoidal vibration
7. Mechanical impact test
Reference Standard: IEC62852 /UL6703
Purpose: To verify the impact resistance of the connector and its components or to assess the firmness of its structure;
Test waveform: half-sine wave, square wave.
8. Thermal shock test
Reference Standard: IEC62852 /UL6703
Purpose: To evaluate the influence of the connector on its functional quality under the immediate and significant temperature difference.
9. Temperature and humidity combined cycle test
Reference Standard: IEC62852 /UL6703
Objective: To evaluate the influence of connectors on the performance of connectors after being stored in a high temperature and high humidity environment.
| TEST ITEMS | LEADER Connector | OTHER Connectors | NOTE |
| Contact resistance | ≤0.35mΩ | ≤0.5mΩ | |
| Contact resistance is stable for a long time | Yes | No | Long-term stability is extremely important to the power station and affects the return on investment |
| Protection class | IP68 | IP67 | |
| Rated current | 39A | 30A | 85℃.4mm² cable |
| Ammonia resistance test | Yes | No | Important technical parameters of complementary agricultural-PV and fishing-PV |
| Salt spray test | Yes | No | Important parameters of floating power station |
| Use recycled materials | No | Yes | Very low price |
10. High-temperature test
Reference Standard: IEC62852 /UL6703
Purpose: To evaluate whether the performance of terminals and insulators changes after a connector is exposed to high temperatures for a specified period.
11. Salt spray test
Reference Standard: IEC62852 /UL6703
Purpose: To evaluate the resistance to salt spray corrosion of connectors, terminals, and coatings
12. Mixed gas corrosion test
Reference Standard: IEC62852 /UL6703
Objective: To evaluate the corrosion resistance of connectors exposed to mixed gases of different concentrations and the effect on their performance.