Connector Testing and Its Importance to User Safety and End Use

Connector testing is the most important phase in ensuring electrical connector safety for users. The verification of responsible design and manufacturing takes place in accredited testing laboratories.

Testing and certification

In the testing phase, a connector is subjected to loads exceeding the rated values. The connector also must withstand temperatures higher than those in normal use. Crimp connectors are additionally tested for tensile strength. The testing phase preceding certification is essential for product safety and reliability.

Prior to testing at Ouneva, we simulate various mechanical forces that the connectors must withstand. With our OTL universal connectors, we simulate the effect of tension and stretching on the connector body due to forces created by the tightening of connector screws. The simulation phase makes our product development smoother and more efficient, and we can verify the functionality of the connector even before testing. This means less surprises in the testing laboratory.

Figure 1: Connector test models. (Image source: Ouneva)

The testing of connectors manufactured by Ouneva is performed in accredited laboratories according to the testing standards. The tests are divided into multiple parts, including mechanical and electrical tests. In the electrical tests, multiple parameters are measured in the product, and the results verify the electrical safety and quality of the product.

Figure 2: Connector test results of short circuit testing. (Image source: Ouneva)

In Figure 2, the connectors showed a slight response to the short circuit events in cycle 200, but the variation is insignificant due to the minimal deviation. The connectors passed the test.

Figure 3: Additional short circuit connector test results. (Image source: Ouneva)

Figure 3 shows no variation in the temperatures after the short circuit events. The connectors passed the test.

Only high-quality and safe connectors pass the tests defined by the standard. After the approved testing phase, the testing laboratory drafts a test report and a certificate, and their validity and equivalence are monitored by the laboratory.

The OTL universal connector family, for example, is tested according to the following standards:

• EN 61238-1:2003 Class A
• EN 60947-7-1:2009
• EN 60947-7-2:2009
• UL 1059, CAN/CSA C22.2 No. 158-10, Terminal blocks.

OTL universal connectors are certified for use with copper and aluminium conductors. The use of aluminium conductors has grown significantly over the years. This makes the OTL universal connectors suitable for a wide range of applications while maintaining a strong focus on safety.

What’s the difference between a Class A and a Class B connector?

Connectors can be classified into two different classes, A and B. The difference between Class A connectors and Class B connectors is that Class A are also short-circuit tested. This means that Class A connectors have a much wider range for applications compared to Class B connectors. Class A connectors are also more cost-efficient considering that, thanks to the short-circuit test, they do not require separate quick circuit breakers. These circuit breakers are often expensive to purchase and installation.

What other safety aspects should you consider in choosing a connector?

Material choices should be considered in the design phase. Correct material choices influence the price, quality and recyclability of the end product. They also make a significant impact on product safety, especially fire safety.

The OTL universal connector family is manufactured using plastic materials, whose fire rating fulfills the requirements of the UL 94 test standard V-0. V-0 classified materials do not boost fire and are self-extinguishing. The classified materials are tested by UL and a material certificate, “yellow card”, is available for viewing. The fire rating has been accomplished without halogens, which means that the materials in the OTL universal connector family are completely halogen-free.

Source: https://www.ul.com/services/combustion-fire-tests-plastics

Summary

When choosing an electrical connector, you should pay attention to the certification of the product. We highly recommend choosing a Class A connector to ensure the safety of the connector. The OTL universal connector family is full of high-quality, tested and certified products that give you the best installation and user properties. If you’re interested in certified manufacturers, here is a link to directory of manufacturers certified by SGS, so you can be sure about the quality and safety of the product you choose:

https://www.sgs.com/en-fi/certified-clients-and-products/certified-client-directory

Sustainable solutions for the future

www.ounevagroup.fi

www.ounevaproducts.fi