Number 2208

Application Note Solutions for Production Testing

Se­ries of Connectors

Introduction The actual test voltage chosen depends on the capabilities of

the instrumentation and the degree of current measurement
As electronics have become increasingly pervasive, the
sensitivity available, as well as the ratings of the connector
importance of electrical connectors has increased dramatically.1
material. For a given resistance value, a higher voltage will result
Quality connectors are vital to ensuring overall product
in a higher current signal, which can be measured with higher
reliability in applications ranging from motor vehicles to
resolution. Figure 2 illustrates the constant voltage method
transatlantic telecom systems. The degree and type of electrical
for measuring high resistances. When the measured current
testing that connectors undergo typically depends on how crucial
is fairly low, the likelihood of measurement errors increases.
they are to the overall performance of the systems in which they
Contributors to error include noise generated by electrically
are installed. Stringent electrical tests are often specified when
charged objects in the environment, leakage current in the test
high reliability is required. Isolation and continuity are the two
fixture, and the amount of cable capacitance present. Strategies
most commonly measured parameters in connector testing.
for overcoming these measurement obstacles are discussed in the
Isolation measurements are usually performed between each of
“Typical Sources of Error” section in this note.
the connector pins or between the pins and the outer shell of
the connector. Isolation measurements are used to verify that
signals are not misdirected and insulation is sufficient under the Connector Shell
operating conditions of the connector. Continuity is measured
R pin1 R pin2 R pin3 R pinX
between pins to ensure that once the connector is installed, the
electrical signals will be transmitted properly. R iso R iso R iso

There are a number of instruments that may be used in

connector testing; thus, selecting the optimal solution for R iso R iso R iso R iso
a particular application may not be an easy task. This note
addresses many of the issues involved in implementing a
connector characterization system.
Figure 1. Electrical Equivalent of a Connector, Showing Pin Continuity and
Isolation Resistance.
Test Description
Isolation (Insulation) Resistance RIsolation
Given today’s ever-shrinking circuit geometry and the higher
frequencies of electronic signals, isolation is an important HI
consideration for reliability and crosstalk. Environmental
Voltage
conditions such as high heat and vibration may also cause Source Ammeter
degradation of insulation and shorts within the connector.
Isolation is typically tested by applying a voltage across two pins LO
in a connector and measuring the resulting current that flows
between them. The corresponding resistance from the test is
compared to a predetermined threshold value. If the resistance
level is too low, the connector is rejected. Common threshold Figure 2. Constant Voltage Method for Measuring High Resistance.

levels range from 1MW to 1TW. Figure 1 shows the electrical

equivalent of a connector; the isolation resistance is identified Pin Continuity
as R iso. When testing very high ohmic devices, the measured As long-term performance of connectors becomes increasingly
resistance may change significantly in response to a change in important, the continuity performance from the input to the
the applied voltage, an effect known as the voltage coefficient output of the connector will also become more important.
of resistance. This effect makes it preferable to test high value Connector pins are often made from metal alloys, so the
resistors with the source voltage, measure current method. measurement result is a very low resistance value. Typically,
continuity is tested by sourcing a constant current through
1 Although this application note targets connector production testing, engineers in cable
assembly manufacturing operations perform tests similar to those presented here. These
the pin and measuring the corresponding voltage drop. Pin
engineers may find the information in this note helpful when selecting test equipment. continuity is identified as Rpin in Figure 1. Using high currents to
test continuity has two advantages. First, using a sufficiently high Solutions Overview
test current ensures the resulting voltage signal will be above the
Table 1 shows a representative selection of Keithley test
noise floor of the test system. The noise floor includes the error
equipment solutions for connector testing. Use this table to
related to the voltage drop in lead resistances and the voltages
identify the solution that best fits the specific measurement
due to the variation of temperature at junctions of dissimilar
parameters.
metals. Second, a higher test current can also serve as a stress
test for the connector. Often, the connector will be tested at When selecting test equipment, the user/design engineer needs
a current level higher than the rated current level in order to to determine appropriate accuracy and speed requirements, the
verify performance margin. Figure 3 illustrates how a current range of resistances to be measured, the method of measuring
source and voltmeter are used to measure resistance. Most resistance, and whether or not it’s necessary to control the
instruments designed to measure low resistances have a built-in value of test current or voltage. Additional features such as
current source and voltmeter and can be configured to measure handler interfacing and limit testing may also be of importance
resistance with one instrument bus command or button on the to the user.
front panel. Selection of a switch solution requires a plan of the test
environment and the sequence of tests to be performed.
Answering the following questions will assist the engineer in
HI designing a switch system:
Current • How many devices are to be tested?
Source RContinuity Voltmeter
• Is parallel testing needed?
LO
• Will the system be performing multi-pin/pin-to-pin testing?
• What are the maximum voltage and current levels to be
Figure 3. Constant Current Method for Measuring Low Resistance sourced and/or measured?

Table 1. Instrument Selection Guide for Connector Test.

Pin Isolation
Test Equipment Continuity Test Measurement Ranges Notable Features
Model 2750 Multimeter/ Pin Continuity: 1mW+ Optional internal switching.
Switch System Isolation: Up to 100MW Offset compensation.
• • Common-side ohms configuration.
Enhanced low ohms measurement capability.
Model 2790 SourceMeter/ Pin Continuity: 10mW+ Optional internal switching.
Switch System Isolation: Up to 1GW Offset compensation.
• • 500V programmable voltage source (low power).
50mA programmable current source.
Model 2400 SourceMeter® Pin Continuity: 1mW+ Programmable test current (pin continuity).
SMU Instruments Isolation: ~ 1GW Programmable voltage source (isolation test).
• • Ability to save 100 test setups in memory.
Auto output-off → reduce device heating.
Contact check option.
Model 2400 SourceMeter and Model Pin Continuity: 1μW+ Programmable test current.
2182A Nanovoltmeter • Delta mode—current reversal technique for 2400 and 2182A.
Model 3706A System Switch/ Pin Continuity: 1mW+ Optional internal switching.
Multimeter Isolation: Up to 100MW Offset compensation.
• • Common-side ohms configuration.
Enhanced low ohms measurement capability.
Up to 576 two-wire multiplexer channels.
Model 6487 Picoammeter with Isolation: 1kW–1TW Independent programmable voltage source (±500V).
Voltage Source • V/I Ohms.
Model 6517B Electrometer Isolation: 200kW–1e17W Independent programmable voltage source (±1000V).
• Optional internal switching.
Optional temperature and humidity measurements.
Model 2001/2002 High Performance Pin Continuity: 10mW Offset compensation.
Multimeter Isolation: Up to 1GW Optional internal switching.
• • Optional Model 1801 Nanovolt Preamp to increase sensitivity (with
this preamp, pin continuity range can extend down to 5mW at a
test current of 9.2mA).
Model 6221 Current Source and Pin Continuity: 100nW Delta Mode for low thermal, low resistance measurements.
Model 2182A Nanovoltmeter • Isolation: Up to 100GW
•
 • What are the speed and accuracy requirements?
After having determined the specific application needs, the Ch. 1
designer may wish to review the switching and measurement
solution with a Keithley Applications Engineer.
Ch. 2

Test System Option Descriptions Contact Pin

and
Mating Sleeve
Series 3700A or Series 2700/Integra Systems
Choosing the appropriate test equipment can be difficult. Ch. 40

Series 3700A or Series 2700 Systems simplify the test setup by

combining the switch and measurement hardware into a single HI LO
unit. These products incorporate a precision digital multimeter Source Source
Ohmmeter
with a wide assortment of switching cards and switching
HI LO
topologies (multiplexer, matrix, etc…). Table 2 provides an Sense Sense
overview of the Series 3700A and 2700. For more details on the 3706A/3721 Multimeter/Switch System
available switching modules, see the [Link] website.
Figure 4. Common-Side Ohms Configuration
Both of these systems measure all ranges of resistance
using the constant current method. The instruments’ range pin-to-pin testing and are available in both the Model 3700A and
(up to 100MW) may be adequate for measuring isolation Series 2700 instruments.
resistance in many applications. These models also offer four-
wire connections, dry circuit testing (3706A and 2750), offset Model 2790 SourceMeter/Switch System
compensation and low current source to prevent device heating If source programmability is required, consider the Model 2790
in low resistance measurements. The section of this note titled SourceMeter Switch System as a possible solution. A member of
“Typical Sources of Error” discusses how these features can be the Integra Series family of products, the Model 2790 has the
useful in reducing or eliminating measurement errors. multimeter functions of the Model 2700 with optional switching
The Model 3706A and Model 2750 mainframes have an modules that include voltage and/or current sources. Three
enhanced ability to measure low ohms accurately. This makes it optional modules for the Model 2790 are available: Model 7751
an ideal choice for pin continuity tests. Pairing the Model 3721 High Voltage Source/Switch Module, Model 7752 Low Voltage
Switch Card with the 3706A or the Model 7701 Switch Card Current-Source-Only Source/Switch Module, and Model 7702
with the Model 2750 permits four-wire connections without 40-Channel General Purpose Multiplexer Module.
comprising channel count. These cards offer the same channel The Model 7751 module contains a low power programmable
count (3721: 40 channels, 7701: 32 channels) for four-wire 500V voltage source with a maximum current output of 50μA. It
resistance measurements as it does for two-wire measurements also has a 50mA programmable current source. Additionally, an
by using a common-side ohms configuration. As shown in Figure I-V converter is included on the 7751 module in order to make
4, a four-wire measurement is made by connecting the Sense more accurate measurements than are possible with the ammeter
HI and Input HI to a bus that is common with one side of all internal to the Model 2790 mainframe. These enhanced source
the devices. With such a configuration, up to 240 low resistance and measure capabilities allow making isolation measurements
devices may be tested using the Model 3706A and six Model 3721 up to 1GW and continuity measurements down to 10mW with
Switch Cards. the Model 2790. The Model 7752 switch card is also as an option
Testing multi-pin connectors may require a switch for the Model 2790. Containing just the 50mA programmable
configuration in which measurements are made from any one current source, the 7752 is ideal for applications where only
pin to any other. A matrix switch card permits convenient continuity measurements will be made.

Table 2. Integra Series Comparison Chart

Maximum Reading
Integra Series Number Communication Maximum Channel Internal Data Rate, Single Channel
Product of Slots Interface Count or Crosspoints Buffer Capacity (readings/second) Additional Features
80 channels or
Model 2700 2 GPIB, RS-232 55,000 2000
96 crosspoints
80 channels or
Model 2701 2 Ethernet, RS-232 450,000 3500 Portable, ½ rack, 2U design
96 crosspoints
200 channels or Low ohms capability (1μW max.
Model 2750 5 GPIB, RS-232 110,000 2500
240 crosspoints sensitivity)
576 channels or Low ohms capability (0.1μW max.
Model 3706A 6 650,000 14,000
576 crosspoints sensitivity)
 Each Model 7751 or 7752 module allows two-wire Like the Model 2400, you have control over the test current.
connections to 12 DUTs. If more connections are required, And the Model 6221 has the trigger link connection to trigger
consider using the Model 7702 40-Channel multiplexer card the Model 2182A for delta measurements. The main advantage
in the second slot of the Model 2790. In addition to higher to using Models 6221/2182A over Models 2400/2182A is that the
channel count, this card permits routing to the DMM for general Model 6221 controls the two units. The data is shown on the
measurements, including voltage, current, and resistance. The Model 6221 in volts, ohms, watts, or siemens. Since the two units
sources on the Model 7751/2 cards are accessible via screw were developed with delta mode in mind, the system is very
terminals and may be routed to the Model 7702 card for simple to configure.
measurement. Once the serial cable and trigger link cable are connected
For some applications, the measurement range of the Series between the two instruments, it takes only a few button
2700 instruments may not be broad enough to accommodate pushes to configure and start the delta mode. The Model 6221’s
the test requirements for both isolation and continuity maximum current is 100mA.
measurements. The engineer may also want more flexibility in
The 2400 Series’ maximum current is 5A. If using 100mA
the level of source current or voltage used in the test. In these
and below, then Models 6221/2182A are recommended. If using
cases, one of the Series 2400 SourceMeter® SMU instruments
above 100mA, then the 2400 Series with the Model 2182A is
may be a more suitable solution.
recommended.
Series 2400 SourceMeter® SMU Instruments As discussed previously, it’s generally preferable to test high
SourceMeter SMU instruments consist of a voltage source, value resistors with the source voltage method. Given that Series
current source, voltmeter, ammeter, and ohmmeter in a single 2400 instruments all have a voltage source, these instruments
half-racksized package. With these components, SourceMeter may be used to measure isolation resistances of up to 1GW or
SMU instruments offer greater measurement sensitivity for pin more with reasonable accuracy. With a 1100V source, the Model
continuity tests and extended range for isolation resistance tests. 2410 offers the possibility of testing very large resistances.
Some devices, however, may not be able to withstand such a high Testing a 10GW resistor at 500V, the Model 2410 offers just
level of current without experiencing device heating, which can 0.67% uncertainty.
introduce significant error to the measurement. The SourceMeter
products have an auto output-off feature that keeps the source Additional Isolation Test Equipment
turned on only long enough to complete the measurement (only Other solutions for high insulation resistance measurement
a few milliseconds), which reduces device heating. As an added include the Model 2001, Model 2002, and Model 3706A Digital
benefit, auto output-off provides cold switching, for extended Multimeters. These instruments offer the ability to measure up to
relay life in switch systems. Series 2400 instruments also include 1GW using the constant current method, in addition to standard
offset compensation, as well as programmable compliance multimeter functions such as AC voltage, AC current, and
settings that allow users to apply dry circuit conditions. temperature. The Model 6487 Picoammeter has an independent
500V programmable source voltage and a “V/I resistance mode,”
For extremely low resistance devices that require a high
which make it suitable and convenient for measuring insulation
degree of test accuracy, a more sensitive voltmeter, such as
resistance. The Model 6517B electrometer, with an independent
the Model 2182A Nanovoltmeter, will likely need to be paired
1000V programmable source and 3fA offset on its ammeter,
with the SourceMeter SMU instrument. Using the Model 2182A
offers the best high resistance measurement accuracy of all
and a SourceMeter SMU instrument, the uncertainty of a 1mW
standard Keithley instruments. This instrument may be necessary
measurement with a 10mA source is 0.45%. Comparing these
for extremely high insulation resistances (hundreds of gigaohms
specifications with the example in the previous paragraph
or teraohms).
(where the SourceMeter SMU instrument alone was used), the
2182A/2400 configuration with a 100× reduction in source Obviously, there are many instrumentation options available.
current leads to only a 0.15% increase in uncertainty. The Therefore, when choosing test equipment, the project engineer
combination of these two instruments offers wider flexibility should carefully consider the entire range of resistance to be
in source current and measurement time. The Delta Mode tested and other measurements or applications for which the
feature of the Model 2182A also allows coordination with the instrument may be used.
SourceMeter SMU instrument to add offset compensation to the
Switching Solutions
measurement.
Once it’s clear what instrumentation option is most appropriate,
Another potential source is to use the Model 6221 Current the project engineer can focus on the switching requirements
Source with the Model 2182A Nanovoltmeter. They were of the application. While the Series 2700 Integra Systems and
designed to work together for low resistance measurements. Model 3706A can be used for switching alone, Keithley also
At 100mA test current from the Model 6221 and the sensitivity offers the Series 7000 line of switching products, which are
of the Model 2182A at 10nV, the low resistance measurement is designed for use with measurement hardware. The Model 7001
sensitive to 1e-7W (100nW). and 7002 mainframes house and control the plug-in switch cards,
which contain the relays that will connect the test equipment The Series 7000 switch mainframes are “smart” in that they
to the test points of the connector. Plug-in switch cards are can save switch patterns and sequences. These mainframes also
available in a variety of relay configurations. The multiplexer have built-in trigger hardware (see the Trigger Link description
and the matrix are the two most common switch topologies. in the section titled “Optimizing the Measurement”) that affords
Multiplexer cards are used to connect one instrument to many hardware handshaking between the switch mainframe and the
measurement equipment. With this external triggering, the
test points or vice versa. Figure 5 shows a simple multiplexer
instruments can execute the programmed test sequence without
configuration in which resistors are connected across each relay.
operator intervention.
When only one channel is closed, a device is connected to the
inputs of the SourceMeter SMU instrument and can be tested. A In addition to the relay configuration, it’s very important to
matrix configuration, on the other hand, provides the flexibility consider the specifications of the switch card when choosing
switch hardware. The goal of switching is to make connections
required to test many different channel patterns. In a matrix, any
without compromising the measurement. When measuring pin
one point in the system may be connected to any other point
continuity (low resistances), it’s important to choose a switch
in the system. For example, this configuration is useful when
card with low contact potential and a current rating high enough
more than one instrument is needed to test each device. Figure 6 to withstand test current. When measuring insulation resistances,
shows a simple matrix configuration with connections to two choose a switch card with low offset current, high isolation
instruments and five pins of a six-pin device. Although two resistance, and a voltage rating high enough to withstand source
channels must be closed in order to perform a measurement, the voltage. For more detailed information on selecting appropriate
matrix configuration allows testing any possible combination of switch hardware, refer to Keithley’s Switching Handbook.
connector pins.
Optimizing the Measurement
Trigger Link
40 The Trigger Link is a hardware handshake bus used by the
Up to 40 instruments to ensure proper test sequencing. It’s a standard
differential
channels per feature on all newer Keithley instruments, including those
7011 Switch Card 39 mentioned in this note. When the meter and switch mainframe
are connected via a Trigger Link cable, they can trigger each
other to allow faster test completion. This built-in bus eliminates
38 the need for direct PC control of most system synchronization
functions. When the Trigger Link function is used properly,
the only functions the PC performs are initiating the test and
Model
1 retrieving data from the system.
24XX
Solutions to Typical Sources of Error
Model 7011
Quad 1×10 Multiplexer Noise
Noise can come from many sources in the production
Figure 5. Multiplexer Configuration environment. When electrically charged objects, such as
machinery, electrical motors, or fluorescent lights are brought
Connector near an uncharged object (i.e., the device under test), small,
Under Test unwanted voltages may be generated. To minimize the effects
of this electrostatic interference, ensure all system cabling is
properly shielded. All shields should be connected to a single
common point such as the signal LO. Whether the system cabling
is single- or multi-conductor, it’s best to use one shield around
Ammeter HI
the wire bundle.
Model 6517B Guard
Electrometer
V-Source LO Leakage Current
LO Stray or leakage current in cables and fixtures can be a source
Model 2010 of error in measurements of extremely low currents, such as for
DMM HI high impedance devices or parameters. To minimize leakage
current problems, the test fixture insulation must be made of
materials with resistances much higher than the impedances
Model 7153 High Voltage/Low Current Matrix Card
being tested. If proper care is not taken, some portion of the test
Figure 6. Matrix Configuration current will flow through any low impedance path to ground,
affecting measurement results. An alternate method of reducing the voltmeter senses the voltage drop across the DUT without the
leakage currents is to guard the test. When testing multi-pin effect of the lead resistance.
connectors, it’s also important to guard the other pins that are
not being tested because the resistance between the other pins
and ground may affect the final measurement. By connecting the
guard output from the meter to the other pins, the undesirable Output Sense Output Sense
HI HI HI HI
resistance and subsequent leakage to ground is eliminated. Refer Model 24XX Model 24XX
RS
to Keithley’s Low Level Measurements handbook for detailed Sour ceMeter Sour ceMeter

information on guarding. Output

LO
Sense
LO
Output
LO
Sense
LO

Figure 7 illustrates how to connect the Model 6517B

Electrometer to make a high resistance measurement properly to
minimize leakage current, cable capacitance, and noise.
Figure 8a. Two-Wire Measurement Figure 8b. Four-Wire Measurement

6517B Triax Shield Thermoelectric EMFs

Input
HI Thermoelectric EMFs may cause measurement problems for
Ammeter DUT
low impedance measurements. The voltage drop across low
impedance devices is typically very small. Thermoelectric EMFs
LO
may be on the same order of magnitude as the test signal,
Meter thereby introducing significant error. Most of the instruments
Connect discussed in this note can be programmed to cancel the effects
Relay
LO of thermoelectric offsets automatically through the offset
compensation or current reversal technique. This technique
V-Source involves taking two measurements. The first measurement is
HI taken at the desired positive source level, then the second is
taken at the opposite source polarity (or at 0A, depending on the
instrument). These two measurements are then subtracted from
Figure 7. Model 6517B Connections for Making Guarded Ohms Measurement
each other and the resulting resistance is calculated as follows:
Cable Capacitance (V2 – V1)
Delta Mode Ohms = __________
The amount of capacitance in the test system cabling will (I2 – I1)
determine the settling time required to obtain an accurate
where: I1 is the source current set to a specified positive value.
reading. Settling time is determined by the system’s RC time
I2 is the same current value as I1 with opposite polarity.
constant; a large resistance value can result in significant settling
V1 is the voltage measured at I1.
times, even with a relatively small capacitance value. For best
V2 is the voltage measured at I2.
accuracy, let four to five time constants elapse before taking
the measurement. System capacitance, and thereby settling
time, can be reduced by keeping cable lengths as short as
Equipment List
possible, guarding the system properly, and using the source The equipment needed to build the connector test system
voltage, measure current method of making high resistance illustrated in Figure 6 includes:
measurements.
• Keithley Model 6517B Electrometer/High Resistance System
Lead Resistance
• Keithley Model 2010 Low Noise Multimeter
A common source of error for low impedance occurs when only
two test leads are connected to the DUT. In this configuration, • Keithley Model 7001 (or 7002) Switching Mainframe
both the current source and voltmeter use the same pair of leads. • Model 7153 4×5 High Voltage Low Current Matrix Switching
The lead resistance, being in series with the DUT, is added to cards. Each card can accommodate up to five connector pins.
the final measurement. Such a setup is especially detrimental
for testing connector pins because the test lead resistance may • Model 7153-TRX cables for connecting to the 7153 card. Two
actually be greater than the resistance of the connector itself. cables are required for each switch card in the system.
Figure 8a illustrates this effect. To eliminate lead resistance • Model 237-TRX-T 3-slot Triax T adapters. Four adapters are
effects, the current source and voltmeter must be separated so required for each switch card in the system.
that four wires (force and sense leads) are used to connect to
• PC with Model KUSB-488 Interface Card
the device. The amount of current in the sense leads is negligible
and so the lead resistance is insignificant. Figure 8b shows how • Three Model 7007 IEEE-488 Interface Cables
Test System Safety
Many electrical test systems or instruments are capable of
measuring or sourcing hazardous voltage and power levels. It’s
also possible, under single fault conditions (e.g., a programming
error or an instrument failure), to output hazardous levels
even when the system indicates no hazard is present. These
high voltage and power levels make it essential to protect
operators from any of these hazards at all times. Protection
methods include:
• Design test fixtures to prevent operator contact with any
hazardous circuit.
• Make sure the device under test is fully enclosed to protect
the operator from any flying debris. For example, capacitors
and semiconductor devices can explode if too much voltage
or power is applied.
• Double insulate all electrical connections that an operator
could touch. Double insulation ensures the operator is still
protected, even if one insulation layer fails.
• Use high reliability, fail-safe interlock switches to disconnect
power sources when a test fixture cover is opened.
• Where possible, use automated handlers so operators do not
require access to the inside of the test fixture or have a need
to open guards.
• Provide proper training to all users of the system so they
understand all potential hazards and know how to protect
themselves from injury. It’s the responsibility of the test
system designers, integrators, and installers to make sure
operator and maintenance personnel protection is in place
and effective.

Alternative Solutions
Some types of connectors must be tested over wider voltage and
current ranges than those described here. Keithley Application
Note #2154, “Testing Devices with High Voltage and High
Current,” describes how to configure a test system based on
SourceMeter SMU instruments that supports testing isolation
resistance up to 1100V and continuity up to 3A.
 Specifications are subject to change without notice. All Keithley trademarks and trade names are the property of Keithley Instruments, Inc.
All other trademarks and trade names are the property of their respective companies.

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