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Performance Testing of Electrical Connectors for Low Voltage Road Vehicles: Understanding SAE J2223-2-2011 (Cancelled)
⚠️ Important: This standard has been cancelled (Feb 2011) and superseded by SAE/USCAR2, which is more frequently updated. Do not use SAE J2223-2 for new designs or validation.
Overview and Scope of SAE J2223-2-2011
SAE J2223-2-2011, Connections for On-Board Road Vehicle Electrical Wiring Harnesses—Part 2: Tests and General Performance Requirements, is a recommended practice that covers performance testing at all phases of development, production, and field analysis of electrical terminals, connectors, and components for low voltage (0–20 VDC) road vehicle applications. Originally issued in 1994 and cancelled in February 2011, the standard defines procedures for terminal mechanical tests, terminal electrical tests, connector mechanical tests, connector electrical tests, connector environmental tests, special tests, and severe duty tests. It is applicable to terminals used in In-Line, Header, and Device Connector systems with or without shorting bars, but not to edge board connectors, high voltage systems (>20 VDC), or eyelet type terminals.
Rationale for Cancellation: The document contains duplicate information that is now covered in SAE/USCAR2, which is updated more frequently to reflect industry progress.
Key Test Categories and Acceptance Requirements
The standard specifies detailed test sequences and acceptance criteria for a wide range of performance characteristics. Below is a summary of the major test categories covered:
| Test Category | Examples of Tests |
|---|---|
| Terminal – Mechanical | Insertion force, retention force, contact stability, wire crimp pull-off |
| Terminal – Electrical | Voltage drop, current cycling, temperature rise, resistance stability |
| Connector – Mechanical | Mating/unmating forces, connector locking mechanism strength, coding/keying |
| Connector – Electrical | Dielectric withstand voltage, insulation resistance, continuity |
| Connector – Environmental | Thermal shock, humidity exposure, dust ingress, salt spray, temperature life |
| Special & Severe Duty | High temperature exposure, vibration, mechanical shock, fluid immersion |
Acceptance criteria are defined for each test, and conformance must be verified and documented by the supplier. The standard also includes test sequences (Section 5.9) that group tests in a logical order to simulate real-world aging.
🛠️ Engineering Design Insight: Before representing compliance, ensure that all applicable requirements are verified and documented. The supplier holds primary responsibility—even if testing is outsourced. The Authorized Person (engineer or customer) has final authority on required tests and may authorize deviations, which must be recorded in the test report. Products must not be used in applications where conditions exceed those for which they were tested; if such conditions exist, special tests simulating the actual environment are mandatory.
Frequently Asked Questions
Can I still use SAE J2223-2-2011 for new connector development?
No. This standard has been cancelled. For current performance testing and validation of low voltage connectors, refer to SAE/USCAR2, which is the active and more frequently updated specification.
What is the exact scope of this standard?
It applies to electrical terminals and connectors for low voltage (0–20 VDC) on-board road vehicle wiring harnesses. It specifically excludes edge board connectors, systems operating above 20 VAC or DC, and eyelet type terminals. It is intended for development, production, and field analysis phases.
Who determines which tests are required for a given product?
The Authorized Person (typically the responsible engineer or customer) is the final authority on required tests. In the absence of contrary instructions from the test request, all applicable portions of the standard must be met. Product design specifications or part drawings may add or exempt tests.
What should I do if my product will face conditions beyond the test limits defined in the standard?
The standard explicitly states that if a product may be subjected to conditions beyond those described (e.g., extreme temperatures, un-sprung vehicle vibration), it must pass special tests that simulate the actual environment. Certification under this standard alone does not cover such uses until additional testing is completed and documented.
