Partial Discharge Testing and AC Characterization of

HV Connectors and Terminations

Jim L. Rush
Teledyne Reynolds Inc.
5005 McConnell Ave
Los Angeles, CA 90066 USA


presence of moisture; and mechanical erosion resulting in
reduction in insulation thickness, material selection is of
primary concern, particularly in AC systems. It is important
to remember that a materials dielectric strength and its ability
to withstand the effects of partial discharge may not be
mutually inclusive. For example Silicone and Ethylene
Propylene Rubbers exhibit superior resistance to partial
discharge effects compared with some fluoropolymers, yet
offer significantly less dielectric strength. Additionally, the
use of semi-conductive insulative layers are useful in
increasing the effective radiating surface area of electrodes
and in minimizing the electrical stress caused by the transition
of electric fields across materials with significantly different
dielectric constants. It has been shown [1] under specific AC
voltage conditions and geometries, for equal thicknesses,
materials with higher dielectric constants exhibit higher
corona inception values (See Fig.1).

Abstract- Characterization of partial discharge behavior is an

effective tool in selecting dielectric materials, establishing voltage
ratings, and indentifying exposure dependent failure modes of
high voltage connectors and terminations. By understanding a
components response to partial discharge activity, material
selection, geometries, and interfaces can be optimized to increase
endurance and reliability.
Partial discharge behavior is
associated with dielectric aging and exposure dependent
reduction in dielectric strength. Long term electrical aging
influences several stress types, which have reversible and/or
irreversible effects on the material and result in electrical,
thermal, and partial discharge breakdown mechanisms. When
combined with partial discharge measurements, a life-stress
relationship is established using accelerated life testing, with
thermal, voltage, and time acceleration factors. Since long-term
electrical ageing exists with the presence of partial discharge,
inception and extinction voltages are used to establish criteria for
accelerated life test voltages. A methodology is presented for
performance of partial discharge detection, selection of life test
parameters, and analyses of post test results.

I.

INTRODUCTION

When a high voltage potential is applied between a

conductor and ground such that the air or gas within the
resulting electric field is overstressed, the air or gas becomes
conducting and a dielectric failure of an interposed solid
dielectric may occur. However, more often this solid
insulation does not puncture, and limits the current flow
between potentials, while the air or gas conducts partially or
ionizes. The characterization of this deleterious effect of
ionization or partial discharge can be useful tool in
predicting material life.
Instantaneous catastrophic dielectric strength failures rarely
occur in electrical systems. The major breakdown mechanisms
are either thermal or a slow deterioration of the dielectric
material by partial discharge.
In most cases thermal
breakdown is time dependent, related to the thermal time
constant of the material and occurring when the heat, caused
by electrical losses, exceeds the materials thermal capability.
This breakdown mechanism is easily avoided by proper
thermal analysis and selection of materials. However, partial
discharge is ever-present, causing cumulative degradation,
which eventually results in the material reaching its
breakdown stress level or in localized thermal breakdown.
Since partial discharge produces ozone, a powerful
oxidizing agent; corrosive nitric acid, particularly in the

978 -1-4244-7129-4/10/$26.00 2010 IEEE

Fig. 1. Corona-starting voltage, RMS, versus equivalent electrical

thickness of insulation system.

The use of corona inception voltages is useful in

characterizing connector and electrical termination
performance. Even more meaningful, yet requiring more
evaluation is the use of pulse counting techniques to determine
the distribution of partial discharge magnitude.
This
distribution helps in the characterization and analysis of
dielectric aging.
Obtaining reliable high voltage
measurements with DC voltages can be challenging. The DC
discharge activity can be difficult to interpret, since it is
strongly dependent on the previous discharge and voltage

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history. In the AC case, one can imagine that the internal

charging and discharging during every cycle removes
history. In DC application, the results of previous exposures
influence future discharge measurements. It is important to
note [2] that DC partial discharges in voids and interfaces are
significantly smaller in magnitude compared with the same
AC peak voltages at the same point. To reach the same
electron transfer due to DC excitation requires an even higher
AC voltage. Also shown, is that there is no effective
difference between partial discharges from a DC voltage than
from an equivalent peak AC voltage. The same electron
avalanche effect exists such that the dielectric damage is the
same for AC and DC excitation for identical numbers of
pulses and amplitudes. It has been determined that the ratio of
DC to AC peak voltage can be as high as 3.5:1 to produce the
same partial discharge activity [3].
II.

TABLE I
CONNECTOR TYPE 1:
5 KV DC RATING
Plug/Cable Assy Mated Plug/Cable Assy Mated
to Receptacle
to Receptacle
(Before Life Test)
(After Life Test)
Inception
Extinction
Inception
Extinction
Life Test
KV RMS, 60 KV RMS, 60 KV RMS, 60 KV RMS, 60
Failure #
Hz
Hz
Hz
Hz

PARTIAL DISCHARGE TEST METHODOLOGYINTERCONNECTIONS

A population of DC rated interconnection pairs were

evaluated and characterized under AC (60 Hz) voltage
conditions. The purpose of the testing was to derive an AC
voltage rating for applications other than those requiring their
proven DC rating. In order to isolate the connector pairs
discharge performance from the required coaxial wiring, AC
inception and extinction tests were performed on the test
cables by themselves to ensure minimal contribution to the
connectors partial discharge results. Connectors were wired
and mated to suitable dead head connectors. Three (3) sets
of connector types were selected with a sample size of ten (10)
each. Each sample was tested for both AC corona inception
and extinction voltages a total of three (3) consecutive times
and voltages averaged. The resulting data was used to select a
starting point for conducting subsequent thermal life tests (See
Tables I, II, III). The data from the life tests would be used to
select an appropriate AC rating for the connectors, including
suitable margin for application specific temperature extremes
and mechanical environments.
Thermal life tests were performed at the connectors
maximum rated temperature. Starting AC voltages varied by
connector depending on partial discharge performance.
Voltages were increased 250 VAC (RMS) approximately
every 96 hrs. Although not shown, time to failure was
recorded to be from 1000 to 1400 hrs depending on the
connector type. Voltage at failure is the voltage at which
approximately half the population failed (See Table IV for
data). Accelerated life calculations using the temperature and
time can be calculated using the typical Arrhenius relationship
with time as a multiplier.

1.2

1.0

1.3

1.2

--

1.1

0.9

1.3

1.1

--

1.2

0.9

1.2

1.0

1.2

0.9

1.2

1.0

1.2

1.0

1.2

0.9

1.2

1.0

1.2

1.0

--

1.2
1.2
1.1
1.2

1.0
0.9
0.9
1.0

1.3
1.2
1.4

1.1
1.0
1.3

Ave
Low
High

2
1.4

1.3

-4
1

TABLE II
CONNECTOR TYPE 2
10 KV DC RATING
Plug/Cable Assy Mated Plug/Cable Assy Mated
to Receptacle
to Receptacle
(Before Life Test)
(After Life Test)
Extinction
Inception
Extinction
Inception
Life Test
KV RMS, 60 KV RMS, 60 KV RMS, 60 KV RMS, 60
Failure #
Hz
Hz
Hz
Hz
2.7

2.2

2.5

2.0

2.6

2.0

2.5

2.1

4
2.4

2.1

--

2.4

2.1

--

2.8

2.3

2.5

1.9

2.3

1.9

--

2.6

2.1

2.4

2.0

--

2.4

2.0

2.6

2.2

2.2

1.8

--

2.5
2.6
2.4
2.8

1.9
2.1
1.9
2.3

2.4
2.3
2.2
2.4

2.2
2.0
1.8
2.2

Ave
Low
High

--

TABLE III
CONNECTOR TYPE 3
15 KV DC RATING
Plug/Cable Assy Mated Plug/Cable Assy Mated
to Receptacle
to Receptacle
(Before Life Test)
(After Life Test)
Extinction
Inception
Extinction
Inception
Life Test
KV RMS, 60 KV RMS, 60 KV RMS, 60 KV RMS, 60
Failure #
Hz
Hz
Hz
Hz

(1)

522
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6.3

5.8

3.8

3.5

--

3.2

2.9

3.3

3.0

--

3.6

3.1

5.7

5.4

3.8

3.6

--

3.0

2.5

3.3

3.0

--

3.1

2.8

3.1

2.7

3.8

3.2

3.3

2.7

3.8

3.6

--

3.5
3.9
3.0
6.3

2.9
3.4
2.5
5.8

2.4
3.4
2.4
3.8

2.1
3.1
2.1
3.6

Ave
Low
High

--

TABLE IV
LIFE TEST DATA
TEST
SAMPLE
1
2
3

III.

minimize voids and gaps which are prone to discharge

events.

VOLTAGE AT
FAILURE
2.0 KVAC
6.0 KVAC
5.0 KVAC

Examination of Connector Type 3 failures show

dielectric breakdown in the connector interface area
between mated plug/receptacle interfaces. This may
indicate a lack of dimensional control of mechanical
interfaces which results in a reduction in mating forces
necessary for proper high voltage seal performance.

OBSERVATIONS AND ANALYSIS-CONNECTORS

Results for the three connector types contain the following

observations
x With some exception, inception and extinction values
have small variance between samples, indicating good
overall quality control. Large variances in values
would indicate poor control of internal dimensions,
including creep lengths, seals, and geometries.
x

Test samples failed at approximately the same voltage

and within an approximate 96 hr period. This indicates
a possible similarity in failure modes.

Samples which did not fail exhibit minimal or no

decrease in corona inception and extinction voltage
performance. This observation is not expected since it
has been suggested earlier that partial discharge would
result in deterioration in the dielectric material resulting
in an increase in voids. Further study is needed in this
area.

Connector type 3 exhibits a slightly lower voltage at

failure than samples 1 and 2 despite its higher DC
rating. This is indicative of a design which provides
superior dielectric strength and dielectric thicknesses,
suitable for DC performance, yet contains less than
optimum geometries and interfaces which may
introduce voids or high e-stress points.

Examination of Connector Type 1 non-failures

indicates expected significant coronal activity exhibited
by dielectric pitting and white discoloration. All failed
units exhibited breakdown within cable insulation at
the wire/braid shield interface (See Fig 2). This is
indicative of a possibly weak design or termination
technique in the cable/connector termination area. The
irregular geometry of braid shields often is the source
of concentrated e-fields.
Improved designs can
incorporate the use of semi-conductive bushings or
layers to provide a smooth field transition from e-stress
concentrating braid strands to electrodes. Also braid
dressing can be improved to isolate braid ends.

Fig. 2. Connector Type I failure mode

Fig. 3. Connector Type II failure mode

Examination of Connector Type 2 failures shows

dielectric breakdown through an insulator wall to the
rear of the contact (See Fig. 3). Electrode geometries,
particularly of contacts must be carefully designed to
prevent sharp corners. Electrode/dielectric interfaces,
whether adhesively or mechanically maintained must

IV.

PARTIAL DISCHARGE TEST METHODOLOGY-WIRE

A population of DC rated fluoropolymer wires were

evaluated and characterized under AC (60 Hz) voltage
conditions. The purpose of the testing was to derive an AC
voltage rating for applications other than those requiring their

523
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proven DC rating. Three (3) sets of wire types (0.050,

0.080, and 0.100 inches on outer diameter with different
conductor gage sizes) were selected with a sample size of ten
(10) each. Each sample was tested for both AC corona
inception and extinction voltages a total of three (3)
consecutive times and voltages averaged (See Tables V). The
resulting data was used to select a starting point for
conducting subsequent thermal life tests. The data from the
life tests would be used to select an appropriate AC rating for
the connectors, including suitable margin for application
specific temperature extremes and mechanical environments.
Thermal life tests were performed at 125C; the wires
suggested operating temperature for high voltage applications.
Wires were wrapped a uniform number of times around an
appropriately sized grounded mandrel (See Fig 4). Starting
AC voltages varied by wire depending on partial discharge
performance. Voltages were increased approximately 250
VAC (RMS) as shown. Voltage at failure is the voltage at
which approximately half the population failed (See Table VI
for data).

Fig. 4. Typical thermal life wire setup

TABLE VI
THERMAL LIFE DATA-TIME TO FAILURE

TABLE V
CORONA INCEPTION/EXTINCTION DATA


0.100 cable on 2.00 inch mandrel

0.100 DIA FEP CABLE TEST (Tested on 2.00 Inch Dia Mandrel)
Test 1

Test 2

Test 3

Sample

inception

extinction

inception

extinction

inception

extinction

avg inc.

avg ext

1
2

2.55
2.60

2.30
2.40

2.50
2.60

2.35
2.40

2.60
2.65

2.40
2.30

2.55
2.62

2.35
2.37

2.60

2.40

2.60

2.40

2.65

2.40

2.62

2.40

4
5

2.40
2.20

2.10
1.95

2.50
2.20

2.10
1.90

2.40
2.15

2.05
1.90

2.43
2.18

2.08
1.92

6
7

2.55
2.60

2.40
2.35

2.60
2.65

2.45
2.40

2.65
2.65

2.45
2.45

2.60
2.63

2.43
2.40

8
9

2.70
2.60

2.40
2.40

2.70
2.65

2.50
2.40

2.70
2.65

2.45
2.40

2.70
2.63

2.45
2.40

2.60
10
Wire ends in air
Tested on Biddle

2.40

2.70

2.45

2.70

2.45
Average
Low
High

2.67
2.56
2.18
2.70

2.43
2.32
1.92
2.45

avg inc.

avg ext

0.080 DIA FEP CABLE TEST (Tested on 1.50 Inch Dia Mandrel)
Sample

Test 1
inception
extinction

Test 2
inception
extinction

Test 3
inception
extinction

1
2

2.15
2.40

1.90
2.20

2.20
2.50

1.80
2.20

2.10
2.45

1.90
2.20

2.15
2.45

1.87
2.20

3
4

2.35
2.40

2.15
2.10

2.40
2.40

2.15
2.05

2.35
2.40

2.10
2.05

2.37
2.40

2.13
2.07

5
6

2.20
1.85

2.00
1.70

2.20
1.90

2.05
1.80

2.25
1.95

2.05
1.70

2.22
1.90

2.03
1.73

7
8
9

2.40
2.35
2.30

2.10
2.05
2.00

2.40
2.40
2.40

2.15
2.05
2.10

2.40
2.30
2.40

2.20
2.05
1.80

2.40
2.35
2.37

2.15
2.05
1.97

2.50
10
Wire ends in air
Tested on Biddle

2.25

2.55

2.10

2.50

2.00
Average
Low
High

2.52
2.31
1.90
2.52

2.12
2.03
1.73
2.20

0.050 DIA FEP CABLE TEST (Tested on 1.00 Inch Dia Mandrel)
Test 1

Test 2

Test 3

Sample
1
2
3

inception

extinction

inception

extinction

inception

extinction

avg inc.

avg ext

1.70
1.75
1.60

1.40
1.60
1.45

1.75
1.80
1.60

1.50
1.55
1.40

1.75
1.75
1.60

1.50
1.50
1.30

1.73
1.77
1.60

1.47
1.55
1.38

4
5
6

1.65
1.50
1.40

1.45
1.30
1.25

1.70
1.50
1.40

1.45
1.40
1.25

1.70
1.45
1.40

1.50
1.35
1.20

1.68
1.48
1.40

1.47
1.35
1.23

7
1.75
8
1.60
1.45
9
1.60
10
Wire ends in air
Tested on Biddle

1.55
1.45
1.35
1.45

1.75
1.65
1.40
1.65

1.50
1.45
1.35
1.40

1.75
1.70
1.40
1.65

1.50
1.55
1.30
1.50
Average
Low
High

1.75
1.65
1.42
1.63
1.61
1.40
1.77

1.52
1.48
1.33
1.45
1.42
1.23
1.55

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532

Time (Hrs)
0
115
137
164
255
286
349
371
444
541
543
553.5
575

KV (60Hz) Current
2.25
2.5
2.75
3
2.1mA
3.25
2.1mA
3.5
2.45mA
3.75
2.55mA
3.75
4.25
4.25
4.25
4.25
4.25

Comments
Start Test
Increase Voltage
Increase Voltage
Increase Voltage
Increase Voltage
Increase Voltage
Increase Voltage
Fail #1
Increase Voltage
Fail #2
Fail #3
Fail #4
Fail #5 - End Test

SN

0.080
cable
2.00 inch mandrel
ble
on 1.50
inchonmandrel
Time (Hrs)
KV (60Hz) Current
0
2
115
2.25
137
2.5
164
2.75
.68mA
255
3
.75mA
286
3.25
.87mA
349
3.5
.91mA
412
3.5
427.5
3.5
430
3.5
454
3.5
532.5
3.5

Com ments
Start Test
Increase Voltage
Increase Voltage
Increase Voltage
Increase Voltage
Increase Voltage
Increase Voltage
Fail #1
Fail #2
Fail #3
Fail #4
Fail #5 - End Test

SN

Com ments
Start Test
Increase Voltage
Increase Voltage
Increase Voltage
Fail #1 - removed
Fail #2 - removed
Fail #3 - removed
Fail #4 - End Test

SN

7
10
2
3
1

1
4
10
7
3

0.050 cable on 2.00 inch mandrel

ble on 1.00 inch mandrel

Time (Hrs)
KV (60Hz)
0
1.25
115
1.5
137
1.75
164
2
168
2
171
2
171.5
2
172
2

1
3
9
8

V.

OBSERVATIONS AND ANALYSIS-WIRE

Of interesting note is that the corona inception values

follow very closely to data present by [1] in Fig. 1. Failure
modes are as expected with failures occurring adjacent to the
grounded mandrel and at 90 from the mandrel adjacent to
neighboring turns of the same wire. It is suggested that these
latter failures may be the result of increased field intensity due
to the additional field lines caused by the adjacent electrode.
Failure modes suggest erosion of the fluoropolymer material
due to partial discharge effects (See Fig. 5). Suggested AC
ratings can be proposed based on the voltage at failure values
of 4.25KVAC (0.100), 3.5KVAC (0.80) and 2.0KVAC
(.050). Using an approximate safety margin, suggested
KVAC ratings may be 3.0KVAC, 2.0KVAC, and 1.0KVAC
respectively. Since these values are very close to the corona
inception values measured for the three wire types, it can also
be suggested that these and similar wires should not be
operated above their corona inception value.
Although not examined in this paper, it was found that
when the same wire types were tested in the same way, but
with a mandrel diameter the size reported here, the voltage
at failure was approximately 40% less that values reported
here. Also, all failure modes were at the outside diameter of
the wire, 180 from the mandrel, adjacent to free air. It may
be suggested that the mechanical stress applied to the wire
weakened the dielectric material resulting in premature failure.

Fig. 5. Erosion of fluoropolymer material due to partial discharge

REFERENCES
[1]

Perkins, J.R., E.I. du Pont de Nemours& Company, Chapter 6,

High Voltage Wiring and Connector Systems, in Handbook of
Wiring, Cabling, and Interconnecting for Electronics, C.A.
Harper, ed

[2]

H.C, Hall and R.M. Russek, Discharge Inception and Extinction

in Dielectric Voids, Proceedings of IEEE, Vol. 101, Part 2, 1954

[3]

R.D. Parker, R.S. Buritz and J. Burnham, A Solid Insulation

System for Airborne High Voltage Components and Systems.
IEEE Transactions on Industrial Electronics and Control
Instrumentation, Vol I IECI-22, No.2, May 1975

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