Product
Specification
108-12057
07Aug08 Rev E
All Paragraphs Revised
ECONOMATE II Connector Receptacle and Blade Header
Assembly
1.
1.1.
SCOPE
Content
This specification covers perform ance, tests and quality requirem ents for the Tyco Electronics
ECONOMATE II Connector Assem bly.
1.2.
Qualification
W hen tests are perform ed on the subject product line, procedures specified in Figure 1 shall be used.
All inspections shall be perform ed using the applicable inspection plan and product drawing.
2.
APPLICABLE DOCUM ENTS
The following Governm ent docum ents form a part of this specification to the extent specified herein.
Unless otherwise specified, the latest edition of the docum ent applies. In the event of conflict between
the requirem ents of this specification and the product drawing, the product drawing shall take
precedence. In the event of conflict between the requirem ents of this specification and the referenced
docum ents, this specification shall take precedence.
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3.
3.1.
MIL-C-28754: Connectors, Electrical, Modular, and Com ponent Parts General Specification for
MIL-C-45662: Calibration of Standards
MIL-W -16867: W ire, Electrical, Insulated High Tem perature
MIL-STD-105: Sam pling Procedures and Tables for Inspection by Attributes
MIL-STD-202: Test Methods for Electronic and Com ponent Parts
MIL-STD-1285: Marking of Electrical and Electronic Parts
REQUIREM ENTS
Design and Construction
Product shall be of the design, construction and physical dim ensions specified on the applicable product
drawing. W hen required, each connector shall be identified by part num ber and date coded in
accordance with applicable portions of MIL-STD-1285.
3.2.
Materials
Materials used in the construction of this product shall be as specified on the applicable product
drawing.
3.3.
Ratings
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Voltage: 800 volts rm s
Current: 3 am peres m axim um unless otherwise restricted by the PCB or circuit wiring
Tem perature: -55 to 105/C
3.4.
Perform ance and Test Description
Product is designed to m eet the electrical, m echanical and environm ental perform ance requirem ents
specified in Figure 1. Unless otherwise specified, all tests shall be perform ed at am bient environm ental
conditions. Measurem ents shall be taken using instrum ents that have been calibrated in accordance
with MIL-C-45662.
©2008 Tyco Electronics Corporation
Harrisburg, PA
All International Rights Reserved.
* Trademark
| Indicates change
For latest revision, visit our website at www.tycoelectronics.com\documents.
For Regional Customer Service, visit our website at www.tycoelectronics.com
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108-12057
3.5.
Test Requirem ents and Procedures Sum m ary
Test Description
Exam ination of product.
Requirem ent
Procedure
Specim ens shall be free of burrs
Visual inspection.
and all contact edges except for the
wire-wrap tail shall be free of sharp
edges. No evidence of other
physical dam age or defects that
would im pair norm al function.
ELECTRICAL
Low level contact resistance.
1 ohm m axim um .
Subject each pair of m ated contacts
to 1 m illiam pere m axim um and 20
m illivolts m axim um open circuit
voltage.
See Figure 3.
MIL-STD-202, Method 307.
Measure contact resistance across
each pair of m ated contacts using a
test current of 1 am pere DC.
See Figure 3.
MIL-STD-202, Method 302, Test
Condition B, 500 volts DC.
Test between all contacts and
between insulated contacts and
conductive m ounting plate, if
applicable.
Contact resistance.
8 m illiohm s m axim um .
Insulation resistance.
25,000 m egohm s m inim um .
Dielectric withstanding voltage.
One m inute hold with no breakdown MIL-STD-202, Method 301.
or flashover.
1,000 volts AC at sea level.
Test between all contacts and
between insulated contacts and
conductive m ounting plate, if
applicable.
See Note.
Subject series wired m ated contacts
to a DC current overload of 125% of
rated current (3.75 am peres) for a
period of 2 hours, im m ediately
followed by an increase to 150% of
rated current (4.5 am peres) for 5
m inutes, then current off.
MECHANICAL
Current overload.
Vibration.
No discontinuities of 1 m icrosecond MIL-STD-202, Method 204, Test
or longer duration.
Condition B.
See Note.
Subject specim ens to 10 to 2,000
Hz.
No discontinuities of 1 m icrosecond MIL-STD-202, Method 213, Test
or longer duration.
Condition B.
See Note.
Figure 1 (continued)
Physical shock.
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108-12057
Test Description
Durability.
See Note.
Requirem ent
Procedure
Mate and unm ate specim ens with a
corresponding blade header
assem bly for 100 cycles at a
m axim um rate of 10 cycles per
m inute.
Measure force required to m ate
specim ens with a corresponding
blade header assem bly.
Measure force required to withdraw
a m inim um size gage from each
individual contact.
See Figure 4.
Apply specified axial load to contact
posts in a direction toward the
connector and hold for 5 to 10
seconds.
Apply specified force to the base of
each contact post in both clockwise
and counterclockwise directions
and hold for 5 to 15 seconds.
MIL-C-28754, paragraph 4.9.6.
Apply specified force in a direction
norm al to a plane passing through
the center line of both keying pins
m idway between the first and
second cavities and .062 +.000/-
.031 inch from the bottom edge of
the shield.
See Figure 5.
Engaging force.
10 ounces m axim um average per
contact.
1 ounce m inim um average per
contact.
Separating force.
Contact retention.
Contacts shall not dislodge when a
m inim um axial force of 15 pounds
for soldered contacts and 7 pounds
for press-fit contacts is applied in
either direction.
Contacts shall not dislodge when a
m axim um force of 3 inch-ounces is
applied in both directions.
Pin shield shall not separate from
the housing nor exhibit dam age or
defects that would im pair norm al
function when a m axim um force of
4 pounds is applied to each end of
each pin shield.
Torque.
Pin shield retention.
ENVIRONMENTAL
Therm al shock.
See Note.
MIL-STD-202, Method 107, Test
Condition A.
Subject specim ens to 5 cycles
between -55 and 105/C.
MIL-STD-202, Method 101, Test
Condition B.
Subject specim ens to 5% salt spray
solution for 48 hours. After
exposure, specim ens shall be
thoroughly washed using tap water
and dried at 100/F for 24 hours
before proceeding with additional
testing.
Salt spray.
See Note.
Figure 1 (continued)
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108-12057
Test Description
Hum idity.
See Note.
Requirem ent
Procedure
MIL-STD-202, Method 103, Test
Condition B.
Subject specim ens to 90 to 95% RH
at 40/C for 96 hours. After
exposure, additional m easurem ents
shall be taken within 1 to 2 hours
after the specim ens are rem oved
form the cham ber.
NOTE
Shall meet visual requirements, show no physical damage, and meet requirements of additional
tests as specified in the Product Qualification and Requalification Test Sequence shown in Figure
2.
Figure 1 (end)
3.6.
Product Qualification and Requalification Test Sequence
Test Group (a)
Test or Exam ination
1
2
3
4
Test Sequence (b)
Exam ination of product
Low level contact resistance
Contact resistance
Insulation resistance
Dielectric withstanding voltage
Current overload
Vibration
Physical shock
Durability
Engaging and separating force
Contact retention
Torque
Pin shield retention
Therm al shock
Salt spray
Hum idity
NOTE
(a)
(b)
6
9
7
4
12
5
6
4,8
12
5
4
9
5
2
1
2
3,8
10
9
7
11
6
1
2,10
3,7,11
1
2
3
8
1
See paragraph 4.1.A.
Numbers indicate sequence in which tests are performed.
Figure 2
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108-12057
4.
4.1.
QUALITY ASSURANCE PROVISIONS
Qualification Testing
A.
Specim en Selection
Specim ens shall be prepared in accordance with applicable Instruction Sheets and shall be
selected at random from current production. Each test group shall consist of 4 specim ens. Four
inch lengths of 26 AW G MIL-W -16867 Type E wire shall be term inated to each connector post in
such a m anner to facilitate the test requirem ents for each specim en.
B.
Test Sequence
Qualification inspection shall be verified by testing specim ens as specified in Figure 2.
4.2.
Requalification Testing
If changes significantly affecting form , fit or function are m ade to the product or m anufacturing process,
product assurance shall coordinate requalification testing, consisting of all or part of the original testing
sequence as determ ined by developm ent/product, quality and reliability engineering.
4.3.
Acceptance
Acceptance is based on verification that the product m eets the requirem ents of Figure 1. Failures
attributed to equipm ent, test setup or operator deficiencies shall not disqualify the product. If product
failure occurs, corrective action shall be taken and specim ens resubm itted for qualification. Testing to
confirm corrective action is required before resubm ittal.
4.4.
Quality Conform ance Inspection
MIL-STD-105 shall specify the sam pling acceptable quality level to be used. Dim ensional and functional
requirem ents shall be in accordance with the applicable product drawing and this specification.
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