DT04-3P-KIT - TE Connectivity / DEUTSCH

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Product

Specification

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PRODUCT INFORMATION 1-800-522-6752

108-151009

28 JUNE 2017 Rev B4

DT Series Connector System

1. SCOPE

1.1. Content

This specification covers performance, tests and quality requirements for the TE Connectivity (TE) DT

Series Connector System.

1.2. Qualification

When tests are performed on the subject product line, procedures specified in Figure 2 shall be used. All

inspections shall be performed using the applicable inspection plan and product drawing.

1.3. Qualification Test Results

Successful qualification testing on the subject product line was completed in 1987. The Qualification

Test Report number for this testing is 501-151032. This documentation is on file at and available from

Engineering Practices and Standards (EPS).

2. APPLICABLE DOCUMENTS AND FORMS

The following documents and forms constitute a part of this specification to the extent specified herein.

Unless otherwise indicated, the latest edition of the document applies.

2.1. TE Connectivity (TE) Documents

● 0425-017-0000: DT Series Performance and Application Characteristics

● 109-1: General Requirements for Testing

● 114-151000: Application Specification for DEUTSCH Size 16 S&F Pin & Socket

● 408-151008: Instruction Guide DEUTSCH Removal Tool DT-RT1

● 501-151032: DT Qualification Test Report

● Product Drawings

X refers to A, B, C, D keys. XXXX refers to product modification.

DT04-2P-XXXX

2pin Receptacle

DT13-2P-XXXX

2pin Receptacle, 90° Header

DT04-3P-XXXX

3pin Receptacle

DT13-4P-XXXX

4pin Receptacle, 90° Header

DT04-4P-XXXX

4pin Receptacle

DT13-6P-XXXX

6pin Receptacle, 90° Header

DT04-6P-XXXX

6pin Receptacle

DT13-08PX-XXXX

8pin Receptacle, 90° Header

DT04-08PX-XXXX

8pin Receptacle

DT13-12PX-XXXX

12pin Receptacle, 90° Header

DT04-12PX-XXXX

12pin Receptacle

DT15-2P-XXXX

2pin Receptacle, 180° Header

DT06-2S-XXXX

2pin Plug

DT15-3P-XXXX

3pin Receptacle, 180° Header

DT06-3S-XXXX

3pin Plug

DT15-4P-XXXX

4pin Receptacle, 180° Header

DT06-4S-XXXX

4pin Plug

DT15-6P-XXXX

6pin Receptacle, 180° Header

DT06-6S-XXXX

6pin Plug

DT15-08PX-XXXX

8pin Receptacle, 180° Header

DT06-08SX-XXXX

8pin Plug

DT15-12PX-XXXX

12pin Receptacle, 180° Header

DT06-12SX-XXXX

12pin Plug

1011-344-0205

2pin Dust Cap

DT16-6SX-XXXX

6pin Plug

1011-345-0305

3pin Dust Cap

DT16-15SX-XXXX

15pin Plug

1011-346-0405

4pin Dust Cap

DT16-18SX-XXXX

18pin Plug

1011-347-0605

6pin Dust Cap

1011-348-0805

8pin Dust Cap

1011-349-1205

12pin Dust Cap

108-151009

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Wedge Lock PN's sold separately but are required for DT functionality

2.2. Industry Documents

● DIN 40050-9: Road vehicles Degrees of Protection (l P Code)

● DIN 72551-6: Road Vehicles—Low-Tension Cables—Part 6: Single-Core, Unscreened with Thin

Insulation Wall; Dimensions, Materials, Marking

● EIA-364: Electrical Connector/Socket Test Procedures Including Environmental Classifications

● IEC-60512: Electronic Equipment - Tests and Measurements

● IEC-60529: Degrees of Protection Provided by Enclosures (IP Code)

● ISO 6722: Road Vehicles—60 V and 600 V Single-Core Cables—Dimensions, Test Methods, and

Requirements

● SAE J1128: Low Voltage Primary Cable

3. REQUIREMENTS

3.1. Design and Construction

Product shall be of the design, construction, materials and physical dimensions specified on the

applicable product drawing.

3.2. Ratings

● Voltage: 250 VDC

● Current (Amp): See Figure 1

Connector Loading

Wire Size

AWG [mm2]

[2.0]

[1.0]

[.80]

[.50]

All Circuits Energized

13.0

10.0

7.5

Figure 1

● Temperature: -55°C to +125°C

● Ingress Protection (IP) Level: IP68 and IP6K9K (with rear protection, such as backshell)

● Flammability: UL Recognized. Parts have been successfully tested to the 20 mm Flame Test per

Standard UL-94

W2P-XXXX

2pin Rcpt Wedge Lock

W2SX-XXXX

2pin Plug Wedge Lock

W3P-XXXX

3pin Rcpt Wedge Lock

W3S-XXXX

3pin Plug Wedge Lock

W4P-XXXX

4pin Rcpt Wedge Lock

W4SX-XXXX

4pin Plug Wedge Lock

W6P-XXXX

6pin Rcpt Wedge Lock

W6S-XXXX

6pin Plug Wedge Lock

W8P-XXXX

8pin Rcpt Wedge Lock

W8S-XXXX

8pin Plug Wedge Lock

W12P-XXXX

12pin Rcpt Wedge Lock

W12S-XXXX

12pin Plug Wedge Lock

108-151009

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3.3. Test Requirements and Procedures Summary

Unless otherwise specified, all tests shall be performed at ambient environmental conditions.

See Appendix A for additional test requirements

See Appendix B for Procedure Comparison Chart with ISO standards

Test Description

Requirement

Procedure

Examination of Product

The connectors shall be correctly

constructed, marked and shall

show good quality and

workmanship

EIA-364-18.

Visually inspected for use of materials, proper

construction, correct part number and insert

markings and over-all quality of workmanship. Poor

molding fabrication, loose materials, damaged or

improperly manufactured contacts, galling of metal

parts, nicks and burrs of metal parts, torn seals or

cracked plastic were considered adequate basis for

rejection.

ELECTRICAL

Insulation Resistance

1000 MΩ minimum at 25C

MIL-STD-1344, Method 3003.1

Using a 500 VDC megohmmeter check each contact

to all other contacts and the shell electrically

connected together.

Dielectric Withstanding

Voltage

No evidence of breakdown or

flashover or current leakage in

excess of 2.0 milliampers.

MIL-STD-1344, Method 3001.1

Check each contact to all other contacts and the

shell electrically connected together for breakdown /

flashover when subjected to a 1500 VAC test

potential for a period of 1 minute.

Contact Resistance

Maximum voltage drop across a 6

inch wire/contact assembly shall

be 89mV max for 16AWG.

MIL-STD-1344, Method 3004.1

15A for 16AWG.

MECHANICAL

Maintenance Aging

There shall be no visible change

or damage to the contact cavities.

MIL-STD-1344, Method 2002.1

Subject 10% of the cavities to 10 cycles of inserting

and removing its respective contact. Insert by hand,

remove using removal tool.

Contact Retention

The contact shall remain in place

MIL-STD-1344, Method 2007.1

Subject each wired contact to an applied load of 25

lbf for a period of 15 seconds in a direction tending to

push the contact out of the rear of the connector.

Durability

No evidence of damage to the

contacts, contact plating,

connector housing or seals which

may be detrimental to reliable

connector performance.

MIL-STD-1344, Method 2016

The connector shall be mated and unmated for a

total of 100 complete cycles at room temperature.

Vibration

No discontinuity in excess of 1.0

μs at 100 mA during the last hour

of each axis. Shall meet visual

requirements, show no physical

damage and meet requirements

of additional tests as needed.

MIL-STD-1344, Method 2005.1

Sine Sweep: 10 to 2000 Hz

Sweep Cycle: 20 minutes

Initial Displacement: .07 inch DA

Maximum Acceleration: 20g

Test Duration: 12 hours

Time Per Axis X, Y, Z: 4 hours

Test Current first 3 hours each axis:

16 AWG: 13A

Figure 2 Cont.

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Test Description

Requirement

Procedure

Shock

No discontinuity in excess of 1.0

μs at 100 mA during the last hour

of each axis. Shall meet visual

requirements, show no physical

damage and meet requirements

of additional tests as needed.

MIL-STD-1344, Method 2004.1

10 cycles of ½ sine pluses, 50g±15%, 11±1 ms

duration X and Z axis are to be tested.

ENVIRONMENTAL

Temperature Life

There shall be no evidence of

cracking, distortion or detrimental

damage to the connector

following the test. Meet 500 MΩ

minimum

MIL-STD-1344, Method 1005.1

The wired mated connectors shall be subjected to

100 hours at 125°C. Insulation resistance shall be

measured immediately after removing sample from

the oven.

Salt Spray

There should be no evidence of

corrosion on the connector or

terminals after the connector is

removed from the test and

cleaned with tap water.

MIL-STD-1344, Method 1001.1

Connector shall be fully mated, then submerged in a

fine mist of 5% by weight of salt solution for 96 hour.

Fluid Immersion

There shall be no evidence of

cracking, distortion or detrimental

damage to the connector

following the test.

MIL-STD-1344, Method 1016

Subject each connector to one fluid only. The wired

mated connectors shall be submerged in the fluids

below at ambient temperature. Each connector shall

be submerged for 5 minutes, then removed from the

fluid to air dry for 24 hours. This cycle is to be

completed a total of 5 cycles.

- Motor Oil 30 weight

- Brake Fluid (disc type 1)

- Gasoline

- Diesel Fuel #2

- Antifreeze Solution (Max Protection)

- Transmission Oil 90 weight

Thermal Shock

There shall be no evidence of

cracking, distortion or detrimental

damage to the connector

following the test. Meet 500 MΩ

minimum

MIL-STD-1344, Method 1003.1

Cycle mated connectors for 30 minutes at –55°C

followed by 30 minutes at +125°C with 2 minute max

transfer time. Repeat for 5 cycles. Insulation

resistance measured during last heat cycle.

Moisture

Connectors shall show no sign of

moisture inside the cavities or

connector interior.

The wired mated connectors shall be immersed in 3

feet of water for 24 hours.

Figure 2 end

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3.4. Product Qualification and Requalification Test Sequence

NOTE

a) Specimens shall be prepared in accordance with applicable Instruction Sheets and shall be

selected at random from current production. Specimens shall consist of 3 position connectors

with DEUTSCH Solid Terminal System size 16 nickel plated pin and socket contacts 16 AWG

GXL wire.

b) Numbers indicate sequence in which tests are performed.

Test

Test Group (a)

Test Sequence (b)

Examination of Product

Insulation Resistance

Dielectric Withstanding Voltage

Maintenance Aging

Temperature Life

Contact Retention

Durability

Salt Spray

Moisture

Fluid Immersion

Thermal Shock

Vibration

Shock

Contact Resistance

Final Examination

108-151009

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3.5. Appendix A Additional test requirements

Test Description

Requirement

Procedure

ELECTRICAL

Low Level Contact Resistance

Wire Size Resistance

AWG [mm2] mΩ max

16 [1.0] 6.0

18 [.80] 7.5

20 [.50] 11.0

EIA-364-23

Test with applied voltage not to exceed 20 mV open

circuit and the test current shall be limited to 100 mA.

The resistance of an equal length of wire (reference wire)

shall be subtracted from the same reel as used for the

connector wiring.

Contact Resistance

Wire Test Voltage Drop

Size Current (mV max)

AWG [mm2] (A) Solid S&F

14 [2.0] 13 60 100

16 [1.0] 13 60 100

18 [.80] 10 60 100

20 [.50] 7.5 60 100

EIA-364-6

Using test currents as defined. The resistance of an

equal length wire (reference wire) shall be subtracted

from the actual readings to determine the added

resistance of the terminal. The reference wire shall be

from the same reel as used for the connector wiring.

MECHANICAL

Vibration

There shall be no discontinuity in excess of

one (1) μs at 20mV and 100 mA during the

last hour of each axis.

Shall meet visual requirements, show no

physical damage and meet requirements of

additional tests as needed.

Sine Sweep: 10 to 2000 Hz

Initial Displacement: 1.78 mm DA

Maximum Acceleration: 20 G’s

Test Duration: 12 hours

Time Per Axis X, Y, Z

Test Current first 3 hours each axis:

14-16 AWG[2.0-1.0]: 10A

18 AWG [.80]: 8A

20 AWG [.50]: 5A

Impact

There shall be no evidence of cracking,

distortion or detrimental damage to the

connector following the test. Small chips and

dents that do not adversely affect the

connector shall be disregarded.

Wired mated connector shall be dropped from a height of

1.2m on a cement floor. This action is to be completed a

total of five (5) times.

Connector Retention

There shall be no evidence of cracking,

distortion or detrimental damage to the

connector following the test

Apply a pulling force to the wire bundles that exit the rear

of the connector for a period of one (1) minute. The

amount of load is to be 111N, times the number of

cavities, up to a maximum of 445N.

ENVIRONMENTAL

Temperature Life

There shall be no evidence of cracking,

distortion or detrimental damage to the

connector following the test.

The wired mated connectors shall be subjected to 1000

hours at +125 ±3°C without current flowing as per MIL-

STD-202, Method 108, Test Condition D.

Fluid Immersion

There shall be no evidence of cracking,

distortion or detrimental damage to the

connector following the test.

Subject each sample group to one fluid only. The wired

mated connectors shall be submerged in the fluids below

at the temperatures listed. Each connector shall be

submerged for five (5) minutes, then removed from the

fluid to air dry for 24 hours. This cycle is to be completed

a total of five (5) cycles.

Figure 3 Cont.

108-151009

Rev B4

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Test Description

Requirement

Procedure

Thermal Cycle

There shall be no evidence of cracking,

distortion or detrimental damage to the

connector following the test.

Cycle mated connectors from –55 ±

3°C to +125 ±3°C at a rate of 3°C ±

1°C per minute. Connectors to remain

at each temperature extreme for one

(1) hour minimum. Mated connectors

are to be cycled a total of 20 complete

cycles.

Water Immersion

Test samples must meet insulation

resistance.

The wired mated connectors shall be

placed in an oven at +125 ±3°C for two

(2) hours minimum then immediately

be placed in water with a 5% salt by

weight content and 0.1 g/L wetting

solution to a depth of 914mm for four

(4) hours minimum. The free ends of

the mated connectors must remain out

of the water to prevent wicking of the

water through the open wires. Water

temperature to be +23 ±3°C.

Figure 3 end

3.6. Appendix B Test Procedure Comparison Chart

Test

MIL-STD-1344

Method

EIA-364

Dash No.

Similar to

SAE J2030

Paragraph

Similar to

ISO 8092-2

Paragraph

Examination of product

6.1

4.2

Insulation Resistance

3003.1

6.3

4.12

Dielectric Withstanding Voltage

3001.1

4.13

Low Level Contact Resistance

3002.1

6.2

4.8

Contact Resistance

3004.1

6.4

4.8

Maintenance Aging

2002.1

6.6

Contact Retention

2007.1

6.18

4.7

Durability

2016

6.11

4.3

Vibration

2005.1

6.15

Shock

2004.1

6.16

Impact

6.17

4.20

Connector Retention

6.20

Temperature Life

1005.1

6.7

4.18

Salt Spray

1001.1

6.12

4.16

Fluid Immersion

1016

6.14

4.23

Thermal Cycle

Thermal Shock

1003.1

6.13

4.22

Moisture

Water Immersion

6.19

4.9

Mouser Electronics

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