Tyco Electronics Corporation
300 Constitutional Drive
Menlo Park, CA 94025 USA
No: C-6114
Rev: A
Date: December 17, 1999
Page: 1 of 23
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MTC Quick-Disconnect Connectors with Removable Contacts
1.0 INTRODUCTION
1.1 Scope. This specification covers the design, performance and qualification
requirements for Raychem MTC connectors with a quick-disconnect coupling
mechanism and using rear-insert rear-release contacts. This specification forms a part
of Master Specification C-6100 for the Raychem Integrated Inter-connection System.
1.2 Description. The Raychem MTC connectors and shield grounding accessories covered
by this specification are rectangular connectors used to interconnect round wires.
Connectors and shield grounding accessories are designed to function in the
environments detailed in ARINC Specification 600 for Class B connectors (semi-
environment resisting for continuous operation with the temperature limits -65oC to
+125oC). Connectors consist of environment-resistant plug and receptacle shells.
Connector shells assure proper orientation of the mating halves and electrical continuity
between shells prior to contact engagement. Connectors covered by this specification
have inserts holding removable size 22, size 16, or size 12 contacts arranged in rows.
The requirements for size 22 contacts are specified in this document. Shield grounding
accessories accept size 22 contacts and provide a common grounding plane for wire
shielding.
1.3 Classification. Connectors covered by this specification are classified in accordance
with 1.3.1 and 1.3.2.
1.3.1 Connectors.
a. Series: MTCPQ: Size 22 contacts on 0.1 inch centers
Size 16 contacts on 0.2 centers
Size 12 contacts on 0.25 inch centers
b. Types: Plugs for cable mounting
Receptacles, unflanged for panel mounting
Receptacles, flanged for panel mounting
c. Classes: Standard
With shield grounding accessories
d. Shell Finish: Electroless nickel
e. Shell Size: Size 1: 1-inch nominal insert width
Size 2: 2-inch nominal insert width
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300 Constitutional Drive
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No: C-6114
Rev: A
Date: December 17, 1999
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1.3.2 Inserts.
a. Types: Removable for size 22 contacts
Removable for size 16 contacts
Fixed for size 12 contacts
b. Contact Style: Pin
Socket
c. Contact Size: Size 22 blade and tuning fork configuration
Size 16 for contacts compatible with MIL-C-38999, Series II
Size 12 for contacts compatible with MIL-C-83723, Series III
1.2.2 Shield Grounding Accessories.
a. Types: Size 10 with fingers, for use with Size 1 plug shells.
Size 10 without fingers, for use with Size 1 receptacle shells.
Size 20 with fingers, for use with Size 2 plug shells.
Size 20 without fingers, for use with Size 2 receptacle shells.
b. Contact Size: Size 22
1.4 Temperature Range. Connectors covered by this specification are suitable for use over
the temperature range -65oC to +125oC. Connectors are rated for 1000-hour service
when the operating temperature of the connector is the maximum rated temperature.
Operating temperature is the maximum temperature reached by any point of the
connector as a result of electrical current flow and ambient temperature.
1.5 Units. SI units in parentheses are for information only.
2.0 APPLICABLE DOCUMENTS
2.1 Issues of Documents. The following documents, of the issue in effect on date of order
or request for proposal, form a part of this specification to the extent specified herein.
This specification takes precedence over the referenced documents.
2.2 Department of Defense.
SPECIFICATIONS
Military
MIL-C-5541 Chemical Conversion Coatings on Aluminum and Aluminum
Alloys
MIL-H-5606 Hydraulic Fluid, Petroleum Base; Aircraft, Missile and
Ordnance
MIL-DTL-18240 Fastener Element, Self-Locking, Threaded Fastener, 250°C
Maximum
MIL-L-23699 Lubricating Oil, Aircraft Turbine Engine, Synthetic Base
MIL-C-26074 Coatings, Electroless Nickel
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300 Constitutional Drive
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No: C-6114
Rev: A
Date: December 17, 1999
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MIL-C-38999 Connectors, Electrical Circular, Miniature, High Density
Quick Disconnect (Bayonet, Threaded, and Breech
Coupling), Environment Resistant, Removable Crimp and
Hermetic Solder Contacts
MIL-G-45204 Gold Plating, Electrodeposited
MIL-C-83723 Connectors, Electrical Circular, Environment Resistant,
Receptacles and Plugs
MIL-P-83800 1,2 Propanediol (Propylene Glycol, Industrial Grade)
Federal
QQ-P-35 Chemical Passivation Treatments for Stainless Steel Parts
P-D-680 Dry Cleaning and Degreasing Solvent
TT-I-735 Isopropyl Alcohol
A-A-2904 Thinner, Paint, Mineral Spirits, Regular and Odorless
STANDARDS
Military
MIL-STD-105 Sampling Procedures and Tables for Inspection by Attributes
MIL-STD-202 Test Methods for Electronic and Electrical Component Parts
MIL-STD-454 Standard General Requirements for Electronic Equipment
MIL-STD-810 Environmental Test Methods and Engineering Guidelines
MIL-STD-1344 Test Methods for Electrical Connectors
MIL-STD-45662A Calibration Systems Requirements
Federal
FED-STD-H28 Screw-Thread Standards for Federal Services
(Copies of Department of Defense documents may be obtained from the Naval
Publications and Forms Center, 5801 Tabor Avenue, Philadelphia, PA l9l20-5099.)
2.3 American Society for Testing and Materials (ASTM).
A693 Precipitation Hardening Stainless Steel and Heat Resisting
Steel Plate Sheet and Strip
B85 Aluminum Alloy Die Castings
(Copies of ASTM publications may be obtained from the American Society for Testing
and Materials, 1916 Race Street, Philadelphia, PA 19103.)
2.5 Aeronautical Radio, Inc. (ARINC).
Specification 600-8 Air Transport Avionics Equipment Interfaces
(Copies of ARINC publications may be obtained from Aeronautical radio, Inc., 2551
Riva Road, Annapolis, MD 21401.)
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300 Constitutional Drive
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No: C-6114
Rev: A
Date: December 17, 1999
Page: 4 of 23
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2.6 Raychem Corporation.
C-6100 System Overview and General Requirements for Integrated
Interconnection System Components
(Copies of Raychem documents may be obtained from Raychem Corporation, 300
Constitution Drive, Menlo Park, CA 94025.)
2.7 International Standards Organization (ISO).
ISO 10012-1 Quality Assurance Requirements for Measuring Equipment,
Part 1.
(Copies of ISO documents may be obtained from International Organization for
Standardization, Case Postale 56, CH-1211 Geneve, Switzerland.)
2.8 Metal Powder Industries Federation (MPIF).
Standard 35 Materials Standards for Metal Injection Molded Parts
(Copies of MPIF documents may be obtained from Metal Powder Industries
Federation, 105 College Road east, Princeton, New Jersey 08540-6692.)
3.0 REQUIREMENTS
3.1 Specification Control Drawings. The requirements for connectors under this
specification shall be as specified herein and in the applicable specification control
drawing. In the event of conflict between the requirements of this specification and
those of the specification control drawing, the latter shall govern.
3.2 Classification of Requirements. The requirements for the connectors are classified
herein as follows:
Requirement Paragraph
Qualification 3.3
Materials 3.4
Design and Construction 3.5
Performance 3.6
Product Identification 3.7
Workmanship 3.8
3.3 Qualification. Connectors furnished under this specification or listed on Qualified
Products List C-6114-QPL shall be products which are qualified to this specification in
accordance with the requirements of Specification C-6100.
3.4 Materials Requirements. All materials used in the manufacture of these connectors
shall be of the quality and form best suited for the purpose intended.
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300 Constitutional Drive
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No: C-6114
Rev: A
Date: December 17, 1999
Page: 5 of 23
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3.4.1 Dissimilar Metals. When dissimilar metals are used in intimate contact with each
other, protection against electrolytic corrosion shall be provided as specified in MIL-
STD-454, Requirement 16.
3.4.2 Fungus Resistance. Finishes and materials shall be fungus-inert in accordance with
MIL-STD-454, Requirement 4, and encompassing the fungus species listed in MIL-
STD-810, Method 508.
3.4.3 Hydrolytic Stability. All nonmetallic materials shall be selected to meet the hydrolytic
reversion resistance requirements specified in MIL-STD-454, Requirement 47.
3.4.4 Component Materials. Materials for specific components of the connector shall be as
follows:
3.4.4.1 Contacts. Size 22 contact material shall be copper-based. Mating surfaces shall be
gold-plated per MIL-G-45204, Type I, Grade C, Class 1, over a suitable underplate.
Silver underplate shall not be used. size 16 and size 12 contacts shall comply with the
relevant contact specification. Grounding contacts shall be copper based with a suitable
plating material per the applicable specification control drawing.
3.4.4.2 Connector Shell. Connector shells shall be die-cast aluminum per ASTM B-85. Shell
finish shall be in accordance with 3.4.4.2.1.
3.4.4.2.1 Shell Finish. Connector shells shall be plated with electroless nickel in accordance
with MIL-C-26074 Class 3 or 4, Grade B.
3.4.4.3 Mounting and Mating Hardware. Connector mounting and mating hardware shall be
17-4 PH corrosion-resistant steel per ASTM A693 or MPIF Standard 35. Grounding
shield accessories shall be mounted with corrosion-resistant fasteners. Hardware shall
be passivated per QQ-P-35 or plated for compatibility with 3.4.4.2.1.
3.4.4.4 Elastomeric Seals. Elastomeric seals shall be resilient dielectric material per the
applicable specification control drawing.
3.4.4.5 Connector Inserts. Connector inserts shall be rigid polymeric dielectric material per the
applicable specification control drawing.
3.5 Design and Construction Requirements. Connectors and shield grounding accessories
shall be designed and constructed to withstand handling during installation and
maintenance. Complete connectors shall consist of a rectangular plug or receptacle
shell; fixed or removable insert(s) with removable pin or socket contacts; mounting
mating hardware, a cable clamp, and where specified shield grounding accessories.
Tyco Electronics Corporation
300 Constitutional Drive
Menlo Park, CA 94025 USA
No: C-6114
Rev: A
Date: December 17, 1999
Page: 6 of 23
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3.5.1 Shells. Plug and receptacle shells shall meet the following requirements:
3.5.1.1 Provision for Shield Grounding Accessories. Plug and receptacle shells shall have two
4-40 UNF tapped mounting holes for the attachment of shield grounding accessories.
Plug shells shall have the provision for the inclusion of spring fingers as part of the
shield grounding accessory which contact the receptacle shell prior to engagement of
the contacts.
3.5.1.2 Coupling. Coupling between mating connectors shall be accomplished by means of
two captive helices on the plug shell engaging keyed posts on the receptacle shell. The
mating hardware shall provide sufficient force to effect a moisture seal between the
socket contact insert and the elastomeric interfacial seal on the pin contact insert.
Complete coupling shall occur when the helices are rotated 120 degrees. A detent shall
be provided on each helix.
3.5.1.3 Polarization. Shell polarization shall prevent the mating of any plug and receptacle
shells if the connectors are not in the correct mating position. Polarization of shells
shall occur before connector keying.
3.5.1.4 Connector Keying. Insertable keying pins shall provide a minimum of 16 different
keying combinations. Keying shall prevent the mating of any plug and receptacle not
properly keyed. Connector keying shall occur before engagement of contacts or
coupling hardware.
3.5.1.5 Insert Retention. Shells shall retain inserts by mechanical means.
3.5.1.6 Cable Clamps. Receptacle shells suitable for cable mounting and all plug shells shall
have provisions for attachment of cable clamps. Cable clamp screws shall have threads
conforming to FED-STD-H28 and shall be self-locking per MIL-DTL-18240, Type P.
3.5.1.7 Mounting Hardware. Mounting hardware shall be provided with each receptacle shell.
Mounting hardware screw threads shall conform to FED-STD-H28 and shall be self-
locking per MIL-DTL-18240, Type P.
3.5.2 Inserts. Connector inserts for size 22 and size 16 contacts shall be removable from the
shells. Connector inserts for size 12 contacts shall be fixed in the shell. Removable
inserts shall have polarizing keyways to ensure proper orientation within the shell.
Inserts shall contain cavities for pin or socket contacts and the cavities shall contain
locking devices. Pin contact inserts shall have an elastomeric interfacial seal bonded to
the mating face.
3.5.2.1 Contact Arrangement. Inserts shall contain one or two rows of contacts. Contact
arrangement shall be in accordance with the applicable specification control drawing,
and is shown in Table I for reference only.
Tyco Electronics Corporation
300 Constitutional Drive
Menlo Park, CA 94025 USA
No: C-6114
Rev: A
Date: December 17, 1999
Page: 7 of 23
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TABLE I: Contact Arrangement
Contact Center-to-Center Rows of Contacts per Connector
Size Contact Spacing Contacts Shell Size 1 Shell Size 2
22 0.1 2 20 40
16 0.2 1 5 10
12 0.25 1 4 Not available
3.5.3 Contacts. Contacts shall be designed to withstand termination and repeated mating and
demating of connectors. Mating surfaces shall be smooth and uniform and shall
provide a wiping action during mating. Mating portions of size 22 contacts shall be of
blade (pin contact) and tuning fork (socket contact) design. size 22 socket contacts
shall have a corrosion resistant steel hood to protect the spring member from handling
damage. Size 16 and size 12 power or shielded contacts shall conform to the applicable
specification sheets and be compatible with the circular connectors shown in Table II.
TABLE II: Contact Compatibility
Contact Size Circular Connector Compatibility
16 MIL-C-38999, Series II
12 MIL-C-83723, Series III
3.5.3.1 Contact Termination. Size 22 contacts shall crimp style. Size 16 and size 12 contacts
shall be crimp or solder style.
3.5.4 Seals.
3.5.4.1 Interfacial Seal. The elastomeric interfacial seal shall be designed to eliminate leakage
paths between adjacent contacts and between contacts and the shell when the connector
is fully mated. The interfacial seal shall be permanently bonded to the mating face of
the pin insert. Suitable marking shall be provided on the mating face of the interfacial
seal to identify the contact positions.
3.5.4.2 Wire Seal. The rear of each insert shall have an elastomeric wire seal. The wire seal
shall be designed to meet the requirements of this specification using wire having an
outer diameter within the ranges specified in Table III.
TABLE III: Wire Diameter
Contact Size Finished Wire Outside Diameter
inch (mm)
22 .030 to .065 (.82 to 1.65)
16 .065 to .109 (1.65 to 2.77)
12 .097 to .158 (2.46 to 4.01)
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300 Constitutional Drive
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No: C-6114
Rev: A
Date: December 17, 1999
Page: 8 of 23
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3.5.4.3 Sealing Plug. Plugs for sealing the rear openings of unused contact cavities shall be
provided when specified. Sealing plugs shall conform to MS27488.
3.5.5 Interchangeability. All components having the same part number shall be completely
interchangeable with each other in regard to installation and performance.
3.5.6 Intermateability. All plug and receptacle connectors of the same series, type and shell
size and containing the appropriate inserts and keying pin combinations shall mate with
each other.
3.5.7 Shield grounding accessories . Shield grounding accessories may be mounted to the
surface of the MTC connector as provided in section 3.5.1.1 using fasteners as defined
in section
3.4.4.1. Shield grounding accessories mounted on plug shells shall include spring fingers as
defined in section 3.5.1.1.
3.6 Performance Requirements. Connector components and assemblies shall conform to
the requirements specified herein and on the applicable specification control drawings.
Requirements specified at 25oC may be satisfied by measurements obtained between 20
and 25oC. Unless otherwise specified, room temperature shall be 25oC. Values given
as "after conditioning" values refer to requirements after any of the environmental
exposures of Table X. All contact requirements are for signal and power contacts,
shielded contact requirements are in accordance with the applicable specification
sheets.
3.6.1 Insulation Resistance. When connector assemblies are tested as specified in 4.5.3, the
insulation resistance at 25oC between any pair of contacts and between any contact and
the shell shall be 5000 megohm minimum, unless otherwise specified. The insulation
resistance at 125oC shall be 1000 megohm minimum.
3.6.2 Dielectric Withstanding Voltage. When connector assemblies are tested as specified in
4.5.4, there shall be no evidence of breakdown or flashover. The leakage current shall
be 1.0 milliampere maximum.
3.6.3 Contact Resistance.
3.6.3.1 Contact Resistance at Specified Current. When connector assemblies are tested as
specified in 4.5.5.1 or 4.5.5.2, mated contacts shall meet the requirements of Table IV.
Tyco Electronics Corporation
300 Constitutional Drive
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No: C-6114
Rev: A
Date: December 17, 1999
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TABLE IV: Contact Millivolt Drop at Rated Current
Millivolt Drop, max.
Contact
Size
Wire Size Test
Current
at Room Temperature
at 125oC
Initial Value After Conditioning After Conditioning
22 24 3 45 54 68
22 22 5 73 88 110
22 20 7.5 55 66 83
16 16 13 50 65 81
12 12 23 45 60 75
3.6.3.2 Low Signal Level Contact Resistance. When connector assemblies are tested as
specified in 4.5.5.3, mated contacts shall meet the requirements of Table V.
TABLE V: Low Signal Level Contact Resistance
Resistance, milliohm, max.
Contact Size Wire Size at Room Temperature
Initial Value After Conditioning
22 24 15 18
22 22 15 18
22 20 8 10
16 16 4 5
12 12 2 3
3.6.4 Shell-to-Shell Conductivity. When mated connectors are tested as specified in 4.5.6,
the measured voltage drop shall be as shown in Table VI.
TABLE VI: Shell-to-Shell Conductivity
Parameter Voltage Drop, millivolt, max.
Initial After Conditioning
Receptacle shell
to panel
1 2
Plug shell to
receptacle shell
10 20
Shield ground to
shield ground
20 40
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300 Constitutional Drive
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No: C-6114
Rev: A
Date: December 17, 1999
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3.6.5 Electrical Engagement. When connector assemblies are tested as specified in 4.5.7, the
electrical engagement shall be as shown in Table VII.
TABLE VII: Electrical Engagement
Contact Size Electrical engagement, min.
inch (mm)
22 .050 (1.27)
16 .034 (0,86)
12 .040 (1.02)
3.6.6 Contact Engagement and Separation Forces. When socket contacts are tested as
specified in 4.5.8, the largest value of the engagement force and the smallest value of
the separation force measured on any contact shall be as shown in Table VIII.
TABLE VIII: Contact Engagement and Separation Forces
Initial After Conditioning
Contact Engagement Force Separation Force Engagement Force Separation Force
Size Ounce, min. Ounce, min. Ounce, min. Ounce, min.
22 12 0.7 14 0.6
16 30 2 36 1.5
12 30 3 36 2.5
3.6.7 Durability. After conditioning as specified in 4.5.9, connector assemblies shall meet
the subsequent performance requirements of Table X and shall show no evidence of
damage detrimental to performance or handling..
3.6.8 Termination Tensile Strength. When individual contacts are tested as specified in
4.5.10, the tensile load required to separate each wire from its terminal shall be in
accordance with Table IX.
TABLE IX: Termination Tensile Strength
Wire Termination Strength , pounds, min.
Size Silver or Tin Plated
Copper Wire
High Strength Copper
Alloy Wire
Nickel Plated
Copper Wire
24 8 15 6
22 12 - 8
20 20 - 15
16 50 - 29
12 110 - 100
3.6.9 Insert Retention. When connector assemblies are tested as specified in 4.5.11, the
inserts shall not be damaged or dislocated from their fully seated positions. The inserts
shall retain their normal positions in the shell for at least 5 seconds at the specified
load.
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No: C-6114
Rev: A
Date: December 17, 1999
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3.6.10 Contact Retention. When terminated inserts are tested as specified in 4.5.12, the axial
displacement of signal and power contacts shall not exceed 0.015 inch while the load is
applied. Shield grounding accessories shall show no evidence of damage detrimental to
performance or handling.
3.6.11 Coupling Torque. When terminated connector assemblies are tested as specified in
4.5.13, the torque required to fully operate the helix shall be 20 in-lb., maximum.
3.6.12 Coupling Mechanism Proof Test. When terminated connector assemblies are tested as
specified in 4.5.14, there shall be no evidence of mechanical damage to shells or mating
hardware.
3.6.13 Maintenance Aging. After conditioning as specified in 4.5.15, connector assemblies
shall meet the subsequent performance requirements specified in Table X, and shall
show no evidence of damage detrimental to performance or handling.
3.6.14 Random Vibration. When terminated, mated connector assemblies are tested as
specified in 4.5.16, there shall be no electrical discontinuities and no evidence of
cracks, breaks or loosening of parts.
3.6.15 Mechanical Shock. When terminated, mated connector assemblies are tested as
specified in 4.5.17, there shall be no electrical discontinuities exceeding 1 microsecond
and no evidence of cracks, breaks, or loosening of parts.
3.6.16 Thermal Cycling. When terminated, mated connector assemblies are tested as specified
in 4.5.18, there shall be no evidence of damage detrimental to performance or handling.
3.6.17 Temperature Life. When terminated, mated connector assemblies are tested as
specified in 4.5.19, the insulation resistance at 125oC shall be 1000 megohm minimum.
3.6.18 Humidity. When terminated, mated connector assemblies are tested as specified in
4.5.20, the insulation resistance shall be 1 megohm minimum within 1 to 2 hours after
humidity and greater than 5000 megohm after 24 hours conditioning at room ambient.
3.6.19 Seal Leakage. When terminated, mated connector assemblies are tested as specified in
4.5.21, the insulation resistance shall be 100 megohm minimum, and the mated
connectors shall meet the dielectric withstanding voltage requirements of 3.6.2.
3.6.20 Polarization Lockout. When connectors are tested in accordance with 4.5.22 the force
required to overcome the polarization keys shall be 50 lb., minimum.
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Rev: A
Date: December 17, 1999
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3.6.21 Salt Spray. When terminated, mated connector assemblies are tested in accordance
with 4.5.23, the specimens shall show no evidence of damage detrimental to
performance or handling.
3.6.22 Ozone Exposure. When terminated, unmated connector assemblies are tested as
specified in 4.5.24, the connectors shall show no evidence of damage detrimental to
performance or handling.
3.6.23 Fluid Immersion. Connector assemblies shall be tested as specified in 4.5.25.
3.6.23.1 Seals. When terminated connector assemblies are tested as specified in 4.5.25.1, the
connectors shall show no evidence of damage detrimental to performance or handling.
3.6.23.2 Retention system. When unmated connectors are tested as specified in 4.5.25.2, they
shall meet the contact retention requirements of 3.6.10 and the insert retention
requirements of 3.6.9.
3.6.24 Magnetic Permeability. When components, with the exception of mating and mounting
hardware, are tested as specified in 4.5.26, the relative permeability shall be 2.0
maximum.
3.6.25 Contact Inductive Load Switching. When terminated, mated connector assemblies are
tested as specified in 4.5.27, size 22 contacts shall meet the room-temperature, after-
conditioning, contact resistance requirements of Table IV.
3.6.26 Circuit Breaker Compatibility. When terminated, mated connector assemblies are
tested as specified in 4.5.28, the connectors shall meet the room-temperature, after-
conditioning, contact resistance requirements of Table IV.
3.6.27 Engaging Force with Contacts. When terminated connector assemblies are tested in
accordance with 4.5.29 the maximum force required to position the second helix prior
to mating shall be 25 lb. The maximum force required to position both helices prior to
mating shall be 40 lb.
3.6.28 Ground Pin Insertion Force. When shield grounding accessories are tested as specified
in 4.5.30, contacts shall typically be capable of being inserted without the use of
insertion tools.
3.6.29 Ground Pin Probe Damage. Shield grounding accessories shall be tested as specified in
4.5.31.
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Rev: A
Date: December 17, 1999
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3.6.30 Contact Walkout. When tested as specified in 4.5.32, contacts shall not become
dislodged from their normal position.
3.6.3 Post Test Examination. Connector assemblies shall be inspected as specified in 4.5.33.
Any evidence of the effects described in 4.5.33 shall constitute failure.
3.7 Product Identification. All marking shall be in accordance with the applicable
specification control drawing. The marking shall remain legible after completion of the
test sequences in Table X.
3.7.1 Shell Identification. Connector shells shall be marked on an external surface with the
shell part number, date code, and the Raychem logo. Every shell shall be permanently
marked at the wire termination end to identify proper insert orientation.
3.7.2 Removable Insert Identification. Removable inserts shall be marked with the part
number, date code, the Raychem logo or manufacturer’s logo, and an orientation
indicator as specified in the applicable specification sheet.
3.7.3 Contact Cavity Identification. The number "1" contact position, as a minimum, shall be
marked on the engaging face of each insert. The identification of at least four contacts
shall be permanently identified on the wire seal.
3.7.4 Shield Grounding Accessories Identification. Shield grounding accessories shall be
marked on an external surface with the shell part number, date code, and the supplier’s
name. The number "1" contact position, as a minimum, shall be marked on the same
surface.
3.8 Workmanship. Connectors and accessories shall be processed in such a manner as to
be uniform in quality; they shall be free from burrs, cracks, voids, chips, blisters, sharp
cutting edges, and other defects that would adversely affect life or serviceability.
4.0 QUALITY ASSURANCE PROVISIONS
4.1 Responsibility for Inspection. The supplier is responsible for the performance of all
inspection tests specified herein. The supplier may utilize his own or any other suitable
testing facility. Inspection records of the tests shall be kept complete and available to
the buyer as specified in the contract or order.
4.1.1 Test Equipment and Inspection Facilities. Test and measuring equipment and
inspection facilities of sufficient accuracy, quality, and quantity to permit performance
of the required inspection shall be established and maintained by the supplier. A
calibration system to control the accuracy of the measuring and test equipment shall be
maintained in accordance with MIL-STD-45662A or ISO 10012-1.
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No: C-6114
Rev: A
Date: December 17, 1999
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4.2 Classification of Inspections. The examination and testing of connectors covered by
this specification shall be classified as follows:
a. Qualification inspection (See par. 4.3)
b. Acceptance inspection (See par. 4.4)
4.3 Qualification Inspection. Qualification inspection shall consist of the tests in Table X.
Qualification may be based on a combination of testing and similarity to previously
qualified parts. Qualification shall be granted upon successful completion of the
inspections and tests of Table X, conducted upon the samples of Table X, in accordance
with Specification C-6100.
4.3.1 Test Samples for Qualification Inspection. Test samples submitted for qualification
inspection shall be produced using equipment and procedures normally used in
production. Test samples for each test group shall be two mated pairs of each
configuration for which qualification is desired. Individual test samples shall be
selected in compliance with the qualification requirements of Specification C-6100.
4.3.2 Failures. One or more failures of the tests listed in Table X shall be cause for failure of
qualification of the parts under test. An exception to this is visual examination, where
occurrence of one major defect or two minor defects shall be cause for failure of
qualification. Major and minor defects shall be as defined in MIL-STD-105E.
4.3. Qualification Report. Qualification shall be documented in a report which shall be
available to the buyer.
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300 Constitutional Drive
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No: C-6114
Rev: A
Date: December 17, 1999
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TABLE X: Qualification Inspection
Test or Examination
Req.
Par.
Test
Group
1
Test
Group
2
Test
Group
3
Test
Group
4
Test
Group
5
Examination Of Product 3.1,
3.5,
3.7, 3.8
X X X X X
Coupling Torque 3.6.11 X X X X
Engaging force with contacts 3.6.27 X X X X
Maintenance aging 3.6.13 X X X
Contact engagement and separation forces 3.6.6 X X X
Low signal level contact resistance 3.6.3.2 X
Contact resistance at room temperature 3.6.3.1 X
Polarization lockout 3.6.20 X
Magnetic permeability 3.6.24 X
Ozone exposure 3.6.22 X
Fluid immersion 3.6.23 X
Shell-to-shell conductivity 3.6.4 X X X X
Ground pin insertion force 3.6.28 X
Ground pin probe test 3.6.29 X
Contact retention 3.6.10 X X
Insulation resistance at 25oC 3.6.1 X X X
Insulation resistance at 125oC 3.6.1 X
Dielectric withstanding voltage at sea level 3.6.2 X X X X
Dielectric withstanding voltage at altitude 3.6.2 X
Thermal cycling 3.6.16 X X X
Durability 3.6.7 X X X
Seal leakage 3.6.19 X
Insulation resistance X
Dielectric withstanding voltage X
Vibration 3.6.14 X
Mechanical shock 3.6.15 X
Humidity 3.6.18 X
Insulation resistance after 1 - 2 hours X
Insulation resistance after 24 hours X
Temperature life 3.6.17 X
Contact resistance at 125oC. X
Insulation resistance, mated, at 125oC X
Salt spray 3.6.21 X
Low signal level contact resistance 3.6.3.2 X X
Contact resistance at room temperature 3.6.3.1 X X
Shell-to-shell conductivity 3.6.4 X X X X
Insulation resistance at 25oC, unmated 3.6.1 X
Dielectric withstanding voltage, unmated 3.6.2 X
Electrical engagement 3.6.5 X
Contact engagement and separation forces 3.6.6 X X X
Coupling Torque 3.6.11 X X X X
Engaging force with contacts 3.6.27 X X X
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Menlo Park, CA 94025 USA
No: C-6114
Rev: A
Date: December 17, 1999
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TABLE X : Qualification Inspection, Continued
Contact retention 3.6.10 X X X
Insert retention 3.6.9 X X X
Contact inductive load switching 3.6.25 X
Contact circuit breaker compatibility 3.6.26 X
Contact walkout 3.6.30 X X X
Coupling mechanism proof test 3.6.12 X
Post test examination 3.6.31 X X X X X
Termination tensile strength 3.6.8 X
4.4 Acceptance Inspection. Lot acceptance inspection for connectors shall consist of the
tests listed in Table XI. Acceptance inspection shall be performed on every lot of
connectors manufactured under this specification. The sample units shall be tested
unterminated and shipped against orders. In-process examination may be used for
acceptance inspection.
TABLE XI: Acceptance Inspection
Test or Examination Requirement
Paragraph
Procedure
Paragraph
Inspection
Level
AQL
Examination of product 3.1, 3.5, 3.7, 3.8 4.5.2 S-3 1.0
Dielectric Withstanding
Voltage
(Inserts Only)
10-second test
3.6.2 4.5.4 100% ---
Contact engagement and
separation forces
(Contacts only)
3.6.6 4.5.8 S-3 1.0
AQL shall apply to individual defects in accordance with MIL-STD-105E, Section 4.5
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No: C-6114
Rev: A
Date: December 17, 1999
Page: 17 of 23
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4.4.1 Sampling for Acceptance Inspection. MIL-STD-105E shall apply for definitions of
inspection terms used herein. For purposes of this specification, the following shall
apply:
4.4.1.1 Inspection Lot. The inspection lot shall consist of all connectors or components of one
part number, manufactured under essentially the same conditions, and offered for
inspection at one time.
4.4.1.2 Inspection Level and Acceptable Quality Levels (AQL). The inspection levels and
acceptable quality levels shall be in accordance with MIL-STD-105E and shall be as
specified in Table XI.
4.4.2 Rejected Lots. If an inspection lot is rejected, the lot shall be replaced, or the defective
units shall be reworked to correct the defect or screened out. If the lot is reworked or
the defective units are screened out, the lot shall be resubmitted for inspection.
Resubmitted lots shall be inspected using tightened inspection in accordance with MIL-
STD-105E.
4.4.3 Examination of Preparation for Delivery. Preparation for delivery of material ready for
shipment shall be examined to determine compliance with the requirements of Section
5.
4.5 Test Procedures.
4.5.1 Test Conditions. Unless otherwise specified, all tests shall be performed at ambient
pressure, and relative humidity as specified in the general requirements of MIL-STD-
1344 with an ambient temperature of 20 to 25oC. Where conditioning at the 125oC is
specified, the temperature tolerances shall be minus 0 and plus 3oC.
4.5.1.1 Connector Assembly Preparation. When terminated connectors are specified for
testing, the contacts shall be terminated in accordance with the applicable specification
control drawing. Wire or cable lengths shall be 3 to 6 feet. Connectors shall be
assembled in accordance with the applicable Raychem engineering standard (ES).
Cable clamps shall be installed, if provided for.
4.5.2 Examination of Product (see 3.1, 3.5, 3.7, 3.8). Connector components and assemblies
shall be visually examined at 4X magnification.
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No: C-6114
Rev: A
Date: December 17, 1999
Page: 18 of 23
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4.5.3 Insulation Resistance (see 3.6.1). Connector assemblies shall be tested in accordance
with MIL-STD-1344, Method 3003. Insulation resistance shall be measured between
all adjacent contacts in the insert and between all contacts and the shell (ground).
When insulation resistance at 125oC is specified, the connector assemblies shall be
conditioned in an oven at the maximum rated temperature for 30 minutes, and the
measurements shall be made while the connector assemblies are at the maximum rated
temperature.
4.5.4 Dielectric Withstanding Voltage (see 3.6.2). Connector assemblies shall be tested in
accordance with MIL-STD-1344, Method 3001. Test voltage shall be 60 Hz ac applied
between all adjacent contacts in the same insert and between all contacts and the shell
(ground). The shell and all contacts not connected to the test voltage shall be grounded.
The magnitude of the test voltage , and altitude pressure equivalents, shall be as
specified in Table XII.
TABLE XII: Dielectric Withstanding Voltages
Altitude (Pressure equivalent) Test Voltage, V rms.
Sea Level (760 torr) 1500
50,000 ft (87.5 torr) 500
4.5.5 Contact Resistance (see 3.6.3).
4.5.5.1 Contact Resistance at Specified Current (Room Temperature). Mated connector
assemblies shall be tested in accordance with MIL-STD-1344, Method 3004. All size
12 and size 16 contacts and at least 20 percent of size 22 contacts in each connector
assembly shall be tested.
4.5.5.2 Contact Resistance at Specified Current (Maximum Rated Temperature). Mated
connector assemblies shall be conditioned in an oven at the 125oC for 30 minutes.
Measurements shall be made as detailed in 4.5.5.1, while the connector assemblies are
at the maximum rated temperature.
4.5.5.3 Low Signal Level Contact Resistance. Mated connector assemblies shall be tested in
accordance with MIL-STD-1344, Method 3002. All size 12 and size 16 contacts and at
least 20 percent of size 22 contacts in each connector assembly shall be tested.
4.5.6 Shell to Shell Conductivity (see 3.6.4). Mated connector assemblies shall be mounted
to a suitable aluminum panel with a MIL-C-5541 Class 3 finish.
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No: C-6114
Rev: A
Date: December 17, 1999
Page: 19 of 23
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4.5.6.1 Shell-to-panel grounding (see 3.6.4). All connectors shall be tested by applying a
direct current of 1 +/- 0.1 ampere from the rear of the receptacle shell to the to the
aluminum panel and measuring the voltage drop between the connector shell adjacent
to the shield grounding accessory mounting holes and the panel adjacent to the
connector.
4.5.6.2 Shell-to-shell conductivity (see 3.6.4). Connectors with shield grounding accessories
shall be tested by applying a direct current of 1 +/- 0.1 ampere between the shields of
shielded cables attached to the shield grounding accessories. The voltage drop between
the mated plug and receptacle shells shall be measured between points adjacent to the
shield grounding accessory mounting holes. The overall voltage drop between the
shield grounds shall be measured from points on the shield ground leads 1-inch behind
the shield grounding accessories. Voltage drop will not be measured on shield ground
leads prior to Salt Fog Conditioning, Test Group 2.
4.5.7 Electrical Engagement (see 3.6.5). A suitable power source and indicator shall be
provided such that the point at which the outermost contact pairs mate can be
established. Connector halves shall be held flat against a smooth, flat surface and
mated by alternately engaging each helix. As the second helix is engaged, the mating
operation shall be stopped at the point where electrical contact is made between the
outermost pin and socket contacts. The separation of the connector halves at the
outermost contact position shall be measured. The mating operation shall then be
continued until the connector halves are completely mated and the shell spacing shall
again be measured. Electrical engagement shall be the difference between the two
measurements.
4.5. Contact Engagement and Separation Forces (see 3.6.6). Contacts shall be tested in
accordance with MIL-STD-1344, Method 2014, Procedure I. Test blades for size 22
signal contacts shall be generally of the shape of pin contacts and as detailed below.
Round test pins for size 12, size 16, size 22 contacts shall be as defined on the
applicable specification sheets. Contacts shall be conditioned by inserting and
withdrawing the maximum thickness test pin. For qualification inspection, at least 20
percent of the contacts in each connector assembly shall be tested. Shield grounding
accessories shall have a minimum of 4 contacts tested on each accessory.
Size 22 test blade details:
Material Hardened tool steel
Hardness Rockwell C 50-55
Surface finish 6 to 10 microinch on sliding surfaces
Blade width 0.050
Tip thickness 0.008 max. at tip
Maximum blade 0.0208 to 0.0210 uniform body thickness
Minimum blade 0.0190 to 0.0192 uniform body thickness
Tyco Electronics Corporation
300 Constitutional Drive
Menlo Park, CA 94025 USA
No: C-6114
Rev: A
Date: December 17, 1999
Page: 20 of 23
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4.5.9 Durability (see 3.6.7). Terminated connector assemblies shall be mated and unmated
250 times at a rate not to exceed 300 cycles per hour and in a manner simulating actual
service. The test may be performed by hand or by mechanical means.
4.5.10 Termination Tensile Strength (see 3.6.8). Terminated contacts shall be tested in
accordance with Method 2003 of MIL-STD-1344. A minimum of twenty percent of
the contacts shall be tested on each connector. Shield grounding accessories shall have
a minimum of 4 contacts tested on each accessory.
4.5.11 Insert Retention (see 3.6.9). Terminated connector assemblies shall be tested in
accordance with MIL-STD-1344, Method 2010, except that the load shall be applied
only against the insert mating surface. The load shall be 200 psi (1.4 MPa), applied
evenly over the entire mating surface. If a tensile tester is used to apply the load, the
speed of head travel shall be 0.02 inch (0.5 mm) per minute.
4.5.12 Contact Retention (see 3.6.10). Terminated inserts shall be tested in accordance with
MIL-STD-1344, Method 2007. Axial load shall be 10 lb. for size 22 contacts and 25
lb. for size 16 contacts, and 30 lb. for size 12 contacts, applied to mating ends of
contacts. In addition to the 10 lb. axial load, shield grounding accessories shall also
have an 8 lb. load applied at ninety degrees in each of the 2 other major axes, pulling in
a direction away from the centerline of the MTC housing.
4.5.13 Coupling Torque (see 3.6.11). The torque required to completely engage the helix on
each side of the connector shall be measured.
4.5.14 Coupling Mechanism Proof Test (see 3.6.12). A torque of 40 inch-lb. shall be applied
to the coupling mechanism at each side of a mated connector. The shells and hardware
shall be visually examined for damage.
4.5.15 Maintenance Aging (see 3.6.13). Terminated connector assemblies shall be fully mated
and unmated three times. 20 percent of size 22 contacts and all size 16 and size 22
contacts shall be removed and reinstalled in the inserts 10 times. Shield grounding
accessories shall be removed and reinstalled 3 times in a manner simulating actual
service. Shield grounding accessories shall have a minimum of 4 contacts tested on
each accessory which shall be removed and reinstalled 3 times.
Tyco Electronics Corporation
300 Constitutional Drive
Menlo Park, CA 94025 USA
No: C-6114
Rev: A
Date: December 17, 1999
Page: 21 of 23
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4.5.16 Random Vibration (see 3.6.14). Terminated, mated connector assemblies shall be
tested in accordance with MIL-STD-1344, Method 2005, Test Condition V, Letter E.
Connectors shall be panel mounted by normal means, with at least 8 inches (200 mm)
of wire unsupported behind each connector. Specimens shall be subjected to vibration
for 8 hours in each major axis for a total of 24 hours. Shield grounding accessories
shall have a minimum of 4 ground circuit wires independently monitored for
discontinuities.
4.5.17 Mechanical Shock (see 3.6.15). Terminated, mated connectors shall be tested in
accordance with MIL-STD-1344, Method 2004, Test Condition A. The connectors
shall be panel mounted by normal means, with at least 8 inches (200 mm) of wire
unsupported behind each connector. Shield grounding accessories shall have a
minimum of 4 ground circuit wires independently monitored for discontinuities.
4.5.18 Thermal Cycling (see 3.6.16). Mated connector assemblies shall be tested in
accordance MIL-STD-202, Method 107, Test Condition B.
4.5.19 Temperature Life (see 3.6.17). Terminated, mated connector assemblies shall be tested
in accordance with MIL-STD-1344, Method 1005, for 1000 hours at 125oC, using an
air-circulating oven. Contacts shall not be wired in series or connected to an electrical
load. Leads shall be brought out through a suitable port so that electrical measurements
can be taken. After 1000 hours and while connectors are still at the maximum rated
temperature and mated, the insulation resistance shall be measured in accordance with
4.5.3.
4.5.20 Humidity (see 3.6.18). Terminated, mated connector assemblies shall be tested in
accordance with MIL-STD-1344, Method 1002, Type II. Polarization voltage is not
required. Step 7 (a) shall be performed during the last cycle. After the end of the last
cycle the connector assemblies shall be removed form the humidity chamber and placed
in ambient conditions. Insulation resistance measurements shall be made within 1 to 2
hours and again after 24 hours.
4.5.21 Seal Leakage (see 3.6.19). Terminated, mated connectors shall be tested in accordance
with the seal leakage procedure specified in ARINC Specification 600 Attachment 19.
4.5.22 Polarization Lockout (see 3.6.20) Connector assemblies shall be prepared with one
side of the shells having compatible keying pins and the other side having keying pins
which completely interfere with each other. The mating hardware on the side of the
connector with compatible keying pins shall be engaged. The force required to
override the keying pins shall be recorded. The applied force shall be limited to 100 lb.
The test shall then be repeated with the interfering keying pins at right angles to each
other forming a 50% interference.
Tyco Electronics Corporation
300 Constitutional Drive
Menlo Park, CA 94025 USA
No: C-6114
Rev: A
Date: December 17, 1999
Page: 22 of 23
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4.5.23 Salt Spray (see 3.6.21). Terminated unmated connector assemblies shall be tested in
accordance with MIL-STD-1344, Method 1001, Test Condition B. Suitable measures
shall be taken to preclude migration of condensation along the conductors.
4.5.24 Ozone Exposure (see 3.6.22). Terminated unmated connector assemblies shall be
tested in accordance with MIL-STD -1344, Method 1007.
4.5.25 Fluid Immersion (see 3.6.23)
4.5.25.1 Seals. One mated pair of connectors shall be tested in accordance with MIL-STD-
1344, Method 1016 in the fluids shown in Table XIII. Following the required number
of cycles the parts shall be subjected to the dielectric withstanding voltage test.
TABLE XIII: Fluid Immersion Test
MIL-STD-1344, Method 1016
Fluid designation
Fluid specification Fluid description
Fluid (e) MIL-L-23699 Lubricating Oil
Fluid (a) MIL-H-5606 Hydraulic Fluid
Fluid (i) TT-I-735 and
TT-I-291 or P-D-680
Isopropyl Alcohol
and Mineral Spirits
4.5.25. Retention System. An unmated pair of connectors, without contacts installed, shall be
immersed in each of the fluids in Table XIII for 20 hours at room ambient conditions.
After removal excess fluid shall be allowed to drain from each connector half for 4
hours prior to the measurement of contact retention forces and insert retention forces.
Shield grounding accessories shall meet the contact retention requirements of 3.6.10.
4.5.26 Magnetic Permeability (see 3.6.24). Connector components shall be tested in
accordance with MIL-STD-1344, Method 3006.
4.5.27 Contact Inductive Load Switching (3.6.25). Each of five contacts shall be demated ten
times while supplying current to an inductive load. The circuit parameters shall be 5.0
amperes for size 22 contacts, 115 volts, 400 Hz, and 0.70 +/- 0.05 lagging power factor.
4.5.28 Circuit Breaker Compatibility (see 3.6.26). Size 22 contacts in a mated connector
assembly shall be subjected to an overload current of 50 amps for 1 second. Each
overload condition shall be tested five times using a different contact each time.
Tyco Electronics Corporation
300 Constitutional Drive
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No: C-6114
Rev: A
Date: December 17, 1999
Page: 23 of 23
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4.5.29 Engaging Force with Contacts (see 3.6.27). The maximum forces required to engage
the connector coupling mechanisms shall be determined under two conditions. The
maximum longitudinal force required to bring the two mating halves of a connector
together, while maintaining the front surfaces parallel to each other, shall be measured.
The connector halves shall then be demated and separated. The coupling mechanism at
one side of the connector shall then be full engaged. The maximum longitudinal force,
applied to the driver, required to bring the coupling helix at the second side of the
connector into an engaging position shall then be measured.
4.5.30 Ground Pin Insertion Force (see 3.6.28). Shield grounding accessories shall be tested
in accordance with MIL-STD-1344, Method 2012 without the use of an insertion tool.
4.5.31 Probe Damage (see 3.6.29). Shield grounding accessories shall be tested accessories
shall be tested in accordance with MIL-STD-1344, Method 2006, except that the probe
depth shall be 0.550 +/- 0.010 inches.
4.5.32 Contact Walkout (see 3.6.30). Two pin contacts and two socket contacts in an insert
shall be tested. The contacts shall be soldered or crimped as applicable, to stranded
steel or steel-cored cable of an appropriate size and the inserts shall be installed in a
shell without a cable clamp. The unmated connector shall be mounted in a test fixture
as described in ARINC 600-8, Section 19.5.21. A 3.0 lb. weight shall be attached to
the cable. One 360° rotation of the fixture with the connector mounted shall constitute
one cycle. The connector shall be subjected to 100 cycles at a rate of 10 to 20 cycles
per minute. Shield grounding accessories shall have a minimum of 2 contacts tested on
each accessory.
4.5.33 Post Test Examination (see 3.6.31). The tested connectors shall be examined for
evidence of cracking, loosening of parts, carbon tracking, excess wear, or missing parts.
5.0 PREPARATION FOR DELIVERY
5.1 Packaging and Packing. Unless otherwise specified in the procurement document,
packaging and packing shall be in accordance with commercial practice.
5.2 Marking. Unless otherwise specified in the procurement document, marking shall be in
accordance with commercial practice.
