ProductSpec INCH - POUND SPECIFICATION 809-009 16 OCTOBER 2006 SUPERCEDING 12 MARCH 2004 Product Specification Series 80 ProDUCT SPECIFICATIoN SErIES 80 "Mighty Mouse" Connectors “MIGHTY MoUSE” CoNNECTorS CONNECTORS, ELECTRICAL, CIRCULAR, MINIATURE, ENVIRONMENTAL, RECEPTACLES AND PLUGS, GENERAL SPECIFICATION FOR DISTRIBUTION STATEMENT: General release, unlimited distribution © 2006 Glenair, Inc. All Rights Reserved. 16 QwikConnectn · November 2006 PRODUCT SPECIFICATION 809-009 16 OCTOBER 2006 TABLE oF CoNTENTS Scope .......................................................................................................................................... 18 . Materials and Finishes ............................................................................................ 18 . Mechanical requirements ..................................................................................... 22 Table 2 Materials and Finishes ......................................................................................... 18 Table 3 Finishes for Connector Shells and Nuts .............................................................. 19 . Electrical Performance requirements ............................................................. 19 3.2.1. Insulation resistance ......................................................................................................... 19 3.2.2 Dielectric withstanding voltage ......................................................................................... 19 3.2.3 Contact resistance ............................................................................................................ 20 3.2.4 Low-signal level contact resistance .................................................................................. 20 3.2.5 Current rating .................................................................................................................... 20 3.2.6 Shell-to-shell conductivity ................................................................................................. 20 3.2.7 EMI shielding effectiveness .............................................................................................. 21 3.2.8 Transfer impedance .......................................................................................................... 21 3.2.9 Magnetic permeability ....................................................................................................... 21 3.2.10 Insertion loss, filter connectors ......................................................................................... 22 3.2.11 Capacitance, filter connectors........................................................................................... 22 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.3.6 3.3.7 3.3.8 Weights ............................................................................................................................. 22 Durability ........................................................................................................................... 22 Contact engaging and separating force ............................................................................ 23 Contact retention............................................................................................................... 23 Crimp joint strength ........................................................................................................... 23 Torque ............................................................................................................................... 24 Insert retention .................................................................................................................. 24 Unmating force Series 804 push-pull................................................................................ 24 . Environmental requirements .............................................................................. 25 3.4.1 3.4.2 3.4.3 3.4.4 3.4.5 3.4.6 3.4.7 3.4.8 3.4.9 3.4.10 3.4.11 3.4.12 3.4.13 3.4.14 3.4.15 3.4.16 3.4.17 3.4.18 Operating temperature ...................................................................................................... 25 Corrosion resistance (salt fog) .......................................................................................... 25 Sand and dust ................................................................................................................... 25 Thermal shock................................................................................................................... 25 Altitude immersion............................................................................................................. 25 Altitude- Low Temperature................................................................................................ 25 Immersion ......................................................................................................................... 25 Air leakage ........................................................................................................................ 26 Outgassing ........................................................................................................................ 26 Vibration ............................................................................................................................ 27 Shock ................................................................................................................................ 27 Acceleration ...................................................................................................................... 27 Gunfire Vibration ............................................................................................................... 27 Fungus .............................................................................................................................. 27 Contamination by fluids..................................................................................................... 27 Humidity ............................................................................................................................ 27 Hydrostatic Pressure Rating ............................................................................................. 27 Open Face Pressure Rating ............................................................................................. 27 QwikConnect n· November 2006 Page 2 17 PRODUCT SPECIFICATION 809-009 16 OCTOBER 2006 ProductSpec 1 SCOPE 1.1 Scope. This specification covers performance requirements for Glenair Series 80 “Mighty Mouse” miniature circular connectors for aerospace and harsh environment applications. 1.2 Description. Series 80 connectors with size 23 contacts, environmental sealing, crimp, solder cup or printed circuit board termination, aluminum and corrosion resistant steel shells and coupling nuts, crimp rear-release or non-removable contacts, hermetic versions, threaded,push-pull and bayonet coupling mechanisms, and filtered versions. 2 ORDER OF PRECEDENCE 2.1 3 Order of precedence. In the event of a conflict between the requirements of this specification and the references cited herein, this document takes precedence. The requirements set forth in customer specifications and Glenair detail drawings shall take precedence over this document. REQUIREMENTS 3.1 Materials and finishes. Materials and finishes shall be in accordance with Table 1 Materials and Table 2 Finishes, unless otherwise specified in detail drawings. Materials and finishes shall be selected to insure the connector is capable of meeting the performance requirements of this specification. Aluminum Shell, Barrel, and Coupling Nut Stainless Steel Shell, Barrel Coupling and Jam Nut Front and Rear Insulators Contact Retention Clip Grommet, Peripheral Seal and Interfacial Seal Hermetic Insert Pin Contact Pin Contact, Hermetic Socket Contact Socket Contact Hood Adhesives Potting Compound, PCB and Solder Cup Versions Filter Element Table 1 Materials and Finishes Aluminum alloy 6061per ASTM B211 Stainless steel per AMS-QQ-S-763 Glass-filled liquid crystal polymer (LCP) in accordance with MIL-M24519, Type GLP-30F Beryllium copper, heat-treated, unplated Blended fluorosilicone/silicone elastomer, 30% silicone per ZZ-R765, 70% fluorosilicone per MIL-R-25988 Vitreous glass Beryllium copper alloy per ASTM B197, 50 microinches gold plated per ASTM B488 Type 3 Code C Class 1,27 over nickel plate per QQ-N-290 Class 2, 50-100 microinches Nickel-iron alloy per ASTM F30 (Alloy 52),50 microinches gold plated per ASTM B488 Type 3 Code C Class 1,27 over nickel plate per QQ-N-290 Class 2, 50-100 microinches Beryllium copper alloy per ASTM B197, 50 microinches gold plated per ASTM B488 Type 3 Code C Class 1,27 over nickel plate per QQ-N-290 Class 2, 50-100 microinches. Stainless steel, passivated per AMS-QQ-P-35 Silicone and epoxy Environmental and Hermetic Connectors: Stycast 2651/Catalyst 9 epoxy encapsulant Filter Connectors: Stycast 2850FT/Catalyst 11 thermally conductive epoxy encapsulant. Multilayer Ceramic Planar Array, ferrite inductors Page 3 18 QwikConnectn · November 2006 PRODUCT SPECIFICATION 809-009 16 OCTOBER 2006 Table 2 Finishes for Connector Shell and Nut Plating Code Aluminum Shell, Barrel, Coupling Nut and Jam Nut Electroless Nickel NF Olive Drab Cadmium over AMS-QQ-P-416, over AMS-CElectroless Nickel 26074 AMS-C-26074 Olive Drab Zinc-Nickel Zinc alloy per ASTM B841-91, Class 1 Type E Grade 3 over Electroless nickel per ASTM B733-90 SC2, Type 1 Class 5 (500 Hour Salt Fog) Zinc Nickel, Black Zinc alloy per ASTM B841-91, Class 1 Type E Grade 3 over Electroless nickel per ASTM B733-90 SC2, Type 1 Class 5 (500 Hour Salt Fog) Black Anodize MIL-A-8625, Type II Class 2 Z1 Passivate AMS-QQ-P-35 ZB Olive Drab Cadmium AMS-QQ-P-416 ZC Black Chromate over Zinc ASTM B841-91 Cobalt ZM Electroless Nickel ZN C 3.2 Specification M ZNU Stainless Steel Shell, Barrel, Coupling Nut and Jam Nut Finish AMS-C-26074 Electrical performance requirements. 3.2.1 Insulation resistance. 3.2.1.1 Insulation resistance at ambient temperature. 5,000 megohms minimum between any pair of contacts and any contact and the shell when tested in accordance with EIA-364-21. 3.2.1.2 Insulation resistance at elevated temperature. 200 megohms minimum between any pair of contacts and any contact and the shell, when tested in accordance with EIA-364-21. Temperature shall be the maximum operating temperature stated in paragraph 3.4.1 3.2.2 Dielectric withstanding voltage. 3.2.2.1 Dielectric withstanding voltage (sea level). 500 volts ac, rms 60 Hz. Connectors shall show no evidence of breakdown or flashover when subjected to the DWV test of EIA-364-20. 3.2.2.2 Dielectric withstanding voltage (70,000 feet). 100 volts ac, rms 60 Hz. Connectors shall show no evidence of breakdown or flashover when subjected to the DWV test of EIA-364-20. QwikConnect n· November 2006 Page 4 19 PRODUCT SPECIFICATION 809-009 16 OCTOBER 2006 ProductSpec 3.2.3 Contact resistance. The voltage drop of a mated pair of contacts attached to wires shall not exceed the values shown in Table 3 when tested in accordance with EIA-364-06, using M22759/11 silver-plated copper wire (six inches between probes of voltmeter). Table 3 Contact Resistance Contact Material Copper Alloy 3.2.4 Wire Size 12 14 16 20 22 24 26 28 Test Current amperes 23 17 13 7.5 5 3 2 1.5 Maximum Voltage Drop (millivolts) 25° C 42 40 49 55 73 45 52 54 Low-signal level contact resistance (dry circuit). Contact resistance shall not exceed the values in table 4 when tested in accordance with EIA-364-23. Table 4 Low-Level Signal Contact Resistance Maximum Contact Resistance (milliohms) Wire Size Initial Condition After Conditioning 16 5 6 20 9 11 22 15 17 24 20 23 26 31 38 28 50 60 3.2.5 3.2.5.1 Current rating. Current rating at ambient temperature, unconfined. Table 5 Maximum Contact Current Rating Contact Size Amperes 12 23 16 13 20HD 7.5 23 5 3.2.6 Shell-to-shell conductivity. The maximum voltage drop across a mated pair of connectors shall not exceed the values shown in Table 6 when tested in accordance with EIA-364-83, for connectors with electroless nickel plating or olive drab cadmium plating. Page 5 20 QwikConnectn · November 2006 PRODUCT SPECIFICATION 809-009 16 OCTOBER 2006 Series 800 801 802 803 804 805 3.2.7 Table 6 Shell-To-Shell Conductivity Maximum Millivolt Drop After Conditioning Initial Condition (Salt Spray) 10 20 10 20 10 20 100 200 2 4 2 4 EMI shielding effectiveness. The EMI shielding effectiveness of mated connectors with electroless nickel plating shall not be less than the values specified in Table 7, when tested in accordance with MIL-DTL-38999 para. 4.5.27. Frequency 100 MHz 200 MHz 300 MHz 400 MHz 800 MHz 1GHz 3GHz 6GHz 10GHz Table 7 EMI Shielding Effectiveness Leakage Attenuation, dB Minimum Connector Series 800 801 802 803 804 75 75 75 60 80 70 70 70 55 76 65 65 65 55 73 63 63 63 50 68 58 58 58 45 64 55 55 55 40 60 50 50 50 --55 45 45 45 --45 40 40 40 --40 805 90 88 88 87 85 80 75 65 60 3.2.8 Transfer impedance. Mated connectors shall be capable of meeting the requirements of FCC docket 20780 Part 15 Subpart J governing emission limits for Class A (office) electronic equipment. 3.2.9 Magnetic permeability. 2.0P maximum. Page 6 QwikConnect n· November 2006 21 PRODUCT SPECIFICATION 809-009 16 OCTOBER 2006 ProductSpec 3.2.10 Insertion loss, filter connectors. When tested in accordance with MIL-STD-220, at 25° C. with no load, the insertion loss shall meet the requirements of Table 8. Table 8 Insertion Loss, Filter Connectors Insertion Loss, dB Min, 25°C., C Filter Frequency Filter Class A B C D E F 1 MHz 6 5 3 10 MHz 24 23 16 8 4 100 MHz 41 39 35 28 21 10 500-1000 50 49 46 41 34 23 MHz Insertion Loss, dB Min., 25°C., Pi Filter Frequency Filter Class A B C D E F 1 MHz 10 8 5 1 10 MHz 40 35 25 14 8 2 100 MHz 62 60 57 50 40 15 500-1000 66 62 60 58 52 32 MHz G 5 17 G 0.8 13 22 3.2.11 Capacitance, filter connectors. Capacitance shall meet the requirements of Table 6 when tested at 25°C., 1kHz, 1.0 VAC RMS. Table 9 Capacitance, Filter Connectors Filter Class Capacitance, C Filter (pF) Capacitance, Pi ilter (pF) A 19000-28000 38000-56000 B 16000-22500 32000 – 45000 C 9000-16500 18000 – 33000 D 4000-6000 8000 – 12000 E 1650-2500 3300 – 5000 F 400-650 800 – 1300 G 200-300 400 - 600 3.3 Mechanical requirements. 3.3.1 Weights. Connector Weights are published in the Series 80 Catalog 3.3.2 Durability. 3.3.2.1 Durability for Series 800, 801, 802, 804. Connectors shall withstand 2000 cycles of mating without mechanical or electrical degradation. Page 7 22 QwikConnectn · November 2006 PRODUCT SPECIFICATION 809-009 16 OCTOBER 2006 3.3.2.2 3.3.3 Durability for Series 803. Connectors shall withstand 250 cycles of mating. Contact engaging and separation force. Contacts shall meet the force requirements of SAE AMS39029 Table IX, when tested in accordance with EIA-364-37. 3.3.3.1 Contact engaging and separation force (initial) 3.3.4 Contact retention. Contacts shall withstand the axial force specified in Table 10 without exceeding the .012 inch (0.30 mm) displacement when tested in accordance with EIA-364-29 method B. Table 10 Contact Retention 3.3.5 Contact Size Load ± 10% in Pounds 12 25 16 25 20HD 15 23 6 Crimp joint strength. Contacts shall meet the wire pull forces in table 11 when crimped to silverplated copper wire in accordance with MIL-W-22759/11. Table 11 Crimp Joint Strength Wire Size Pull Force in Pounds 12 110 14 70 16 50 20 20 22 12 24 8 26 5 28 3 QwikConnect n· November 2006 Page 8 23 ProductSpec PRODUCT SPECIFICATION 809-009 16 OCTOBER 2006 3.3.6 Torque. Table 12 Recommended Torque Shell Size 5 6 7 8 9 10 12 14 15 3.3.7 Coupling Torque In-Lbs. NM Min. Max. Min. Max. 35 45 4.0 5.1 40 50 4.5 5.7 40 50 4.5 5.7 40 50 4.5 5.7 45 55 5.1 6.2 50 60 5.7 6.8 50 60 5.7 6.8 55 65 6.2 7.3 55 65 6.2 7.3 Jam Nut Tightening In-Lbs. NM Min. Max. Min. Max. 30 40 3.4 4.5 35 45 4.0 5.1 35 45 4.0 5.1 35 45 4.0 5.1 35 45 4.0 5.1 45 55 5.1 6.2 45 55 5.1 6.2 45 55 5.1 6.2 45 55 5.1 6.2 Backshell Tightening In-Lbs. NM Min. Max. Min. Max. 25 35 2.8 4.0 30 40 3.4 4.5 35 45 4.0 5.1 35 45 4.0 5.1 35 45 4.0 5.1 40 50 4.5 5.7 40 50 4.5 5.7 40 50 4.5 5.7 40 50 4.5 5.7 Insert retention. Unmated connectors shall retain their inserts in their proper location in the shell and there shall be no cracking or loosening when an axial force is applied to the mating face of the insert per the values shown in Table 13, when tested in accordance with EIA-364-35. Table 13 Insert Retention Shell Size Minimum force in Pounds 5 25 6 25 7 25 9 25 12 30 14 45 15 50 3.3.8 Unmating force, Series 804 push-pull. The force required to unmate Series 804 quickdisconnects shall be as specified in Table 14. Table 14 Series 804 Unmate force Average force in Layout Pounds 5-3 10.6 6-4 10.8 6-7 11.4 7-10 12.0 8-13 12.6 9-19 13.8 10-26 15.2 12-37 17.4 14-55 21.0 15-85 27.0 24 Page 9 QwikConnectn · November 2006 PRODUCT SPECIFICATION 809-009 16 OCTOBER 2006 3.4 Environmental requirements. 3.4.1 Operating temperature. 3.4.1.1 Operating temperature, environmental and hermetic Connectors: Connectors shall be capable of performing satisfactorily when operated at a temperature range of -65° C. to +150° C.. 3.4.1.2 Operating temperature, filter connectors: Connectors shall be capable of performing satisfactorily when operated at a temperature range of -55° C. to +125° C. 3.4.2 Corrosion resistance (salt fog). Following exposure to the salt fog requirement of EIA-364-26, connectors shall exhibit no corrosion sites or other defects detrimental to the function of the connector. Table 15 Corrosion Resistance Shell Material Plating Code M NF Aluminum ZN ZNU C Stainless Steel Z1 Shell Finish Electroless Nickel Olive Drab Cadmium-Nickel Olive Drab Zinc-Nickel Zinc Nickel, Black Black Anodize Passivate Test Condition B Length of Exposure (Hrs.) 48 C 500 C 500 C B 500 48 D 1000 3.4.3 Sand and dust. Connectors shall be able to withstand the effects of blowing sand and dust test specified in MIL-STD-810, Method 510.4. 3.4.4 Thermal shock. Connectors shall be able to withstand rapid changes in temperature from the minimum operating temperature to the maximum recommended operating temperature. Connectors shall be considered capable of meeting this requirement if they are successfully subjected to 5 cycles as defined in EIA-364-32, with each cycle consisting of the following steps: Step 1: 60 minute duration –65° C. Step 2: 2 minute duration Transition from -65° to +150°C. Step 3: 60 minute duration 150° C. Step 4: 2 minute duration Transition from +150° to -65°C. 3.4.5 Altitude immersion: A mated pair of connectors shall be capable of meeting 500 VAC dielectric withstanding voltage and 1000 megohms insulation resistance requirements during and subsequent to simulated exposure to condensation caused by three cycles of rapid descent from 40,000 feet altitude. EIA-364-03 shall define the test procedure. 3.4.6 Altitude –low temperature: Connectors shall be able to withstand concurrent exposure to -65° low temperature and 40,000 feet altitude for a 1 hour duration, when tested in accordance with EIA-364-105. Wired, mated connectors shall not exhibit voltage breakdown between the connector shell and contacts with 100 VAC applied to all contacts in series. 3.4.7 Immersion. 3.4.7.1 Immersion, Series 800,801, 804 and 805. Mated connectors shall be able to withstand 1 hour immersion in fresh water at a depth of 1 meter. QwikConnect n· November 2006 Page 10 25 3.4.6 Altitude –low temperature: Connectors shall be able to withstand concurrent exposure to -65° low temperature and 40,000 feet altitude for a 1 hour duration,PRODUCT when tested in accordance with SPECIFICATION 809-009 EIA-364-105. Wired, mated connectors shall not exhibit voltage breakdown between the 16 OCTOBER 2006 connector shell and contacts with 100 VAC applied to all contacts in series. 3.4.7.2 Immersion, Series 803. 3.4.7 Immersion. Series 803 connectors are not required to meet immersion requirements. ProductSpec 3.4.7.1 3.4.8 Immersion, 800,801, 804 and 805. Air leakage.Series Hermetic connectors shall meet an air leakage requirement of less than 1 X 106 PRODUCT SPECIFICATION Mated be abledifferential to withstand hour immersion in fresh water a depth ofis809-009 1 cc/sec connectors of helium atshall a pressure of 11 atmosphere (30 PSI). The testatprocedure 16 OCTOBER 2006 PRODUCT SPECIFICATION 809-009 meter. defined in MIL-STD-1344 method 1008.1. 16 OCTOBER 2006 3.4.7.2 Immersion, Series 803. Page 10 3.4.93.4.7.2 Outgassing. The entire connector assembly shall be capable of meeting a maximum Total Mass Immersion, Series 803. Series 803 connectors are not required to meet immersion requirements. Loss Series (TML)803 of 1% and a Total Collected Volatile Material requirements. Loss (TCVML) of 0.1% when tested in connectors are not required to meet immersion accordance with ASTM-E595, following additional processing for outgassing control. This 6 3.4.83.4.8additional Air leakage. Hermetic connectors shallmeet meet an airpurchase leakage requirement of less than 1 X 10 processing, invoked customer order requirements, Air leakage. Hermeticwhen connectors shallby an air leakage requirement of less than 1 Xcustomer 106 cc/sec of helium at a pressure differential of 1 atmosphere (30 PSI). The test procedure is cc/sec of helium at a pressure differential of shall 1 atmosphere PSI). The test procedure is specification or Glenair modification code, consist (30 of the following: defined in MIL-STD-1344 method 1008.1. defined in MIL-STD-1344 method Fully assembled connectors shall 1008.1. be baked out for 24 hours at a temperature of +125°C and a vacuum of 10-6 Torr.. Outgassing. Theentire entireconnector connector assembly shall be be capable of meeting a maximum Total Mass 3.4.93.4.9Table Outgassing. The assembly shall of meeting a maximum 16(TML) provides detailed information regarding the capable outgassing characteristics of theTotal non-Mass Loss of 1%and andaaTotal Total Collected Volatile Material LossLoss (TCVML) of 0.1% when tested intested in Loss (TML) of 1% Collected Volatile Material (TCVML) of 0.1% when metallic materials. accordance withASTM-E595, ASTM-E595, following processing for outgassing control.control. This accordance with followingadditional additional processing for outgassing This additional processing, when invoked by customer purchase order requirements, customer additional processing, when invoked by customer purchase order requirements, customer specification or Glenair modification code, shall consist of the following: Table 1624 hoursofatthe specification or Glenair modification code, shall following: of +125°C and a Fully assembled connectors shall be baked out forconsist a temperature Outgassing Properties of Non-Metallic Materials Fully assembled connectors shall be baked out for 24 hours at a temperature of +125°C and a vacuum of 10-6 Torr.. TMLcharacteristics TCVML of the nonvacuum Torr.. Tableof 1610-6 provides detailed information regarding the outgassing metallic materials.detailed information Component Material Test Reference % % Table 16 provides regarding the outgassing characteristics of the nonmetallic materials. Liquid Crystal Polymer Vectra NASA Test # Front and Rear Insulator 0.0 0.03 C130Table 16 GSC17478 Outgassing Properties of Non-Metallic Materials Front and Rear Insulator Epoxy Table 16 NASA Test GSC15435 0.84TCVML0.00 TML 3, 4 and 7 pin 1908 of Non-Metallic OutgassingEpiall Properties Materials Component Rear Grommet Front and Rear Insulator Component Front and Rear Insulator FrontInterfacial and RearSeal Insulator 3, 4 and 7 pin Seal, FrontPeripheral andRear Rear Insulator Grommet Receptacle 3, 4 and 7 pin Front-To-Rear Insulator Interfacial Seal Rear Grommet Bonding Material Peripheral Seal, Insulator-to-Rubber Receptacle Interfacial Seal Bonding Material Front-To-Rear Insulator Material % % Test Reference TML TCVML 0.14 0.48 Liquid Crystal Polymer Vectra NASA Test # Blended flourosilicone/silicone 0.03 % 0.0 % Glenair testing Material Test Reference C130 GSC17478 elastomer, 30% silicone per ZZconducted at NuSil Liquid Polymer Vectra NASA Test # R-765,Crystal 70%Epoxy flourosilicone per 0.840.03 0.48 0.00 0.14 NASATechnology Test GSC15435 0.0 02/27/2001 Epiall 1908 C130 GSC17478 MIL-R-25988 Epoxy 0.480.48 Blended flourosilicone/silicone 0.00 Glenair NASAtesting Test GSC15435 0.84 0.14 0.14 1908 per ZZelastomer,Epiall 30% silicone conducted at NuSil Emerson & Cuming R-765, 70% flourosilicone 0.480.52 0.14 0.08 Eccobond 104 A/Bper 0.14Technology 02/27/2001 0.48 Blended flourosilicone/silicone Data Sheet MIL-R-25988 Glenair testing elastomer, 30%Clear, silicone ZZ-0.48 0.14 DC3145 RTV, perper MIL-Aconducted at NuSil 0.90 NASA Test GSFC0191 1.74 R-765, 70%46146 flourosilicone per 0.14 0.48 Technology 02/27/2001 Emerson & Cuming MIL-R-25988 Eccobond 104 A/B 0.08 0.52 Glenair Data SheetTest at NuSil Torlon® 4203L 0.01 1.88 0.14 0.48 Technology 03-12-2003 DC3145 RTV, Clear, per MIL-A- Bonding Material Peripheral Seal, Coupling Nut Retainer Insulator-to-Rubber Receptacle 0.90 NASA Test GSFC0191 1.74 Bonding Material 46146 NASA & Test # Emerson Cuming Front-To-Rear Coupling NutInsulator Epoxy ScotchEccobond Weld Epoxy #2214 Gray 0.02 0.77 104 A/B 0.08 Glenair TestGSFC3835 0.52 at NuSil Data Sheet Bonding CouplingMaterial Nut Retainer Torlon® 4203L 0.01 1.88 Technology 03-12-2003 Insulator-to-Rubber DC3145 RTV, Clear, per MIL-A- TBD O-Ring Flourosilicone Rubber TBD NASA Test # GSFC0191 0.90 NASA Test 1.74 Coupling Nut Epoxy Scotch Weld Epoxy 0.02 Bonding Material 46146#2214 Gray 0.77 GSFC3835 White Epoxy Ink for NASA Glenair TestTest at NuSil Markem 7224 White O-Ring Flourosilicone Rubber Coupling Nut Retainer Torlon® 4203L 0.01 TBD0.49 1.88 TBD 0.03 Silkscreening #GSC19899 Technology 03-12-2003 Black Ink for Epoxy Part Number White Ink for NASANASA Test Test # #16-5600Q Markem 7224 White Coupling Nut Epoxy ScotchVideojet Weld Epoxy #2214 Gray0.49TBD 0.02 0.77 0.03 TBD Silkscreening #GSC19899 Identification GSFC3835 Black Ink for PartSolder Number Potting Compound, Videojet #16-5600Q TBD TBD Identification Flourosilicone Rubber 9 TBD TBD Cup O-Ring and PC Tail Stycast epoxy 2651/Catalyst 0.31 0.03 Mfgr Data Sheet Potting Compound, Solder Connectors WhiteCup Epoxy for NASA Test and Ink PC Tail Stycast epoxy 2651/Catalyst Markem White 9 0.310.49 0.03 0.03 Mfgr Data Sheet Potting Compound, Stycast epoxy,7224 2850FT/Catalyst Silkscreening #GSC19899 ConnectorsFilter 0.02 Mfgr Data Sheet 0.29 Receptacles 11 Filter Stycast epoxy, 2850FT/Catalyst BlackPotting Ink forCompound, Part Number 0.29TBD 0.02 TBD Mfgr Data Sheet Videojet11 #16-5600Q Receptacles Identification Potting Compound, Solder CupVibration. and PC Tail epoxy 2651/Catalyst 9 0.31 0.03sine and random Mfgr Data Sheet 3.4.10 ConnectorsStycast shall be capable of withstanding the following vibration 3.4.10 Vibration. Connectors shall be capable of withstanding the following sine and random vibration Connectors requirements with no discontinuities greater than 1 microsecond. requirements with no discontinuities than 1 microsecond. Potting Compound, Filter Stycast epoxy, greater 2850FT/Catalyst 0.02 Mfgr Data Sheet 0.29 Receptacles 11 Page Page 1111 26 n · November 2006 Qwik Connect 3.4.10 Vibration. Connectors shall be capable of withstanding the following sine and random vibration requirements with no discontinuities greater than 1 microsecond. PRODUCT SPECIFICATION 809-009 PRODUCT SPECIFICATION 809-009 16 OCTOBER 2006 16 OCTOBER 2006 3.4.10.1 Vibration, random. Connectors shall be able of withstanding the random vibration test defined 3.4.10.1 Vibration, random. Connectors bethe able of withstanding in EIA-364-28 Condition V Lettershall I with following details: the random vibration test defined in EIA-364-28 Condition Letteraxes I with the following details: Duration: 4 hours each ofV three Duration: 4 hours each of three axes Temperature: ambient PRODUCT SPECIFICATION 809-009 Temperature: ambient Frequency range: 50 Hz to 2000 Hz. 16 OCTOBER 2006 Frequency 37.8 g RMSrange: 50 Hz to 2000 Hz. 37.8 g RMS 3.4.10.1 Vibration, random. Connectors shall be able of withstanding the random vibration test defined in Condition Vshall Letter the following details: 3.4.10.2 Vibration,EIA-364-28 sine. Connectors beI with subjected to the sine vibration test of MIL-STD-202 Method Duration: 4Connectors hours each ofshall threebe axes 3.4.10.2 Vibration, sine.G. subjected tominutes the sineper vibration test of MIL-STD-202 204 Condition 12 sweep cycles per axis, 20 10-2000-10Hz sweep cycle.Method Temperature: ambient 204 Condition G. 12 sweep cycles per axis, 20 minutes per 10-2000-10Hz sweep cycle. Frequency range: 50 Hz to 2000 Hz. 3.4.11 Shock. Connectors 37.8 g RMS shall be capable of meeting the shock requirement specified in EIA-364-27. 3.4.11 Shock. Connectors shall beduration, capable 3ofaxes. meeting the shock requirement specified in EIA-364-27. 300 g. half-sine, 3 millisec. No discontinuities greater than 1 microsecond, no 3.4.10.2 Vibration, Connectors shall3be subjected to the sine vibration test ofthan MIL-STD-202 Method no 300 g. half-sine, 3sine. millisec. duration, axes. No discontinuities greater 1 microsecond, visible signs of damage. 204 Condition G. 12 sweep cycles per axis, 20 minutes per 10-2000-10Hz sweep cycle. visible signs of damage. 3.4.12 Acceleration: Wired, mated be the ableshock to withstand 50g acceleration with no circuit 3.4.11 Shock. Connectors shallconnectors be capable ofshall meeting requirement specified in EIA-364-27. 3.4.12 Acceleration: Wired,than mated connectors be able to withstand 50g with circuit interruption 1 microsecond. MIL-STD-1344 Method 2011-1 Condition A shall 300 g.greater half-sine, 3 millisec. duration, 3 shall axes. No discontinuities greater thanacceleration 1Test microsecond, no no interruption greater than 1 microsecond. MIL-STD-1344 Method 2011-1 Test Condition A shall apply. visible signs of damage. apply. 3.4.12 Acceleration: Wired, mated shallshall be able withstand 50g acceleration with no effects circuit of 3.4.13 Gunfire Vibration: Wired, matedconnectors connectors be to able to withstand the simulated interruption greater than 1 microsecond. MIL-STD-1344 Method 2011-1 Test Condition A shall 3.4.13 Gunfire Vibration:when Wired, mated connectors shallMIL-STD-810F be able to withstand the519.5. simulated effects of gunfire apply. vibration tested in accordance with Method The frequency gunfire vibrationshall when tested in accordance with MIL-STD-810F Method 519.5. The and amplitude approximate close proximity to the M230 chain gun deployed onfrequency an AH-64 and amplitude shall approximate close proximity M230 chain gun deployed on an Apache helicopter. 3.4.13 Gunfire Vibration: Wired, mated connectors shalltobethe able to withstand the simulated effects of AH-64 Apachegunfire helicopter. vibration when tested in accordance with MIL-STD-810F Method 519.5. The frequency amplitude shall approximate to the M230 chain caused gun deployed on an AH-64 3.4.14 Fungus.andConnector materials shall close resistproximity microbial deterioration by fungus growth when Apache helicopter. 3.4.14 Fungus. Connector materials shall resist microbial deterioration caused by fungus growth when tested per MIL-STD-810, Method 508.5 tested per MIL-STD-810, Method 508.5 3.4.14 Fungus. Connector materials shall resist microbial deterioration caused by fungus growth when 3.4.15 Contamination Fluids. Connectors shall withstand intermittent exposure to the fluids shown in tested perby MIL-STD-810, Method 508.5 3.4.15 Contamination Fluids. shall withstand exposure shall to thewithstand fluids shown in Table 17 when by tested per Connectors MIL-STD-810 method 504. intermittent Unmated connectors Table 17 when tested per MIL-STD-810 method 504. Unmated connectors shall withstand 3.4.15 Contamination by Fluids. Connectors shall withstand intermittent exposure to the fluids shown in to complete immersion in the specified fluid without excessive swelling, damage or distortion Table 17 whenincluding tested MIL-STD-810 method 504. Unmated connectors shall withstand complete immersion in theper specified fluid without excessive swelling, damage or distortion to dielectric materials seals, grommets and insulators. complete immersion in the specified fluid without swelling, damage or distortion to dielectric materials including seals, grommets andexcessive insulators. dielectric materials including seals, grommets Table and 17 insulators. Table Contamination by Fluids Table17 17 Contamination FluidsTest Fluid Contamination by by Fluids Test Fluid Test Fluid Contaminant Immersion Temperature Contaminant Immersion Temperature Contaminant Immersion Temperature Fluid Group Test Fluid +/-2° C. Duration (Hrs.) Fluid Group TestFluid Fluid +/-2° C. Duration (Hrs.)(Hrs.) Fluid Group Test +/-2° Duration Kerosene JP-4 (NATO F40) 70C. 8 Kerosene JP-4 (NATO F40) 70 8 Fuels Fuels Kerosene JP-4 (NATO F40) 70 88 Gasoline ASTM ambient Fuels Gasoline ASTM4814 4814 ambient 8 Gasoline ASTM 4814 ambient 88 Hydraulic Oils OilsMineral oil based MIL-H-5606 Hydraulic Mineral oil based MIL-H-5606 7070 8 Hydraulic Oils Mineral oil based MIL-H-5606 70 8 Solvents Solvents and and Cleaning Isopropyl alcohol ambient 8 Solvents and Cleaning Isopropyl alcohol ambient 8 Cleaning Isopropyl alcohol ambient 8 Fluids Fluids 25% urea/ 25% ethylene glycol Fluids De-icing Fluids ambient 8 25% urea/ 25% ethylene glycol water De-icing Fluids 25% urea/ 25%inethylene ambient 8 glycol in water De-icing Fluids ambient 8 inconnectors water 3.4.16 Humidity. Fully wired, mated shall be able to withstand high humidity environments at varying temperatures without degradation. Connectors be considered be able toenvironments meet 3.4.16 Humidity. Fully wired, mated connectors shall be able shall to withstand hightohumidity at requirement subjected to the humidity test MIL-EIA-364-31, Method IV. Connectors 3.4.16 Humidity. Fully wired,ifwithout mated connectors shall beofable toshall withstand high humidity varyingthis temperatures degradation. Connectors be considered to be environments able shall to meet at show no evidence of deterioration and shall be tested forshall insulation resistance. The minimum varying temperatures without degradation. Connectors be considered be able to meetshall this requirement if subjected to the humidity test of MIL-EIA-364-31, MethodtoIV. Connectors insulation resistance shall be 100 megohms. this requirement if subjected to the humidity test of MIL-EIA-364-31, Method IV. Connectors show no evidence of deterioration and shall be tested for insulation resistance. The minimumshall show evidence of deterioration and802 shall be tested forbeinsulation The minimum insulation resistance shallpating. be 100 megohms. 3.4.17noHydrostatic pressure Series connectors shall capable ofresistance. meeting a hydrostatic insulation resistance shall be 100 megohms. pressure rating of 3500 PSI (241 bar) fully mated. 3.4.17 Hydrostatic pressure pating. Series 802 connectors shall be capable of meeting a hydrostatic 3.4.18 Open faceofpressure rating. Hermetic receptacles be capable of meeting 1000 PSI bar) 3.4.17 Hydrostatic pressure pating. Series 802 connectors shall be capable of meeting a (68 hydrostatic pressure rating 3500 PSI (241 bar) fully mated.shall pressure unmated condition. pressure rating in ofan 3500 PSI (241 bar) fully mated. 3.4.18 Open face pressure rating. Hermetic receptacles shall be capable of meeting 1000 PSI (68 bar) 3.4.18 Open faceinpressure rating. Hermetic receptacles shall be capable of meeting 1000 PSI (68 bar) pressure an unmated condition. Page 12 pressure in an unmated condition. QwikConnect n· November 2006 Page 12 Page 12 27