TYPE
NUMBER
PRODUCT SPECIFICATION
TITLE
PAGE
BUS-12-067
REVISION
Crimp-to Wire, Mini-PV™ Receptacles and Mini-Latch Housings
1 of 16
AUTHORIZED BY
DATE
K
31-May-06
H.T. Brewbaker
CLASSIFICATION
UNRESTRICTED
1.0
OBJECTIVE
This specification defines the performance, test, quality and reliability requirements of Crimp-to-Wire Mini-
PV (TM) receptacles and Mini-Latch housings.
2.0
SCOPE
This specification is applicable to the termination characteristics of the Crimp-to-Wire Mini-PV (TM) receptacles
and Mini-Latch housings which are designed for interconnection of discrete wires and
0.025 inch round or square pins.
These connectors provide only the receptacle half of the interconnection and are designed to mate with
single or double rows of pins, free standing or in headers, on 0.100, 0.125, 0.150 or 0.156 inch centers.
3.0
GENERAL
This document is composed of the following sections:
Paragraph
1.0
2.0
3.0
4.0
5.0
5.1
5.2
5.3
5.4
6.0
7.0
8.0
9.0
9.1
9.2
9.3
9.4
9.5
9.6
TABLE VI
3.1 Banned/Restricted Substances
All product where the part number ends in “LF” meet the European Union directives and other
country regulations as described in GS-22-008. The part numbers that do not end in “LF” meet all
regulations except for Pb in SnPb plating, if available. Tin plated “LF” product has 100% tin plating
in the interface and has not been tested for whisker growth in all interconnect environments.
Title
OBJECTIVE
SCOPE
GENERAL
APPLICABLE DOCUMENTS
REQUIREMENTS
Qualification
Material
Finish
Design and Construction
ELECTRICAL CHARACTERISTICS
MECHANICAL CHARACTERISTICS
ENVIRONMENTAL CONDITIONS
QUALITY ASSURANCE PROVISIONS
Equipment Calibration
Inspection Conditions
Sample Quantity and Description
Acceptance
Qualification Testing
Requalification Testing
QUALIFICATION TEST MATRIX
Copyright
Form E-3334
Rev E
FCI
GS-01-001
PDM: Rev:K
STATUS:
Released
Printed: Nov 28, 2010
.
TYPE
NUMBER
PRODUCT SPECIFICATION
TITLE
PAGE
BUS-12-067
REVISION
Crimp-to Wire, Mini-PV™ Receptacles and Mini-Latch Housings
2 of 16
AUTHORIZED BY
DATE
K
31-May-06
H.T. Brewbaker
CLASSIFICATION
UNRESTRICTED
3.2 Manufacturing Processability
This product is not designed to be exposed to manufacturing solder processes.
4.0
APPLICABLE DOCUMENTS
4.1
Specifications
4.1.1
4.1.2
4.1.3
4.1.4
4.2
Engineering drawings
Process drawings
MIL-G-45204: Electrodeposited Gold
MIL-W-16878: High Temperature Insulated Electrical Wire
Military Standards
4.2.1 MIL-STD-1344: Test Methods for Electrical Connectors
4.2.2 MIL-STD-202: Test Methods for Electronic and Electrical Component Parts.
4.3
Federal Specifications
4.3.1 QQ-N-290: Nickel Plating (Electrodeposited)
4.3.2 QQ-B-613: Leaded and Non-Leaded Brass
4.4
Other Standards and Specifications
4.4.1 UL94-V0: Flammability
4.4.2 ASTM B579: Electrodeposited Coatings of Tin-Lead Alloy
4.4.3 ASTM B122: Copper-Nickel-Tin Alloy, Copper-Nickel-Zinc Alloy (Nickel Silver), and Copper-
Nickel Alloy Plate, Sheet, Strip and Rolled Bar
4.4.4 ASTM B-194: Copper-Beryllium Alloy Plate, Sheet, Strip and Rolled Bar
4.4.5 ANSI/ASQC M-1: American National Standard for Calibration Systems
4.4.6 BUS-03-404: FCI Test Specification for Normal Force Measurements
4.4.7 BUS-03-302: FCI Test Specification for Sulfide Vapor Test
4.4.8 TA-75: FCI Latch Housing Mini-PV Crimp/Application Data
5.0
REQUIREMENTS
5.1
Qualification
Terminals furnished under this specification shall be capable of meeting the qualification test
requirements specified herein.
5.2
Material
The material for each component shall be as specified herein or equivalent.
5.2.1 Body. The contact body shall be Quarter-Hard Brass Alloy UNS C26000 in accordance with
QQ-B-613 or Quarter-Hard CuNi Alloy UNS 72500 in accordance with ASTM B122.
Copyright
Form E-3334
Rev E
FCI
GS-01-001
PDM: Rev:K
STATUS:
Released
Printed: Nov 28, 2010
.
TYPE
NUMBER
PRODUCT SPECIFICATION
TITLE
PAGE
BUS-12-067
REVISION
Crimp-to Wire, Mini-PV™ Receptacles and Mini-Latch Housings
3 of 16
AUTHORIZED BY
DATE
K
31-May-06
H.T. Brewbaker
CLASSIFICATION
UNRESTRICTED
5.2.2 Spring. The contact spring shall be Half-Hard, Beryllium Copper Alloy UNS C17200 in
accordance with ASTM B-194 heat treated to full hard condition.
5.2.3 Housing. The latch housings shall be of the material specified on the product
drawings.Materials shall have a flame retardant rating of UL94-V0.
5.2.4 Polarizing Plug. The plug shall be of the material specified on the product drawings.Materials
shall have a flame retardant rating of UL94-V0.
5.3
Finish
The finish for applicable components shall be as specified herein or equivalent.
5.3.1 Contact Body. As specified by the product drawings, the contact body shall be plated in the
contact area with the specified gold plating thickness per MIL-G-45204, Type II,Grade C over
50 microinches nickel per QQ-N-290,Class 2, or shall be plated with tin-lead in accordance
with ASTM B579. Lead free tin plating is also available, the material shall be hot dip tin coated
with a thickness of 100-160 micro inches.
5.3.2 Spring. The contact spring shall be plated with a flash of gold per MIL-G-45204, Type II, Grade C
over 50 microinches nickel per QQ-N-290, Class 2 or where specified on the product drawing with
tin-lead in accordance with ASTM B579. Lead free tin plating is also available, plated per GS-46-
001 (Confidential).
5.4
Design and Construction
Terminals and housings shall be of the design, construction and physical dimensions specified on
the applicable product drawing.
These crimp-to-wire terminals are designed to be either individually mated with pins without a
housing or inserted into a Mini-Latch or Rod Housing and connected to a header or bare pin field.
They are designed to crimp to discrete stranded 18 to 36 AWG wire. Hand tools and bench
mounted applicators are available for crimping terminals.
The terminals are available in a choice of spring thicknesses to provide several levels of contact
normal force.
5.5
Polarization/Keying/Latching.
Polarization and /or keying of the connector is accomplished through the use of individual polarizing
plugs inserted into selected contact positions. As an option, in some cases one or more housing
positions can be molded closed. In either case, the polarized position is rendered non-functional.
Special external polarization, keying and/or latching features are available depending on part
number and specific requirements.
Copyright
Form E-3334
Rev E
FCI
GS-01-001
PDM: Rev:K
STATUS:
Released
Printed: Nov 28, 2010
.
TYPE
NUMBER
PRODUCT SPECIFICATION
TITLE
PAGE
BUS-12-067
REVISION
Crimp-to Wire, Mini-PV™ Receptacles and Mini-Latch Housings
4 of 16
AUTHORIZED BY
DATE
K
31-May-06
H.T. Brewbaker
CLASSIFICATION
UNRESTRICTED
6.0
Electrical Characteristics
6.1
Current Rating - The maximum current rating of the connector is dependent on wire size and
housing/circuit geometry. Figure 1 shows typical graphs of the temperature rise as a function of
current for various wire sizes. Figure1A shows typical graphs of temperature rise as a function of
current for various wire sizes as they were tested in a dense pack (2x36 position) housing. Figure 2
shows temperature rise profiles based on current applied. Charts for Figure 1 and 2 show test results
of PV's that were tested in a single position housing except for 18 and 20 AWG. These are not
recommended for use in a Mini Latch housing.
6.2 Contact Resistance, Low Level - After environmental testing, the change in contact resistance of the
mated connector shall not exceed 2 milliohms when measured in accordance with MIL-STD-1344,
Method 3002. The following details shall apply:
a. Method of Connection - Attach current and voltage leads as shown in Figure 3
b. Test Voltage - 20 millivolts DC max open circuit.
c. Test Current - Not to exceed 100 milliamperes.
6.3 Crimp Resistance, Low Level - When properly crimped, the change in crimp resistance shall not exceed
1 milliohms for wire sizes 18-30 AWG. The change in crimp resistance for 32-36 AWG shall not exceed
2 milliohms. Crimp resistance shall be measured in accordance with MIL-STD-1344, Method 3002. The
following details shall apply:
a. Method of Connection - Attach current and voltage leads as shown in Figure 3A.
b. Test Voltage - 20 millivolts DC max open circuit.
c. Test Current - Not to exceed 100 milliamperes.
6.4 Insulation Resistance - The insulation resistance of unmated terminals, properly mounted in Mini-Latch
housings, shall not be less than 10,000 megohms ( 5000 megohms after exposure to the humidity
environment described below) when measured in accordance with MIL-STD-202,Method 302. The
following details shall apply:
a. Test Voltage - 500 volts DC
b. Electrification Time - 2 minutes
c. Points of Measurement - Between adjacent and opposing contacts.
Copyright
Form E-3334
Rev E
FCI
GS-01-001
PDM: Rev:K
STATUS:
Released
Printed: Nov 28, 2010
.
TYPE
NUMBER
PRODUCT SPECIFICATION
TITLE
PAGE
BUS-12-067
REVISION
Crimp-to Wire, Mini-PV™ Receptacles and Mini-Latch Housings
5 of 16
AUTHORIZED BY
DATE
K
31-May-06
H.T. Brewbaker
CLASSIFICATION
UNRESTRICTED
Copyright
Form E-3334
Rev E
FCI
GS-01-001
PDM: Rev:K
STATUS:
Released
Printed: Nov 28, 2010
.
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