TYPE
NUMBER
PRODUCT SPECIFICATION
TITLE
PAGE
BUS-12-098
REVISION
Crimp to Wire Male Pin Electrical Contact
1 of 6
AUTHORIZED BY
DATE
E
2-Jun-06
H.T. Brewbaker
CLASSIFICATION
UNRESTRICTED
1.0
SCOPE:
1.1
This specification sets forth the physical and performance parameters for the crimp to wire pin when
mated with a Mini PV ™contact.
2.0
APPLICABLE DOCUMENTS:
2.1
The following documents and specifications form part of this specification to the extent specified
herein:
MIL-C-45204-Gold Plating: Electro deposited.
MIL-STD-202-Test Methods for electronic parts.
ASTM B-36-71, Alloy 260-Brass
UNS-C26000-Brass
3.0
PHYSICAL PARAMETERS:
3.1
Qualifications
3.1.1
The pin furnished under this specification shall be a product which has been tested and
passed the qualification test specified herein.
3.2
Definitions
3.2.1
Crimp To Wire Pin: A crimp to wire pin is a metallic .025 square contact normally
crimped to wire and intended to mate with a Mini PV ™contact. The pin, incorporating
wire and insulation barrels, can be crimped to 18 to 32 AWG wire.
3.3
Materials
3.3.1
Contact Material: The pin shall be fabricated from brass conforming to ASTM B-36-71,
Alloy 260, 3/4 hard, Federal Spec. QQ-B-613 A and UNS-C26000.
3.4
Finish
3.4.1
All contact surfaces shall have a smooth finish and be free of die marks and burrs. The
inside of the wire and insulation crimp barrels shall have a fine pitch knurl.
Contact Body Plating - the contact body will be supplied with any of three plating
specifications.
3.4.2.1
The pin contact area plating shall be .000050 inch thick gold over .000050
inch thick nickel underplate. Gold plating conforming to MIL-G-45204.
The pin contact area plating shall be .000100 inch thick 60/40 tin-lead.
The pin contact area plating shall be .000100 inch to .000160 inch hot dip tin.
3.4.2
3.4.2.2
3.4.2.3
Copyright
Form E-3334
Rev E
FCI
GS-01-001
PDM: Rev:E
STATUS:
Released
Printed: Nov 28, 2010
.
TYPE
NUMBER
PRODUCT SPECIFICATION
TITLE
PAGE
BUS-12-098
REVISION
Crimp to Wire Male Pin Electrical Contact
2 of 6
AUTHORIZED BY
DATE
E
2-Jun-06
H.T. Brewbaker
CLASSIFICATION
UNRESTRICTED
3.5
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.
3.6
Manufacturing Processability
This product is not designed to be exposed to manufacturing solder processes.
4.0
PERFORMANCE PARAMETERS:
The crimp to wire pin shall meet the mechanical, electrical and environmental parameters specified herein
when mated with a Mini PV ™contact. Test shall be performed in accordance with MIL-STD-202 where
applicable.
4.1
Mechanical
4.1.1
Crimp Tensile Strength: Pins crimped to wires shall be placed in a standard tensile
testing machine, and an axial load applied. The wire shall not pull out of the wire barrel,
nor break, nor become distorted to such an extent that it is unusable before the minimum
strength is reached. Minimum tensile strength being 75% of wire tensile strength.
4.2
Electrical
4.2.1
Initial Contact Resistance: D.C. resistance shall be measured using the four point
Voltage Current Method. The ohmmeter used must have an accuracy of at least +/- 0.5
milliohms. The digital readout shall be capable of 3 digit display with accuracy of +/- 1 in
the last digit. the probe shall provide suitable metal-to-metal contact. The contact
resistance, when measured as described above and mated with a Mini PV,™ shall be 3.0
milliohms maximum initial and 5.0 milliohms maximum after aging.
Current Carrying Capacity: A pin mated with a Mini PV™ contact and subjected to 3
Amperes continuous load shall show no more than 30oC temperature rise above
ambient.
4.2.3
Wear Test: All pins cycled 100 times with a Mini PV™ contact shall meet the initial
contact resistance as described in 4.2.1.
Temperature Cycling: All pins submitted to temperature cycling test MIL-STD-202C
Method 102A shall be tested and shall meet contact resistance as described in 4.2.1.
Flowers of Sulphur Aging Test: Unmated pins shall be placed in an enclosure containing
flowers of sulphur and water for 10 days. Temperature within the enclosure shall be
150oF +/- 10oF and 80% relative humidity. After aging, terminals shall be stabilized at
room temperature and subjected to 5 cycles of mating with Mini PV's™. Pins shall then
be tested for and meet contact resistance as described in 4.2.1.
4.2.2
4.2.4
4.2.5
Copyright
Form E-3334
Rev E
FCI
GS-01-001
PDM: Rev:E
STATUS:
Released
Printed: Nov 28, 2010
.
TYPE
NUMBER
PRODUCT SPECIFICATION
TITLE
PAGE
BUS-12-098
REVISION
Crimp to Wire Male Pin Electrical Contact
3 of 6
AUTHORIZED BY
DATE
E
2-Jun-06
H.T. Brewbaker
CLASSIFICATION
UNRESTRICTED
4.2.6
Setup for Flowers of Sulphur Test using an enclosure with a volume of approximately
32000 cubic centimeters, 100 grams of sulphur and 500 milliliters of distilled water. A
quantity of 345 grams of anhydrous sodium carbonate shall be added to the distilled
water. Arrangement of material during test shall be as follows:
4.2.6.1
Water on the bottom in a 150 millimeter diameter by 75 millimeter high
beaker.
Sulphur in a 150 milliliter beaker placed inside 150 millimeter x 75 millimeter
beaker.
Test samples placed on a rack suspended over the sulphur and facing the
water.
4.2.6.2
4.2.6.3
4.2.7
Aging Test: After the initial contact resistance test, contaminate each pin with one of the
following contaminants:
a. synthetic dust - formulation II
b. artificial perspiration
Contacts contaminated with a and b must be tested in the unmated condition and
subjected to 50 cycles in the following environment.
1. 50o +_ 10oF 50% maximum R.H.
2. 170o +_ 10oF 92% +_ 3% R.H.
3. 170o +_ 10oF 50% R.H.
4 hours
4 hours
16 hours
After the 50 cycles have been completed, the pins shall be stabilized to room temperature
(70oF +_ 10oF). Pins shall then be subjected to 15 cycles (one cycle equals one insertion
and one withdrawal) with a Mini PV ™contact. Resistance shall not exceed 5.0 milliohms
when measured as described in 4.2.1.
Copyright
Form E-3334
Rev E
FCI
GS-01-001
PDM: Rev:E
STATUS:
Released
Printed: Nov 28, 2010
.
TYPE
NUMBER
PRODUCT SPECIFICATION
TITLE
PAGE
BUS-12-098
REVISION
Crimp to Wire Male Pin Electrical Contact
4 of 6
AUTHORIZED BY
DATE
E
2-Jun-06
H.T. Brewbaker
CLASSIFICATION
UNRESTRICTED
4.2.8
Test Method for 4-4-16 aging test:
a. A synthetic Dust II is applied to contacts with a 1/2 inch (maximum) wide brush. After
application, samples shall be tapped with fingers to remove excess dust.
1. Synthetic Dust II formation:
Parts
KNO3
KCI
KF
NH4CI
NH4NO3
Mg(NO3) .2.6H2O
MgSO4 .7H2O
CaSO4
CaO.AI203.S102
Ti02
V2O5
MnO2
Fe203
Cu SO4.5H20
ZnO
Hg CI2
Pb Ciz
Pb SO4
1.81
2.48
1.48
4.46
6.67
2.64
38.1
3.39
20.7
0.33
0.089
0.10
9.42
1.57
1.25
0.136
2.69
1.47
*NOTE:
Card Dust *
17.2
Paper fiber 100% pass 80 mesh screen. Estimated 50% by volume consisting of fibers
larger and 50% smaller than 75 +/- 25 microns measured on long dimension.
Copyright
Form E-3334
Rev E
FCI
GS-01-001
PDM: Rev:E
STATUS:
Released
Printed: Nov 28, 2010
.
TYPE
NUMBER
PRODUCT SPECIFICATION
TITLE
PAGE
BUS-12-098
REVISION
Crimp to Wire Male Pin Electrical Contact
5 of 6
AUTHORIZED BY
DATE
E
2-Jun-06
H.T. Brewbaker
CLASSIFICATION
UNRESTRICTED
75 micron fiber having average width of 15 microns.
b) Artificial perspiration formulation
KCI
NaCI
NaH2PO4
10%
10%
.005%
Lactic Acid
.005%
Balance Distilled Water
Adjusted to PH of 4 with 10% sulfuric acid as required.
4.2.9
Salt Spray: All pins submitted to salt spray erosion tests MIL-STD-202C method 101B
shall be tested for an exhibit contact resistance as described in 4.2.1.
5.0
QUALITY ASSURANCE PROVISIONS:
5.1
Test Conditions: Unless otherwise specified tests and examinations shall be conducted under any
combination of conditions within the following ranges:
Temperature: 20 - 30oC
Relative Humidity: 80% maximum
Barometric Pressure: 24 to 31 inches mercury
5.2
Test Samples: The samples shall consist of 25 crimped pins and 25 Mini PV™ contacts
representative of production.
Samples of production pins shall be examined to insure that all requirements of Section 3 have been
met, except performance. Final examination of product shall include a thorough examination to
insure that the pin is free from mechanical defects and that there are no cracks around the crimp
area. Inspection shall be made with a device having magnification power of approximately 3
diameters.
5.3
Copyright
Form E-3334
Rev E
FCI
GS-01-001
PDM: Rev:E
STATUS:
Released
Printed: Nov 28, 2010
.
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