MIL-DTL-21097G
4.3 Preparation of samples.
4.3.1 Connectors. Unless otherwise specified (see 3.1), connectors having solder type contacts shall be wired using
no. 20 AWG wire in accordance with MIL-DTL-16878, type E.
4.3.2 Crimped contacts. Contacts shall be crimped to the appropriate wire size. The wire size shall be in accordance
with MIL-DTL-16878, type E.
4.4 Qualification inspection. Qualification inspection shall be performed at a laboratory acceptable to the
Government (see 6.3) on sample units produced with equipment and procedures normally used in production. Use of
alternate materials, platings and processes (see 3.3) shall be identified for inclusion in the product test documentation.
4.4.1 Sample size. Ten connectors assemblies (with a full complement of contacts) of each style shall be subjected
to qualification inspection. The samples shall be of the size, mounting provision, and class of the connectors as
specified (see 3.1).
4.4.1.1 Individual contact measurements. Unless otherwise specified herein or in the individual specification sheet,
individual contact measurements shall be made on 15 contacts in each connector or 50 percent of the contacts in each
connector where the number of measurements are limited by style to less than 15 contacts.
4.4.1.2 Crimp type contacts. Fifty crimp type contacts for which approval is desired shall be crimped to the
appropriate wire size. Where a contact covers a range of wire sizes, one-half of the contacts of each group shall be
crimped to the smallest wire size in the range.
4.4.2 Inspection routine. The sample shall be subjected to the inspections specified in tables VIII and IX, as
applicable, in the order shown. The sample shall be divided as specified in tables VIII and IX, and the sample units
subjected to the inspection for their particular group.
4.4.3 Failures. One or more failures shall be cause for refusal to grant qualification approval.
4.4.4 Verification of qualification. To retain qualification, the contractor shall verify in coordination with qualifying
activity the capability of manufacturing products which meet the requirements of this specification. The qualifying
activity shall be notified whenever inspection data indicates failure of the qualified product to meet the performance
requirements of this specification.
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