MIL-DTL-24308G
4.2.3 Established reliability and high reliability practice. An established reliability and high reliability practice shall
be maintained in accordance with MIL-STD-790. Evidence of such compliance shall be verified by the qualifying
activity of this specification as a prerequisite for initial and continued qualification.
4.3 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 shall be identified in the product test documentation (see 3.3.1).
4.3.1 Sample size.
4.3.1.1 Connectors. A minimum of 6 completely assembled plugs and receptacles of each class (1.3.1) of each
type (1.3.3), and of each style (1.3.2), with the largest insert arrangement for which qualification is desired shall be
subjected to the examinations and tests, except for thermal vacuum outgassing, in the sequence shown in table XI.
For classes D, K, and M, all the nonmetallic materials, including lubricants, of two additional connectors shall be
subjected to the thermal vacuum outgassing test. If classes G and N or M and D are being qualified at the same time,
a minimum of three completely assembled plugs and receptacles with the insert arrangement of the largest size
connector of the type (1.3.3) with the same style of termination (1.3.2), and each class (classes G and N, 3 class G, 3
class N; classes D and M, 3 class M, 3 class D) shall be subjected to the examinations and tests, except for thermal
vacuum outgassing, in the sequence shown in table XI. For classes D and M, all the nonmetallic materials, including
lubricants, of one additional connector of each class shall be subjected to the thermal vacuum outgassing test. The
connectors shall have a full complement of contacts. Half of the class H and class K contacts shall have solder cups
and the remainder shall have eyelets. The samples subjected to qualification testing shall be provided with
counterpart connectors for those tests requiring mating assemblies. The counterpart connectors provided for this
purpose shall be new, previously qualified connectors or new connectors submitted for qualification testing. Suppliers
not producing mating connectors shall submit substantiating, certification data that tests were performed with qualified
counterpart connectors. The samples shall be taken from a production run and shall be produced with equipment and
procedures normally used in production.
4.3.1.1.1 Printed wiring board connectors. When qualifying plugs and receptacles of printed wiring board
termination types, both the plug and receptacle shall be mounted to printed wiring boards and test as mated
connectors.
4.3.1.2 Qualification of additional connectors. For all other connector sizes of the same type, class, and style of
termination for which qualification is desired, two each of the completely assembled plugs and receptacles shall be
subjected to the examinations and tests in the sequence shown in table XI. Mating plugs and receptacles shall be
furnished.
4.3.1.3 Preparation of samples. Connectors shall be wired with approximately 2 feet of wire in accordance with
NEMA HP3, type E and table X. Half of the connectors of each type shall be wired with the maximum wire size and
the remainder shall be wired with the minimum wire size specified in table X. Termination of wires to contacts shall be
accomplished as follows: A MIL-C-22520/2 crimping tool (see 3.1), shall be used for removable contacts. Soldering
shall be used for nonremovable contacts. Insulation displacement connectors shall use flexible, flat, unshielded,
round conductor cable (see 3.3.1).
TABLE X. Test wire sizes.
Contact size
Maximum
Minimum
wire size
wire size
20
20
24
22D
22
28
IDC
28 stranded
28 stranded
4.3.2 Inspection routine. The sample shall be subjected to the inspections specified in table XI, in the order shown.
All sample units shall be subjected to visual and mechanical inspection before wiring (see 4.3.1.2 and 4.4.1).
4.3.3 Failures. One or more failures shall be cause for refusal to grant qualification approval.
4.3.4 Verification of qualification. To retain qualification, the contractor shall verify in coordination with the
qualifying activity the capability of manufacturing products which meet the requirements of this specification. Refer to
the qualifying activity for the guidelines necessary to retain qualification to this specification. The contractor shall
immediately notify the qualifying activity when inspection data indicates failure of the qualified product to meet the
requirements of this specification.
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