MIL-DTL-28804D
4. VERIFICATION
4.1 Classification of inspection. The inspection requirements specified herein are classified as follows:
a. Qualification inspection (see 4.3)
b. Quality conformance inspection (see 4.6).
c. Verification of qualification (see 4.5.4).
4.2 Inspection conditions. Unless otherwise specified, all inspections shall be performed in accordance with the test conditions
specified in (applicable test method document or applicable paragraph(s) in the specification).
4.2.1 Verification testing. The following identified tests and test methods assure socket integrity within typical operating
conditions and applications. Alternate commercial industry standard test methods are allowed, however when an alternate method
is used, the alternate method must be coordinated with the qualifying activity prior to performance of the test. The test methods
described herein are proven methods and shall be the referee method in cases of dispute.
4.2.2 Test equipment and inspection facilities. Test and measuring equipment and inspection facilities of sufficient accuracy,
qualify and quality to permit performance of the required inspection shall be established and maintained by the contractor. The
establishment and maintenance of a calibration system to control the accuracy of the measuring and test equipment (i.e.
ANSI/NCSL Z540-1-1994, ISO 10012-1 part, or comparable standards) shall be required.
4.2.3 Assembly distributor. Assembly distributors must be listed on, or approved for listing on, the applicable qualified products
list. The qualified connector manufacturer shall certify that the assembly distributor is approved for the distribution of the
manufacturer's parts. The assembly distributor shall use only piece parts supplied by the qualified connector manufacturer. No
testing other than visual examination is required of certified piece parts obtained from the qualified connector manufacturer, except
when there is cause for rejection. All assemblies produced at the assembly distributor's plant shall be subjected to examination of
product to assure that the assembly process conforms with that established at the qualified manufacturing plant. Quality control
requirements, including Government inspection surveillance, shall be the same as required for the qualified connector
manufacturer.
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, plating, and
processes shall be identified for inclusion in the product test documentation (see 3.3.1).
4.4 Inspection conditions. Unless otherwise specified herein, all inspections shall be performed in accordance with the test
conditions specified in the "GENERAL REQUIREMENTS" of MIL-STD-1344 and MIL-STD-202.
4.5 Sample size and inspection routine.
4.5.1 Connectors. The sample connectors submitted for qualification approval shall be produced with the contractor's regular
production equipment and procedures; shall be selected from a production run after manufacturer's normal quality inspection has
been performed; and shall not be subjected to any special preliminary screening test. Use of alternate materials, platings, and
processes (see 3.3.1) shall be identified for inclusion in the product test documentation. A minimum of six completely assembled
plugs and receptacles, with crimp termination's or nine completely assembled plugs and receptacles with solder termination's with
the insert arrangement of the largest size connector for which qualification is desired shall be subjected to the examinations and
tests in the sequence shown in table IX. If both classes E and S or SE connectors are being qualified at the same time, a minimum
of three completely assembled plugs and receptacles of class E and a minimum of six completely assembled plugs and
receptacles of class S or SE with the insert arrangement of the largest size connector shall be inspected. The connectors shall
have their full complement of contacts. The minimum number of contact cavities or contacts shown in table X shall be inspected.
Additional samples may be required to provide the contact cavities or contacts as specified in table X. Half of the connectors shall
be wired with the maximum size wire (size 22) and the remainder shall be wired with the minimum size wire (size 26). The samples
subjected to qualification testing shall be provided with counterpart connectors provided for this purpose shall be new, previously
qualified connector 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
representative of the manufacturer's production. Connectors shall be wired with approximately 2 feet of M22759/11-22 wire
conforming to MIL-W-22759/11 for maximum size wire and M22759/44-26, /45-26, /33-26, or /46-26 wire conforming to MIL-W-
22759/44, /45, /33, 46 for minimum size wire. Termination of wires to crimp contacts shall be accomplished using a MIL-C-22520/2
crimping tool. Classes S and SE connectors may be wired with flexible printed wiring rated at the minimum test current in table V.
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