Generic Requirements for Separable Electrical Connectors Used In Telecommunications Hardware

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1 Generic Requirements for Separable Electrical Connectors Used In Telecommunications Hardware Telcordia GR Documentation Information Preface...Preface 1 1. Introduction Scope Application Document Organization Major Changes from TR-NWT , Requirements Terminology Requirement Labeling Conventions Numbering of Requirement and Related Objects Requirement, Conditional Requirement, and Objective Object Identification General Requirements and Administration Safety Other Requirements Nonconformance Administration Numerical Values Workmanship Standards System Requirements for Connector Products Environmental Exposure Requirements IEEE Std (IEEE Standard Microcomputer Environmental Specifications for Computer Modules) IEEE Std Performance Levels Maximum Exposure Temperature Other Environmental Requirements System Quality Requirements Basis for Quality Classification SQ Requirement I for Small Systems SQ Requirement II for Medium Systems SQ Requirement III for Large Systems Connector Classification and Reliability Assurance Classification by Quality Level Methodology to Demonstrate Reliability Connector Failure Rates Determined from Field Experience Failure Mechanisms Considered in Connector Qualification Organization of Qualification Procedures and Reliability Verification Standard Testing Procedures New Technology Prequalification and Reliability Verification v

2 4.4 The Concept of Performance Testing Connector Qualification Incoming Inspection Acceptance Tests Ship-to-Stock Practices Design Requirements Physical and Mechanical Requirements General Contact Normal Force Contact Wipe Geometry of Contact Surfaces Mate/Unmate Force Insertion/Removal Force Plated Through-Hole Requirements for Use with Press Fit Pins Contact Strength Polarizing Method Contact Metallization General Contact Metallization Thickness Porosity Contact Finish, Surface Roughness, and Adhesion Durability of Contact Finishes Lubrication Lubrication of Noble Metallizations Lubrication of Non-Noble Metallizations Electrical Requirements Contact Resistance Contact Resistance Stability Contact Disturbance Low-Nanosecond Events Current Rating Temperature Rise at Rating Insulation Resistance Withstanding Voltage Temperature/Humidity Stress Immunity Miscellaneous Requirements for Special Connector Types Semi-Permanent Mechanical Connections Component Sockets Component Socket Usage Zero Insertion Force Connectors Coaxial Connectors Summary Table for Design Requirements for Separable Connectors Design Verification and Performance Testing Physical and Mechanical Requirements Visual Examination vi

3 6.1.2 Examination of Dimension, Markings, and Mass Contact Normal Force Mate/Unmate Force Insertion/Removal Force Plated-through Hole Requirements for Use with Press Fit Pins Contact Strength Contact Metallization Thickness Contact Finish, Surface Roughness, Porosity, and Adhesion Durability of Noble Metal Contact Finishes Durability of Non-noble Metal Contact Finishes Electrical Requirements Low-Level Contact Resistance (LLCR) Contact Resistance (Specified Test Current Method) Contact Disturbance Low-Nanosecond Events Current Rating Temperature Rise at Rating Insulation Resistance Withstanding Voltage Environmental Stress Immunity General Temperature Life Thermal Shock Moisture Resistance (Humidity with Thermal Cycling) Test Vibration and Mechanical Shock Testing Testing Connectors Without Mass Loading Testing PWB/Connector Assemblies Testing System Level Assemblies, Vibration Only Four-Gas MFG Testing Special Tests for Semi-Permanent Mechanical Connections Contact Resistance Stability of Semi-Permanent Connections Gas Tight Hermiticity of Non-noble Metal Contacts Flex/Pull Test for Semi-Permanent Cable Connections Test Organization and Sequencing Samples Required Alternative Industry Standard Tests Qualification Test Environment EIA Qualification Test Sequences New Technology Prequalification and Reliability Verification Purpose of Prequalification Prequalification in TR-NWT Versus Prequalification in GR-1217-CORE Instances Where Prequalification Is Required vii

4 Specific Concerns Sample Sizes and Acceptance Criteria Sample Sizes and Criteria for Prequalification Lot-by-Lot Sampling Control Samples The Four Key Environmental Tests Temperature Life Test Humidity with Temperature Cycling Test Vibration and Mechanical Shock Testing Testing Connectors Without Mass Loading Testing PWB/Connector Assemblies Testing System Level Assemblies Mixed Flowing Gas Testing Requalification Significant Changes Requiring Requalification Periodic Partial Requalification Quality Level II and III Periodic Full Requalification Test Methods Environmental Tests Environmental Preconditioning Dust and Fiber Contamination Test Module Prewear and Postwear Module Vibration and Mechanical Shock Testing of Connectors Without Mass Loading Vibration and Shock Tests for PWB/Connector Assemblies Vibration and Shock Tests for System Level Assemblies Four Gas MFG Testing Test Control and Verification MFG Test Sequence with Parallel Mated and Unmated Exposure MFG Test Sequence with Sequential Mated and Unmated Exposure Fretting and Lubrication Tests Fretting Test - Standard Rider/Flat Method Connector Hardware Vibration Test for Fretting and Lubrication Hardware Test for Noble Metal Contacts Metal Finishes Thickness of Noble Metal Contact Finishes Noble Metal Porosity Testing Alkaline Polysulfide Test for Porosity Electrographic Testing - Paper Electrographic Tests - Gel viii

5 Corrosive Gas Tests - Nitric Acid Vapor Finish Adherence Flex/Pull Test for Permanent Cable Connections References... References 1 Glossary...Glossary 1 ix

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7 List of Tables List of Tables Tables Table 4-1. Definition of Quality Levels Table 5-1. Noble Metallization Thicknesses - Excluding PWB Contact Fingers Table 5-2. Noble Metallization Thicknesses - PWB Contact Fingers Table 5-3. Lubricants for Noble Metallization Contacts Table 5-4. Examples of Lubricants for Tin/Lead-To-Tin/Lead or Reflowed Tin-To-Reflowed Tin Contacts Table 5-5. Generic Design Requirements for All Types of Separable Connectors Table 6-1. Summary of Standard Test Procedures for Design Qualification Table 6-2. Telcordia Modified Recommended Test Sequences Table 7-1. Sample Sizes and Test Criteria Table 9-1. Dust Composition Number 1 (Benign) Table 9-2. Gas Compositions for Industrial MFG Gas Testing Table 9-3. Typical Pore Counts for Electrographic Porosity Test xi