Mini Power User Manual - Equip-Test
Contents
1. 50 C to 105 C 3 4 Performance and Test Description Product is designed to meet electrical mechanical and environmental requirements specified in Figure 1 Unless otherwise specified all tests should be performed at ambient environmental conditions 20f5 For more information vist voc com Rev 5 9 22 09 MINI POWER CONTACTS AND MODULES USER S MANUAL APPENDIX VIRGINIA PANEL CORPORATION 3 5 Test Requirements and Procedures Summary Preliminary Electrical Mechanical 30f5 Test Description Procedure Visual dimensional and functional examination per applicable quality inspection plan Meets requirements of Examination of Product product drawing Initial Contact Measure with digital Ohmmeter using 4 Resistance terminal method 30 C maximum 100 of pin positions populated and Current Rating temperature rise subjected to 50A current with 8 AWG wire 1500 VDC between pins in a module for no less then 60 seconds Capacitance measured between adjacent Capacitance contacts in a module de EIA 364 9 Mate and unmate sample for Durability See test sequence Figure 2 20000 cycles EIA 364 13 Measure force necessary to Max 5 7 Ibs force per Mating Force mate samples at a normal rate of contact engagement of the ITA EIA 364 13 Measure force necessary to unmate samples at a normal rate of disengagement of the ITA Dielectric Breakdown Current leak lt 20 mA Max 5 0 Ibs force per contact2. MINI POWER ICON MODULE INSTALLATION AND REMOVAL TOOLS REQUIRED Phillips Head Screwdriver INSTALLATION INSTRUCTIONS Note The receiver strain relief plate or the ITA cover may need to be removed prior to installing or removing an iCon module Please refer to the appropriate User s Manual for instructions on how to perform these steps 1 Place the module in the receiver or ITA until the upper and lower module screws touch the mating holes in the inner frame Install modules such that Position 1 is located at the top of the ITA receiver frame 2 Using a Phillips head screwdriver tighten the top screw 1 to 2 full revolutions while pushing lightly against the face of the module 3 Maintain this pressure while tightening the bottom screw 1 2 full revolutions 4 Repeat this sequence until the module is seated Torque the screw to 1 5 in lbs 0 16 Nm REMOVAL INSTRUCTIONS 1 Toremove loosen the top screw 1 to 2 full revolutions Loosen bottom screw 1 to 2 full revolutions 2 Repeat this sequence until the module is separated from the receiver or NOTE For optimum performance and system longevity distribute the contact load evenly throughout the module Figure A Receiver Module Figure B ITA Module 4 2 For more information visit voc com 1 25 10 VIRGINIA PANEL CORPORATION NOILOVaLXA VOL 211016 1 OL TLL OLS 70109101 SITNAOW YOL LOL
3. ASSEMBLY INSTALLATION AND REMOVAL OF YPI CONTACTS AND MODULES FOR MINI POWER CONTACTS AND MODULES TABLE OF CONTENTS SECTION 1 RECEIVER CONTACT ASSEMBLY INSTRUCTIONS SECTION 2 ITA CONTACT ASSEMBLY INSTRUCTIONS SECTION 3 CONTACT INSTALLATION AND REMOVAL INSTRUCTIONS SECTION 4 MODULE INSTALLATION AND REMOVAL INSTRUCTIONS SECTION 5 CROSS REFERENCE TABLES APPENDIX PRODUCT PERFORMANCE SPECIFICATIONS 1 25 10 MINI POWER CONTACTS AND MODULES USER S MANUAL SECTION 1 VIRGINIA PANEL CORPORATION MINI POWER RECEIVER CONTACT ASSEMBLY PART 610 116 112 ASSEMBLY INSTRUCTIONS Strip wire Figure Insert a piece of 0 125 3 175 mm diameter shrink tubing 1 00 25 4 mm long onto wire Solder and clean Figure VPC solders per IPC S J STD 001 NOTE Make sure the heat from the solder does not shrink the tubing Slide the piece of shrink tubing over the soldered end up to the inspection hole make sure that the inspection hole is not covered Figure C Shrink the tubing Dimensions shown millimeters inches SHRINK 7 62 TUBING 30 Figure A Strip length SHRINK TUBING SOLDER Figure B Solder taking care not to shrink the tubing SHRINK INSPECTION TUBING HOLE Figure C Ensure inspection hole is not covered For more information visit voc com 1 25 10 MINI POWER CONTACTS AND MODULES USER S MANUAL SECTION 2 VIRGINIA PANEL CORPORATIO
4. Unmating Force Figure 1 Test Requirements and Procedure Summary For more infomation visit voc com Rev 5 9 22 09 MINI POWER CONTACTS AND MODULES USER S MANUAL APPENDIX VIRGINIA PANEL CORPORATION 3 6 Product Qualification and Requalification Test Sequence EE Test or Examination Examination of Product ER Contact Resistance 2 8 2 Current Rating C 131 Dielectric Breakdom 4 gt Capacitance Frequency Range Durability 1 gt Force 1371 1 2 46 3 Unmating Force Figure 2 Test Sequence Numbers indicate the sequence in which the tests are performed For test group sample selection see 4 1 A 4 Quality Assurance Provisions 4 1 Qualification Testing A Sample Selection Samples shall be prepared in accordance with applicable instruction sheets and shall be selected at random from current production All test groups shall each consist of minimum of 5 connectors containing at least 30 contacts total each and equal posts to mate with receptacles Test group 1 shall have both minimum and maximum position size connectors B Test Sequence Qualification inspection shall be verified by testing samples as specified in Figure 2 4 2 Re Qualification Testing If changes significantly affecting form fit or function are made to product or manufacturing process product assurance shall coordinate re qualification testing consisting of all or part of original testing sequence as determ
5. OLS UIAID3P COL OGL OLS SATNAOW Mee YLI NODI COL 091016 x COL LOL OLS 1 25 10 CROSS REFERENCE TABLES MINI POWER CONTACTS AND MODULES USER S MANUAL SECTION 5 J1NAOW 08 SSVD 08 SSVD area 902 OL OLS x 8 1 801015 ES moro EG 2 CONTACTS For more information visit voc com Navy Part Number does not exist for Part 610 115 125 5 1 MINI POWER CONTACTS AND MODULES USER S MANUAL APPENDIX VIRGINIA PANEL CORPORATION Product Performance Specification Mini Power Connector 1 Scope 1 1 Content This specification covers the performance tests and quality requirements for the Mini Power Connector and connector system This contact is a separable electrical connection device Variations of this contact can be crimped to 8 12 and 14 AWG wire or soldered to wires up to 8 AWG in size All Mini Power contact types are to be used in connector modules 1 2 Qualification Testing When tests are performed on subject product line the following procedures shall be used All inspections shall be performed using applicable inspection plans and product drawings Upon completion of qualification testing this specification will be assigned a number and be classified as a Product Qualification Report which will be identified in section 2 2 Applicable Documents 2 1 Content The following documents form a part of this specification to the extent specifi
6. N MINI POWER ITA CONTACT ASSEMBLY PART 610 115 124 610 115 125 ASSEMBLY INSTRUCTIONS Strip wire Figure Dimensions shown millimeters inches SHRINK 7 62 TUBING 30 2 Insert a piece of 0 125 3 175 mm diameter shrink tubing 1 00 25 4 mm long onto wire Figure A Strip length 3 Solder and clean Figure VPC solders per IPC S J STD 001 NOTE Make sure the heat from the solder does not shrink the tubing SHRINK SOLDER TUBING 4 Slide the piece of shrink tubing over the soldered end up to the inspection hole make sure that the inspection hole is not covered Figure C Figure B Solder taking care not fo shrink the tubing 5 Shrink the tubing SHRINK INSPECTION TUBING HOLE Figure C Ensure inspection hole is not covered 2 1 For more information visit voc com 1 25 10 MINI POWER CONTACTS AND MODULES USER S MANUAL SECTION 3 VIRGINIA PANEL CORPORATION MINI POWER RECEIVER CONTACT INSTALLATION AND REMOVAL PART 610 116 112 TOOLS REQUIRED Flat Blade Screwdriver Phillips Head Screwdriver for iCon modules Mini Coaxial Mini Power Receiver ITA Contact Extraction Tool Part 910 112 104 CONTACT INSTALLATION INSTRUCTIONS 1 Assemble the contact to the respective wire NOTE For more information concerning the contact assembly process please see contact assembly instructions in Section of this User s Manual 2 Insert the assembled cont
7. act into the back wiring side of the assembled module Once in place pull the wire slightly ensure that the contact is seated CONTACT REMOVAL INSTRUCTIONS 1 Remove the module from the receiver frame NOTE For more information concerning the process of removing the module from the receiver frame see module installation and removal instructions in Section 4 of this User s Manual NOTE Some Mini Power receiver modules are one piece modules If your module does not have two flat head or Phillips screws holding the module together skip to step 4 2 Use a flat blade screwdriver Phillips for iCon modules to remove the screws located at the top and bottom of the module RETAINING nee 3 Grasp the module halves and apply force in opposite directions rocking the ends of the module while slightly pulling the top of the module away from the mating bottom section until separated Be sure to open both sides of the module simultaneously or contacts could be damaged DETAIL A 4 Place the Mini Coax Mini Power Receiver ITA Contact Extraction Tool Part 910 112 104 Figure A over the contact to be removed replaced Use care to keep the tool perpendicular to the surface of the module otherwise the tool or contact could be bent MINI POWER RECEIVER CONTACT 5 Once the extraction tool is seated and the retaining tabs on the retaining ring are compressed push the tool into the module Figu
8. d CONTACT REMOVAL INSTRUCTIONS 1 Remove the module from the ITA frame NOTE For more information concerning the process of removing the module from the ITA frame see module installation and removal instructions in Section 4 of this User s Manual 2 Place the Mini Coax Mini Power Receiver ITA Extraction Tool Part 910 112 104 Figure A over the contact to be removed replaced Use care to keep the tool perpendicular to the surface of the module as not to bend the tool or the contact to be removed Rotate the tool slightly while pushing it into the Counter bore on the mating side of the module 3 Once the extraction tool is seated properly and the tabs on the retaining ring are compressed Figure push the tool into the module The contact will be pushed out of the rear of the module DO NOT PUSH THE TOOL INTO THE MODULE UNTIL THE TIP OF THE EXTRACTION TOOL HAS BEEN FULLY SEATED INTO THE MODULE AND COMPRESSED THE RETAINING RING TABS ON THE CONTACT NOTE The process shown here uses standard 90 series modules The same process is used for modules from other series NOTE If you are using a hybrid module you may need to reference the User s Manual for the other contact type for extraction instructions VIRGINIA PANEL CORPORATION Figure A Extraction tool Part 910 112 104 RETAINING RING TAB DETAIL A MINI POWER TA CONTACT Figure B Fully seat extraction tool befoere d
9. ed herein Unless otherwise specified the latest edition of the document applies In the event of a conflict between requirements of this specification and product drawing product drawing will take precedence In the event of a conflict between requirements of this specification and referenced documents this specification shall take precedence 2 2 Documents A Standards EIA 364 13 MIL STD 1344 e MIL STD 202 B Qualification Test Plans e MET ESL Test Plan 24785 C Product Qualification Reports e MET Test Report 31238T D Product Drawings Housing e 510104123 e 510104246 e 510108115 e 510108132 lof5 For more information vist voc com Rev 5 9 22 09 MINI POWER CONTACTS AND MODULES USER S MANUAL APPENDIX VIRGINIA PANEL CORPORATION Contacts 610116112 610116124 610116125 610115124 610115125 610115127 610115128 610115129 610115130 3 Requirements 3 1 Design and Construction Product shall be of design construction and physical dimensions specified on applicable product drawings 3 2 Materials A Female Contact e Brass e Gold over nickel plating per MIL DTL 45204D B Male contact e Beryllium Copper e Gold over nickel plating C Housing e G10 Epoxy Glass or Black PPS 3 3 Ratings A Voltage AC up to 100 MHz e DC B Current e 16 AWG 25 ampere maximum e 14 AWG 30 ampere maximum e 12 AWG 40 ampere maximum e 8 AWG 50 ampere maximum C Temperature
10. epressing 3 2 For more information visit voc com 1 25 10 MINI POWER CONTACTS AND MODULES USER S MANUAL SECTION 4 VIRGINIA PANEL CORPORATION MINI POWER STANDARD 90 SERIES MODULE INSTALLATION AND REMOVAL TOOLS REQUIRED 3 32 Allen Wrench INSTALLATION INSTRUCTIONS 1 Place the module in the receiver or ITA until the upper and lower module screws touch the mating holes in the inner frame Ensure that Position 1 is located at the top for systems in which the modules are oriented vertically or to the left for systems in which the modules are oriented horizontally 2 Using a 3 32 Allen wrench tighten the top screw 1 to 2 full revolutions while pushing lightly against the face of the module 3 Maintain this pressure while tightening the bottom screw 1 to 2 full revolutions 4 Repeat this sequence until the module is seated Torque the screw to 4 in lbs 0 45 Nm REMOVAL INSTRUCTIONS 1 Toremove loosen the top screw 1 to 2 full revolutions Loosen bottom screw 1 to 2 full revolutions 2 Repeat this sequence until the module is separated from the receiver NOTE For optimum performance and system longevity distribute the contact load evenly throughout the module POSITION 1 Figure A Receiver Module Figure ITA Module 4 For more information visit voc com 1 25 10 MINI POWER CONTACTS AND MODULES USER S MANUAL SECTION 4 VIRGINIA PANEL CORPORATION
11. ined by development product quality and reliability engineering 4 3 Acceptance Acceptance is based on verification that product meets requirements of Figure 1 Failures attributed to equipment test set up or operator deficiencies shall not disqualify product When product failure occurs corrective action shall be taken and samples resubmitted for qualification Testing to confirm corrective action is required before re submittal 40f5 For more information visit voc com Rev 5 9 22 09 MINI POWER CONTACTS AND MODULES USER S MANUAL APPENDIX VIRGINIA PANEL CORPORATION 5of5 4 4 Quality Conformance Inspection A Certificate of Conformance C of C dimensional inspection must be completed for all samples prior to Qualification testing The applicable quality inspection plan will specify sampling acceptable quality level to be used Dimensional and functional requirements shall be in accordance with applicable product drawing and this specification For more information visit voc com Rev 5 9 22 09
12. re B The contact will be pushed out of the rear of the module Figure B Fully seat extraction tool before depressing DO NOT PUSH THE TOOL INTO THE MODULE UNTIL THE TIP OF THE EXTRACTION TOOL HAS FULLY SEATED INTO THE MODULE AND COMPRESSED THE RETAINING RING TABS ON THE CONTACT NOTE The process shown here uses standard 90 series modules The same process is used for modules from other series 6 If necessary replace the module cap using both hands to push the separated halves together Replace and tighten the module retaining screws maximum torque of 1 5 in Ibs 0 17 Nm not required for all Mini Power modules NOTE If you are using a hybrid module you may need to reference the User s Manual for the other contact type for extraction instructions 3 For more information visit voc com 1 25 10 MINI POWER CONTACTS AND MODULES USER S MANUAL SECTION 3 MINI POWER ITA CONTACT INSTALLATION AND REMOVAL PART 610 115 124 610 115 125 TOOLS REQUIRED Mini Coaxial Mini Power Receiver ITA Contact Extraction Tool Part 910 112 104 CONTACT INSTALLATION INSTRUCTIONS 1 Assemble the contact to the respective wire NOTE For more information concerning the contact assembly process please see contact assembly instructions in Section 2 of this User s Manual 2 Insert the assembled contact into the back wiring side of the module Once in place pull the wire slightly to ensure the contact is seate
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