Stewart Connector
Product Specification
PR041-01
Revision A0 (Date 4-3-2017)
Modular Connectors with Circular Shells
Stewart Connector
11118 Susquehanna Trail South
Glen Rock, Pa. 17327-9199
Ph: (717) 235-7512 Fax: (717) 235-4675
http://www.stewartconnector.com
Product Specification PR0410-01
Page 1 of 12
Stewart Connector
1.0
Objective
This document establishes the performance requirements and outlines qualification tests for modular
connectors produced by Stewart Connector. These products are intended to be terminated onto a cable
and mated to a compatible Stewart modular product.
2.0
Scope
This specification is applicable to modular products in circular shells.
3.0
General
This document is comprised of the following sections (specifications subject to change without notice):
Paragraph
Title
1.0
2.0
3.0
Table 1
4.0
5.0
6.0
Table 2
7.0
8.0
Table 3
Figure 1
Figure 2
Figure 3
Table 4
Table 5
Table 6
9.0
Table 7
Table 8
Table 9
10.0
Table 10
Table 11
Table 12
Objective
Scope
General
Qualification Test Matrix
Applicable Documents
General Requirements
Quality Assurance Provisions
Inspection Conditions
Requalification of Products
Electrical Requirements
LLCR
Bulk Contact Interface LLCR Measurement
Bulk Shield Interface LLCR Measurement
LLCR Measurement Configuration
Insulation Resistance
DWV (Adjacent Contacts)
DWV (Contacts to Shield )
Mechanical Requirements
Mechanical Shock
Sinusoidal Vibration
Random Vibration
Environmental Conditions
Temperature Life
Thermal Shock
Temperature / Humidity
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Product Specification PR041-01
Page 2 of 12
Stewart Connector
Table 1
Qualification Testing Matrix
Qualification
Test Groups
Testing Matrix
1
Test
2
3
4
5
6
7
1,3
Testing Sequence 3
Para.
Examination of Product
5.5
1,5
1,7
1,5
1,6
1,8
1,3,6
Low Level Contact Resistance
8.1
2,4
2,6
2,4
2,4
2,4
2,5
Temperature Rise vs. Current
8.2
3
Mechanical Shock
9.1
3
Vibration (Sinusoidal)
9.2
4
Vibration (Radom)
9.3
5
Temperature Life
10.1
Thermal Shock
10.2
Temperature/Humidity
10.3
Insulation Resistance
8.3
D. W. V. (Adj. Contacts)
2
D. W. V. (Contacts-Shield)
1,2
Durability
3
3
3
5
5
8.4
6
8.5
7
9.4
Ingress protection
10.4
Note:
4
8
6
7
9
(4)
(4)
(4)
(4)
1
Applies to Shield and Shell
2
DWV stands for Dielectric Withstand Voltage
3
Numbers indicate sequence in which tests are performed.
4
Test is recorded on separate test
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2
(4)
Product Specification PR041-01
Page 3 of 12
Stewart Connector
4.0
Applicable Documents
4.1
Bel Stewart Specifications:
4.1.1 Product Drawings
4.1.2 Customer Drawings
4.1.3 Test Specifications
4.2
Other Standards and Specifications (Applicable in Part):
4.2.1 UL94V-0 Flammability
4.2.2 EIA-364
4.2.3 EIA/TIA-568
4.2.4 EIA/TIA-570
4.2.5 IEC 60603-7
4.2.6 IEEE 802.3
Additional specifications and standards may be referenced as applicable. The latest revisions of
the above specifications available at the date of issue of this specification are used unless
otherwise indicated.
5.0
General Requirements
5.1
Qualification:
Connectors furnished under this specification shall be capable of meeting the qualification test
requirements specified herein.
5.2
Material:
5.3
5.4
5.2.1
5.2.2
5.2.3
5.2.4
Plastic Housings: UL94V-0
Contacts: Copper Alloy
Shield: Copper Alloy
Shell: Plastic UL94V-0
5.3.1
5.3.2
5.3.3
5.3.4
Contacts: Gold Selectively Plated
Contacts: Nickel Plated All Over
Shield: Tin or Nickel Plated All Over
Shell: N/A
Finish:
Design and Construction:
Connectors shall be of the design, construction and physical dimensions as specified on the
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Product Specification PR041-01
Page 4 of 12
Stewart Connector
applicable product drawing and TIA 1096 specifications. In case of conflict between this
specification and product drawings, the drawings shall take precedence. 50 inch (1.27 m) gold
plated connectors compliant with TIA 1096 specifications.
5.5
Examination of Product:
Connectors shall meet all specified dimensions of product drawings and internal workmanship
standards. There shall be no evidence of cracking, chipping, contamination or loose parts when
inspected, without magnification, to the unaided eye.
5.6
Operating and Storage Temperature Range: -40°C to 85°C
5.7
Ratings:
5.7.1 Current:
5.7.2 Voltage:
5.8
1.2 amperes maximum at 25C
150 VAC maximum
Minimum Number of Mating/Unmating Operations:
5.8.1 Level I:
750 Cycles
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Product Specification PR041-01
Page 5 of 12
Stewart Connector
6.0
Quality Assurance Provisions
6.1
Equipment Calibration:
All test equipment and inspection facilities used in the performance of any test shall be
maintained and calibrated in accordance with Stewart Operating Procedures and/or other
applicable specifications.
6.2
Inspection Conditions:
Unless otherwise specified, all inspections shall be performed under the conditions noted.
See Table 2 below:
Table 2
Inspection Conditions
Temperature
(±5 ºC)
25
Barometric
Pressure
Local Ambient
6.3
Sample Quantity and Description:
The test samples required for groups 1 through 5 in Table 1 shall be chosen to comprise a group
that consists of 80 contacts (10 examples minimum) of each individual contact design.
6.4
Acceptance:
6.4.1 All samples tested in accordance with this product specification shall meet the stated
requirements.
6.4.2
7.0
Relative
Humidity
(%)
30 to 50
Failures attributed to equipment, test set-up, sample preparation problems, contaminants
or operator error, should not disqualify the product. Corrective action will be taken and
samples re-submitted for qualification.
Requalification of Products
7.1
Requalification Testing
If changes are made to the product, design or manufacturing process after initial product
qualification that are judged by the management of Stewart Connector to materially affect the
product form, fit or function, then new product samples shall be subject to full or partial
requalification testing.
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Product Specification PR041-01
Page 6 of 12
Stewart Connector
8.0
Electrical Requirements
8.1
Low Level Contact Resistance:
LLCR of the Coupler should be measured (mated with Stewart Connector plugs) in
accordance with EIA-364-23 with a test current of 100 mA and a maximum open circuit
voltage of 20 mVDC (dry circuit test). See Table 5 below:
Table 3
Low Level Contact Resistance
Contacts
Initial
(m)
100*
Shield Interface if applicable
Final
Initial
Final
(m)
(m)
(m)
100
20
100
All values listed are maximum values.
* 100 m Initial LLCR Includes Bulk
Low Level Contact Resistance (LLCR) is measured between the two (2) mated connectors
(one plug is within the Plug Shell) and the Coupler that is within the Receptacle Shell.
Measurements are generally performed before and after environmental exposure or
mechanical conditioning. Bulk LLCR is measured between the signal contacts and shield
connections of the Plugs that are mated through the Coupler. Signal Contact Bulk resistance
consists of the sum of all interface connections between the conductors, contacts and
coupler.
FIGURE 1
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Product Specification PR041-01
Page 7 of 12
Stewart Connector
8.1
Low Level Contact Resistance: (Cont.)
Shield Bulk resistance consists of the sum of all interface connections between the ground
interfaces of the cable shields, the Plug shields, and the Coupler shield.
Stewart’s product specification requirement is a bulk contact resistance change after
conditioning. In most cases, the maximum allowable change in bulk contact resistance after
environmental conditioning is 100 m.
LLCR measurements are conducted utilizing a four (4) wire dry circuit test method.
Implementation consists of a 100 mA DC current source with a maximum open circuit
voltage of 20 mV. Measurements are performed using low current and voltage levels to
preserve oxides and films that may form during environmental conditioning.
In practice, Jacks are typically mounted on PWB boards (although jacks can be measured
manually as well), which are design to interface with automated switching and measuring
equipment. Stewart Connector LLCR measuring system consists of a Micro-Ohmmeter and a
Hewlett Packard Data Acquisition Switch Unit. Automation software is utilized to fully control
the measurement sequence. Refer to measurement configuration in Figure 4 below.
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Product Specification PR041-01
Page 8 of 12
Stewart Connector
8.1
Low Level Contact Resistance: (Cont.)
FIGURE 3
8.2
Temperature Rise versus Current:
The temperature rise above ambient (25C) shall not exceed 30 C at any point on the
connector when all contacts are powered in series with 1.2 Amps DC in accordance with
EIA-364-70.
8.3
Insulation Resistance:
The insulation resistance of the unmated connectors shall be measured in accordance with
EIA-364-21. See Table 6 below:
Table 4
Insulation Resistance
Test Voltage
(VDC)
500
500
Test Duration
(Minutes)
1
1
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Requirement
(M)
500
500
Points of Measurement
Between adjacent contacts
Between contacts and shield
Product Specification PR041-01
Page 9 of 12
Stewart Connector
8.4
Dielectric Withstanding Voltage (DWV) Adjacent Contacts:
There shall be no arc over, insulation breakdown or excessive leakage (>1 mA) when tested in
accordance with EIA-364-20 on mated connectors. See Table 7 below:
Table 5
DWV – Adjacent Contacts
Test Voltage
Test Duration
(Minutes)
1
1000 VDC
8.5
Points of Measurement
Between adjacent contacts
Dielectric Withstanding Voltage (DWV) Contact to Shield:
There shall be no arc over, insulation breakdown or excessive leakage (>1 mA) when tested in
accordance with EIA-364-20 on mated connectors. See Table 8 below:
Table 6
DWV – Contact to Shield
Connector
All Connectors
Test Voltage
Test Duration
(Minutes)
1500 VACRMS or 2121 VDC
1
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Points of Measurement
Between contacts and shield
Product Specification PR041-01
Page 10 of 12
Stewart Connector
9.0
Mechanical Requirements
9.1
Mechanical Shock:
Mechanical Shock shall be measured in accordance with EIA-364-27, condition A, with
assembled connectors mounted rigidly to table and no discontinuities of >1 microsecond. See
Table 12 below:
Table 7
Mechanical Shock
Velocity
Change
(ft/s)
11.3
Wave Type
Half Sine
9.2
9.3
Duration
Each Face
(milliseconds)
11
Applied
Energy
(g)
50
Mutually
Perpendicular
Axis
3
Vibration (Sinusoidal):
Sinusoidal Vibration shall be measured in accordance with EIA-364-28 Test Condition I, with
assembled connectors mounted rigidly to vibrating table and no discontinuities of >1
microsecond. See Table 13 below:
Table 8
Sinusoidal Vibration
Wave Type
Amplitude
Frequency
(Hz)
Sine
.06 in. DA
10 to 55
Duration
Each Face
(hours)
2
Mutually
Perpendicular
Axis
3
Vibration (Random):
Random Vibration shall be measured in accordance with EIA-364-28 Test Condition V Letter D,
with assembled connectors mounted rigidly to vibrating table and no discontinuities of >1
microsecond. See Table 14 below:
Table 9
Random Vibration
Frequency
(Hz)
50 to 2000
9.4
Number of
shocks
per direction
6
Duration
Each Face
(minutes)
90
Overall
rms
(g)
11.95
Mutually
Perpendicular
Axis
3
Durability:
Cycles (number of times) 500 mated and unmated
There to be no evidence of any damage or negative impact to form, fit or function.
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Product Specification PR041-01
Page 11 of 12
Stewart Connector
10.0
Environmental Conditions
Note: Unless otherwise specified, all environmental testing is to be done with the connector in the mated
state.
10.1
Temperature Life:
Temperature life shall be measured in accordance with EIA-364-17, per method A. See Table 16
below:
Table 10
Temperature Life
Temperature (ºC)
85±2
10.2
Duration (hours)
500
Thermal Shock:
Thermal Shock shall be measured in accordance with EIA/TIA-568. See Table 17 below:
Table 11
Thermal Shock
Temperature
(±3 ºC)
-40 to +85
10.3
Duration at Each
Extreme (Minutes)
30
Test
Condition
1
Temperature / Humidity:
Temperature / Humidity shall be measured in accordance with EIA-364-31, Method IV. See
Table 18 below:
Table 12
Temperature / Humidity
Relative
Humidity
(±3 %)
93
10.4
Number of
Cycles
25
Low
Temperature
(±2 ºC)
25
High
Temperature
(±2 ºC)
65
Cold
Sub-cycle
(±2 ºC)
-10
Cycle
Time
(hours)
24
Number
Of
Cycles
21
Ingress protection:
Tested per IEC/EN 60529, section 14.2.8. Depth up to 1 meter, duration 30 minutes (IP67
versions only).
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Product Specification PR041-01
Page 12 of 12