Boeing SSQ22680 (Rev L)

Connectors, Rectangular, (ORU), Space Quality, General
Specification For
SPECIFICATION CUSTODIAN:
THE BOEING COMPANY
13100 SPACE CENTER BLVD
HOUSTON TEXAS 77059-3556
INTERNATIONAL SPACE STATION PROGRAM
SSQ 22680, Revision L

October 2015
EXPORT CONTROLLED - The technology or software is subject to the Export

Administration Regulations (15 C.F.R. Parts 730-774). Export, re-export or retransfer
contrary to U.S. law is prohibited. EAR/9E002
National Aeronautics and Space Administration

International Space Station Program
Johnson Space Center, Houston, Texas
Contract Number: NAS15-10000
CAGE NO. 2B945
SSQ 22680, Revision L Export Controlled see Title Page October 2015
REVISION HISTORY PAGE

REVISION DESCRIPTION OF CHANGE PUB DATE
A Unofficial Distribution 10/30/92
B Unofficial Distribution -
C Incorporated CR22680-001 and 22680-002 Unofficial Distribution in ISS 2/20/95
Program
D Official PCB Initial Release. Includes CRs 22680-003, 22680-004, 12/06/96
22680-005, 22680-006, 228-680-007 & 22680-008
DCN 001 SSCN 000675 Authorizes the release of DCN 001 which includes CR 06/27/97
22680-011
DCN 002 DCN 002 incorporates SSCN 01800 (Administratively Canceled), 3/14/01
Incorporated into Revision E
DCN 003 DCN 003 incorporated SSCN02322 (Administratively Canceled), 3/14/01
Incorporated into Revision E
E Revision E is authorized by SSCN2588 and incorporates the approved 3/14/01
engineering per DCN 001, DCN 002 SSCN 01800 and DCN 003 SSCN
02322
DCN 004 DCN 004 to Revision E is authorized by SSCN 03015 03/30/01
F Revision R is authorized by SSCN 004275 and incorporates the approved
engineering per DCN 004 through DCN 008 and SSCN 0044275
G Revision G is authorized by SSCN 009560, and includes DCN 009 and 03/12/07
DCN 010
H Revision H is authorized by SSCN 010992 03/03/08
J Revision J is authorized by SSCN 011824 08-10-11
K Revision K is authorized by SSCN 014305 10-17-14
L Revision L is authorized by SSCN 015210 12-07-15
ERU: /s/ Sheree Phillips 12-07-15
ii
PREFACE
SSQ 22680, Space Station Program Connectors, Rectangular, (ORU), Space Quality, General
Specification, establishes the performance, design, manufacturing, and test verification
requirements for a class S-level, rectangular, self aligning, blind mate, electrical plug and
receptacle connectors, contacts and accessories for use in the Electric Power System (EPS) on
the International Space Station.
iii
SPACE STATION PROGRAM OFFICE

Connectors, Rectangular, (ORU), Space Quality, General Specification for
CONCURRENCE
iv
Table of Contents
1.0 SCOPE ..........................................................................................1
1.1 PURPOSE ............................................................................................................................................................1
2.0 APPLICABLE DOCUMENTS ..........................................................2-1

2.1 GOVERNMENT DOCUMENTS ............................................................................................................................... 2-1
2.2 OTHER PUBLICATIONS ....................................................................................................................................... 2-2
3.0 REQUIREMENTS ........................................................................3-1

3.1 ITEM DEFINITION.............................................................................................................................................. 3-1
3.1.1 Part Number ...................................................................................................................................... 3-1
3.1.2 Connector Identification .................................................................................................................... 3-1
3.1.3 Standard Tolerances .......................................................................................................................... 3-2
3.1.4 Appendix Description ......................................................................................................................... 3-2
3.2 CHARACTERISTICS ............................................................................................................................................. 3-2
3.2.1 Electrical Performance ....................................................................................................................... 3-2
3.2.1.1 Contact Resistance .................................................................................................................................... 3-2
3.2.1.2 Dielectric Withstanding Voltage ............................................................................................................... 3-2
3.2.1.3 Insulation Resistance ................................................................................................................................ 3-2
3.2.1.4 Shell to Shell Conductivity......................................................................................................................... 3-3
3.2.1.5 Size 8 Concentric Twinax Cavity Grounding .............................................................................................. 3-3
3.2.1.6 Connector Current Rating ......................................................................................................................... 3-3
3.2.1.7 Connector De-mating Under Electrical Load ............................................................................................. 3-3
3.2.2 Physical Characteristics ...................................................................................................................... 3-3
3.2.2.1 Weight ...................................................................................................................................................... 3-3
3.2.2.2 Center of Gravity ....................................................................................................................................... 3-3
3.2.2.3 Connector Mating Sequence..................................................................................................................... 3-3
3.2.2.4 Contact Separation Force.......................................................................................................................... 3-3
3.2.2.5 Contact Retention ..................................................................................................................................... 3-3
3.2.2.6 Insert Retention ........................................................................................................................................ 3-4
3.2.2.7 Insert Bond Integrity ................................................................................................................................. 3-4
3.2.2.8 Contact Insertion and Removal Force ....................................................................................................... 3-4
3.2.2.9 Durability .................................................................................................................................................. 3-4
3.2.3 Reliability ........................................................................................................................................... 3-4
3.2.3.1 Mean Time Between Failure (MTBF) ........................................................................................................ 3-4
3.2.3.2 Design Life ................................................................................................................................................. 3-4
3.2.3.3 Storage Life ............................................................................................................................................... 3-4
3.2.3.4 Accelerated Aging ..................................................................................................................................... 3-4
3.2.3.4.1 Connector Accelerated Aging .............................................................................................................. 3-4
3.2.3.4.2 Contact Twinax Accelerated Aging ...................................................................................................... 3-5
3.2.4 Maintainability................................................................................................................................... 3-5
3.2.5 Environmental conditions .................................................................................................................. 3-5
3.2.5.1 Ground environment ................................................................................................................................ 3-5
3.2.5.1.1 Temperature ........................................................................................................................................ 3-5
3.2.5.1.2 Humidity .............................................................................................................................................. 3-5
3.2.5.1.3 Pressure ............................................................................................................................................... 3-5
3.2.5.1.4 Shock ................................................................................................................................................... 3-5
3.2.5.1.5 Salt Spray (Corrosion) .......................................................................................................................... 3-5
3.2.5.2 Launch and Orbit Environment ................................................................................................................. 3-5
3.2.5.2.1 Temperature ........................................................................................................................................ 3-6
3.2.5.2.1.1 Temperature for ORU Connector(s) (Table 6-2) ............................................................................ 3-6
3.2.5.2.1.2 Temperature for FRAM Connector(s) (Table 6-3) .......................................................................... 3-6
3.2.5.2.2 Humidity .............................................................................................................................................. 3-6
v
3.2.5.2.3 Pressure ............................................................................................................................................... 3-6

3.2.5.2.4 Random Vibration ................................................................................................................................ 3-6
3.2.5.2.4.1 Random Vibration for ORU Connector(s) (Table 6-2) .................................................................... 3-6
3.2.5.2.4.2 Random Vibration for FRAM Connector(s) (Table 6-3) .................................................................. 3-6
3.2.5.2.5 Atomic Oxygen..................................................................................................................................... 3-7
3.2.5.2.6 Radiation.............................................................................................................................................. 3-7
3.2.5.2.7 Plasma ................................................................................................................................................. 3-7
3.2.5.2.8 Thermal Cycling, Vacuum Conditions .................................................................................................. 3-7
3.2.5.2.8.1 Thermal Cycling, Vacuum conditions for ORU Connector(s) (Table 6-2) ....................................... 3-7
3.2.5.2.8.2 Thermal Cycling, Vacuum Conditions for FRAM Connector(s) (Table 6-3) .................................... 3-7
3.3 DESIGN AND CONSTRUCTION .............................................................................................................................. 3-7
3.3.1 Materials, Processes, and Parts ......................................................................................................... 3-8
3.3.1.1 Process Specification................................................................................................................................. 3-8
3.3.1.2 Controlling Documents ............................................................................................................................. 3-8
3.3.1.3 Special Material Problems ........................................................................................................................ 3-8
3.3.1.4 Metals ....................................................................................................................................................... 3-8
3.3.1.5 Nonmetallic materials ............................................................................................................................... 3-9
3.3.1.6 Processes .................................................................................................................................................. 3-9
3.3.1.7 Non-Magnetic Materials ......................................................................................................................... 3-10
3.3.1.8 Dissimilar Metals ..................................................................................................................................... 3-10
3.3.1.9 Moisture and Fungus Resistance ............................................................................................................ 3-10
3.3.1.10 Ozone Exposure ...................................................................................................................................... 3-10
3.3.1.11 Manufacturing and Inspection Contamination Control .......................................................................... 3-10
3.3.1.12 Corrosion Prevention and Control .......................................................................................................... 3-10
3.3.1.13 Cleanliness .............................................................................................................................................. 3-10
3.3.1.14 Surface Outgassing.................................................................................................................................. 3-10
3.3.1.15 Flammability ........................................................................................................................................... 3-11
3.3.1.16 Toxicity .................................................................................................................................................... 3-11
3.3.2 Electromagnetic Interference........................................................................................................... 3-11
3.3.2.1 EMI Transfer Impedance (10 kHz to 100 MHz) ....................................................................................... 3-11
3.3.2.2 EMI Shielding Effectiveness (100 MHz to 1 GHz) .................................................................................... 3-11
3.3.3 Identification and Product Marking ................................................................................................. 3-11
3.3.3.1 Connector and Accessories Marking ....................................................................................................... 3-11
3.3.3.2 Contact Location Identification ............................................................................................................... 3-12
3.3.3.3 Identification and Product Marking, Retrofit Connectors ....................................................................... 3-12
3.3.4 Workmanship ................................................................................................................................... 3-12
3.3.4.1 Defect Criteria ......................................................................................................................................... 3-12
3.3.4.2 Wire Sealing Member (Rear Grommet) Defect Criteria .......................................................................... 3-12
3.3.5 Interchangeability ............................................................................................................................ 3-13
3.3.6 Safety ............................................................................................................................................... 3-13
3.3.6.1 Mechanical Safety Criteria ...................................................................................................................... 3-13
3.3.7 Polarization ...................................................................................................................................... 3-13
3.3.8 Angular Connect and Disconnect Capability .................................................................................... 3-13
3.3.8.1 Angular Connect and Disconnect Capability, ORU Connectors (Table 6-2) ............................................. 3-13
3.3.8.2 Angular Connect and Disconnect Capability, ORU Connectors, FRAM Connector(s) (Table 6-3)............ 3-14
3.3.9 Contact Protection, Connector Mating (Scoop Proof) ...................................................................... 3-14
3.3.10 Actuation Force to Mate or De-mate .......................................................................................... 3-14
3.3.10.1 Actuation Force (Room Temperature) .................................................................................................... 3-14
3.3.10.2 Actuation Force (Differential Temperature) for FRAM Connector(s) (Table 6-3) ................................... 3-14
3.3.11 Shell Design ................................................................................................................................. 3-14
3.3.12 Shell Material .............................................................................................................................. 3-14
3.3.13 Finish ........................................................................................................................................... 3-14
3.3.14 Backshell ..................................................................................................................................... 3-15
3.3.14.1 Backshell Material ................................................................................................................................... 3-15
3.3.15 Insert Face Seal ........................................................................................................................... 3-15
3.3.16 Wire Sealing Member (Rear Grommet) ...................................................................................... 3-15
3.3.17 Grommet Sealing Plugs ............................................................................................................... 3-15
3.3.18 Inserts .......................................................................................................................................... 3-15
vi
3.3.19 EMI Spring ................................................................................................................................... 3-16

3.3.20 Threads and Fasteners ................................................................................................................ 3-16
3.3.21 Fastener Torque .......................................................................................................................... 3-17
3.3.22 Contacts ...................................................................................................................................... 3-17
3.3.23 Connector Use Accessories .......................................................................................................... 3-17
3.3.23.1 Protective Covers .................................................................................................................................... 3-18
3.3.23.2 Dummy Connectors ................................................................................................................................ 3-18
3.3.23.2.1 EVA Friendly Dummy Connectors ...................................................................................................... 3-18
3.3.23.2.2 Blind Mate Dummy Connectors ......................................................................................................... 3-19
3.3.24 Induced Attenuation ................................................................................................................... 3-19
3.3.25 Substitution Loss ......................................................................................................................... 3-19
4.0 QUALITY ASSURANCE PROVISIONS ............................................4-1

4.1 RESPONSIBILITY FOR INSPECTION ......................................................................................................................... 4-1
4.1.1 Test Equipment and Inspection Facilities ........................................................................................... 4-1
4.1.2 Standard Test Conditions ................................................................................................................... 4-1
4.2 BASELINE CONFIGURATION CONTROL ................................................................................................................... 4-1
4.3 BASELINE CONTROL DEVIATIONS ......................................................................................................................... 4-1
4.4 SUPPLIER TRACEABILITY REQUIREMENTS ............................................................................................................... 4-2
4.4.1 Serialization and Date Code ............................................................................................................... 4-2
4.4.1.1 Connectors and Accessories ..................................................................................................................... 4-2
4.4.1.2 Contacts .................................................................................................................................................... 4-2
4.4.1.3 Tools.......................................................................................................................................................... 4-2
4.4.2 Purge Capability ................................................................................................................................. 4-2
4.4.3 Critical Materials and Processes ........................................................................................................ 4-2
4.5 CLASSIFICATION OF INSPECTION .......................................................................................................................... 4-2
4.6 QUALIFICATION INSPECTION ............................................................................................................................... 4-2
4.6.1 Analysis In Accordance With Table 6-18 ............................................................................................ 4-3
4.6.2 Examination In Accordance With Table 6-18 ..................................................................................... 4-3
4.6.3 Qualification by Similarity .................................................................................................................. 4-3
4.6.4 Qualification Tests ............................................................................................................................. 4-3
4.6.4.1 Qualification Test Samples ........................................................................................................................ 4-3
4.6.4.2 Qualification Objective ............................................................................................................................. 4-3
4.6.4.3 Qualification Rejection .............................................................................................................................. 4-3
4.6.4.4 Disposition of Qualification Sample Units ................................................................................................. 4-4
4.7 ACCEPTANCE INSPECTIONS ................................................................................................................................. 4-4
4.7.1 Acceptance Objective ......................................................................................................................... 4-4
4.7.2 Acceptance Rejection ......................................................................................................................... 4-4
4.7.2.1 Connector Acceptance Rejection .............................................................................................................. 4-4
4.7.2.2 Contact Acceptance Rejection .................................................................................................................. 4-4
4.7.3 Periodic Inspection ............................................................................................................................. 4-4
4.7.4 Final Inspection .................................................................................................................................. 4-4
4.8 TEST METHODS ............................................................................................................................................... 4-5
4.8.1 Contact Resistance ............................................................................................................................. 4-5
4.8.2 Dielectric Withstanding Voltage ........................................................................................................ 4-5
4.8.3 Insulation Resistance ......................................................................................................................... 4-6
4.8.4 Shell to Shell Conductivity .................................................................................................................. 4-6
4.8.5 Size 8 Concentric Twinax Grounding .................................................................................................. 4-6
4.8.6 Connector Current Rating .................................................................................................................. 4-7
4.8.7 Connector De-mating Under Electrical Load ...................................................................................... 4-7
4.8.8 Contact Separation Force ................................................................................................................... 4-7
4.8.9 Contact Retention .............................................................................................................................. 4-8
4.8.10 Insert Retention ............................................................................................................................. 4-8
4.8.11 Insert Bonding Integrity ................................................................................................................ 4-8
vii
4.8.12 Contact Insertion and Removal Force ........................................................................................... 4-8

4.8.13 Durability ....................................................................................................................................... 4-9
4.8.14 Accelerated Aging ......................................................................................................................... 4-9
4.8.14.1 Connector Accelerated Aging.................................................................................................................... 4-9
4.8.14.2 Contact Twinax Accelerated Aging.......................................................................................................... 4-10
4.8.15 Humidity ...................................................................................................................................... 4-10
4.8.16 Shock ........................................................................................................................................... 4-10
4.8.17 Salt Spray (Corrosion) .................................................................................................................. 4-11
4.8.18 Vibration ..................................................................................................................................... 4-11
4.8.19 Thermal Cycling, Vacuum Conditions .......................................................................................... 4-11
4.8.20 Moisture and Fungus Resistance................................................................................................. 4-12
4.8.21 Electromagnetic Radiation .......................................................................................................... 4-12
4.8.21.1 Transfer Impedance Measurements ....................................................................................................... 4-12
4.8.21.2 Shielding Effectiveness Measurement .................................................................................................... 4-13
4.8.22 Actuation Force to Mate or De-mate .......................................................................................... 4-13
4.8.23 Termination Tensile Strength ...................................................................................................... 4-15
4.8.23.1 Termination Tensile Strength Qualification Test Procedure ................................................................... 4-15
4.8.23.2 Termination Tensile Strength Final Inspection Test Procedure .............................................................. 4-16
4.8.24 EVA Dummy Connectors Axial Installation / Removal Force ....................................................... 4-16
4.8.25 Protective Cover Easy Installation / Removal .............................................................................. 4-16
4.8.25.1 Installation / Removal Test ..................................................................................................................... 4-16
4.8.25.2 Protective Cover Storage Test (Connector Receptacle only) .................................................................. 4-17
4.8.26 Fiber Optic Cable Assembly Power Loss Test ............................................................................... 4-17
4.8.26.1 Test Equipment ....................................................................................................................................... 4-17
4.8.26.1.1 Light Source ....................................................................................................................................... 4-17
4.8.26.1.2 Optical Power Meter ......................................................................................................................... 4-17
4.8.26.2 Test Sample ............................................................................................................................................. 4-17
4.8.26.3 Optical Test Set Cleaning ........................................................................................................................ 4-17
4.8.26.4 Induced Attenuation ............................................................................................................................... 4-18
4.8.26.4.1 Test Procedure................................................................................................................................... 4-18
4.8.26.5 Substitution Loss ..................................................................................................................................... 4-19
4.8.26.5.1 Test Procedure................................................................................................................................... 4-19
4.9 DESTRUCTIVE PHYSICAL ANALYSIS (DPA) ............................................................................................................ 4-20
4.9.1 Connectors ....................................................................................................................................... 4-20
4.9.2 Contacts ........................................................................................................................................... 4-20
4.9.3 Accessories ....................................................................................................................................... 4-20
4.10 CONNECTOR FAILURES................................................................................................................................ 4-20
4.10.1 Failure Reporting Notification ..................................................................................................... 4-20
4.10.2 Failure Analysis ........................................................................................................................... 4-21
4.11 DOCUMENTATION AND DATA ...................................................................................................................... 4-21
4.11.1 Test Procedures ........................................................................................................................... 4-21
4.11.1.1 Qualification Test Procedure .................................................................................................................. 4-21
4.11.1.1.1 Scope ................................................................................................................................................. 4-21
4.11.1.1.2 Data Description ................................................................................................................................ 4-21
4.11.1.2 Final Inspection Test Procedure .............................................................................................................. 4-22
4.11.1.2.1 Scope ................................................................................................................................................. 4-22
4.11.1.2.2 Data Description ................................................................................................................................ 4-22
4.11.2 Acceptance Data Package ( ADP ) ............................................................................................... 4-23
4.11.2.1 Scope....................................................................................................................................................... 4-23
4.11.2.2 Data Description ..................................................................................................................................... 4-23
4.11.3 Failure Analysis Report ................................................................................................................ 4-24
4.11.3.1 Scope....................................................................................................................................................... 4-24
4.11.4 Qualification Test Report ............................................................................................................ 4-25
4.11.4.1 Scope....................................................................................................................................................... 4-25
4.11.5 Supporting Engineering Drawings, Analyses, Specifications, List and Data ................................ 4-26
viii
4.11.5.1 Scope....................................................................................................................................................... 4-26

4.11.5.2 Applicable documents............................................................................................................................. 4-26
4.11.5.3.1 Analysis and Data............................................................................................................................... 4-26
4.11.5.3.2 Drawings and Lists ............................................................................................................................. 4-27
4.11.5.3.3 Specifications ..................................................................................................................................... 4-27
4.11.5.4 Maintenance ........................................................................................................................................... 4-27
4.11.6 List of Materials and Processes ................................................................................................... 4-28
4.11.6.1 Scope....................................................................................................................................................... 4-28
4.11.7 Engineering Change Proposals (ECPs) ......................................................................................... 4-29
4.11.7.1 Scope....................................................................................................................................................... 4-29
4.11.8 Deviation/Waiver to Program Contract Requirement ................................................................ 4-29
4.11.8.1 Scope....................................................................................................................................................... 4-29
4.11.9 Quality Assurance Program Plan ................................................................................................. 4-30
4.11.9.1 Scope....................................................................................................................................................... 4-30
4.11.9.2 Applicable Documents ............................................................................................................................ 4-30
4.11.9.3 Baseline Control Document Requirements ............................................................................................. 4-31
4.11.9.4 Change Control ....................................................................................................................................... 4-31
4.11.9.4.1 Major Change Procedure ................................................................................................................... 4-32
4.11.9.4.2 Minor Change Procedure ................................................................................................................... 4-32
4.11.9.5 Baseline Audits ........................................................................................................................................ 4-32
4.11.9.6 Quality Survey by the Buyer .................................................................................................................... 4-32
4.11.10 Document Cross-Reference ......................................................................................................... 4-32
4.11.11 Record Retention ......................................................................................................................... 4-32
5.0 PREPARATION FOR DELIVERY ....................................................5-1

5.1 GENERAL REQUIREMENTS .................................................................................................................................. 5-1
5.2 PACKAGE IDENTIFICATION .................................................................................................................................. 5-1
6.0 NOTES .......................................................................................6-1

6.1 CONNECTOR COMPATIBILITY............................................................................................................................... 6-1
6.1.1 Connector Assembly Procedures Applicability ................................................................................... 6-1
6.2 APPROVED SOURCE(S) OF SUPPLY ....................................................................................................................... 6-1
10.0 APPENDIX I .......................................................................... I-2

10.1 SCOPE ........................................................................................................................................................ I-2
10.2 PART NUMBERS ........................................................................................................................................... I-2
10.3 APPLICABLE DOCUMENTS ............................................................................................................................... I-2
10.4 REQUIREMENTS............................................................................................................................................ I-2
10.5 PHYSICAL CHARACTERISTICS ............................................................................................................................ I-2
10.5.1 Weight ............................................................................................................................................ I-2
10.5.1.1 Physical Envelope ....................................................................................................................................... I-2
10.5.1.2 Strain Relief Screw Length ......................................................................................................................... I-2
10.6 QUALITY ASSURANCE PROVISIONS ................................................................................................................... I-2
10.7 PREPARATION FOR DELIVERY........................................................................................................................... I-3
10.8 APPROVED SOURCE(S) OF SUPPLY.................................................................................................................... I-3
20.0 APPENDIX II ........................................................................ II-2

20.1 SCOPE ....................................................................................................................................................... II-2
20.1.1 Contact Part Numbers ................................................................................................................... II-2
20.2 APPLICABLE DOCUMENTS .............................................................................................................................. II-2
ix
20.3 REQUIREMENTS........................................................................................................................................... II-2

20.3.1 Physical Characteristics ................................................................................................................. II-2
20.3.1.1 Weight ...................................................................................................................................................... II-2
20.3.1.2 Physical Envelope ...................................................................................................................................... II-3
20.3.2 Marking ......................................................................................................................................... II-3
20.4 QUALITY ASSURANCE PROVISIONS .................................................................................................................. II-3
20.4.1 Final Inspection ............................................................................................................................. II-3
20.4.1.1 Inspection Lot ........................................................................................................................................... II-3
20.4.1.2 Inspection of Contacts for Delivery ........................................................................................................... II-3
20.4.1.3 Sampling Plan ............................................................................................................................................ II-3
20.5 PREPARATION FOR DELIVERY.......................................................................................................................... II-3
20.6 APPROVED SOURCE(S) OF SUPPLY................................................................................................................... II-3
30.0 APPENDIX III ...................................................................... III-3

30.1 SCOPE ...................................................................................................................................................... III-3
30.1.1 Part numbers ................................................................................................................................ III-3
30.2 APPLICABLE DOCUMENTS ............................................................................................................................. III-3
30.3 REQUIREMENTS.......................................................................................................................................... III-3
30.3.1 Physical Characteristics ................................................................................................................ III-3
30.3.1.1 Weight ..................................................................................................................................................... III-3
30.3.1.2 Physical Envelope ..................................................................................................................................... III-3
30.4 QUALITY ASSURANCE PROVISIONS ................................................................................................................. III-3
30.5 PREPARATION FOR DELIVERY......................................................................................................................... III-3
30.6 APPROVED SOURCE(S) OF SUPPLY .................................................................................................................. III-5
40.0 APPENDIX IV ...................................................................... IV-2

40.1 SCOPE ...................................................................................................................................................... IV-2
40.1.1 Contact insertion and removal tool part numbers ....................................................................... IV-2
40.2 APPLICABLE DOCUMENTS ............................................................................................................................. IV-2
40.3 REQUIREMENTS.......................................................................................................................................... IV-2
40.3.1 Durability ...................................................................................................................................... IV-3
40.3.2 Insertion and Removal of Contacts Using Metal Tools ................................................................ IV-3
40.3.3 Quality Assurance Provisions ....................................................................................................... IV-3
40.4 PREPARATION FOR DELIVERY......................................................................................................................... IV-3
40.4.1 Tool Quantity ............................................................................................................................... IV-3
40.5 APPROVED SOURCE(S) OF SUPPLY.................................................................................................................. IV-3
50.0 APPENDIX V ........................................................................ V-2

50.1 SCOPE ....................................................................................................................................................... V-2
50.1.1 Grommet Sealing Plug Part Numbers ........................................................................................... V-2
50.2 APPLICABLE DOCUMENTS .............................................................................................................................. V-2
50.3 REQUIREMENTS........................................................................................................................................... V-2
50.4 QUALITY ASSURANCE PROVISIONS .................................................................................................................. V-2
50.5 PREPARATION FOR DELIVERY.......................................................................................................................... V-2
50.5.1 Grommet Sealing Plug Quantity.................................................................................................... V-2
50.6 APPROVED SOURCE(S) OF SUPPLY................................................................................................................... V-2
60.0 APPENDIX VI ...................................................................... VI-2

60.1 SCOPE ...................................................................................................................................................... VI-2
60.2 APPLICABLE DOCUMENTS ............................................................................................................................. VI-2
60.2.1 Specification ................................................................................................................................. VI-2
60.2.2 Materials ...................................................................................................................................... VI-2
x
60.2.3 Application of Chemical Conversion Coating................................................................................ VI-2

60.2.3.1 Surface Preparation ................................................................................................................................. VI-2
60.2.3.2 Application of Conversion Coating ........................................................................................................... VI-3
60.2.3.3 Application of Corrosion Coating ............................................................................................................. VI-3
60.3 EMI SPRING REPAIR PROCEDURE FOR CONNECTOR RECEPTACLES ........................................................................ VI-3
60.3.1 Scope ............................................................................................................................................ VI-3
60.3.1.1 Note ......................................................................................................................................................... VI-3
60.3.2 References .................................................................................................................................... VI-3
60.3.3 Materials List ................................................................................................................................ VI-3
60.3.3.1 Repair Kits ................................................................................................................................................ VI-3
60.3.3.2 Tools......................................................................................................................................................... VI-3
60.3.3.3 Equipment................................................................................................................................................ VI-4
60.3.3.4 Recommended Consumables .................................................................................................................. VI-4
60.3.4 Procedure ..................................................................................................................................... VI-4
60.3.5 Data Sheet .................................................................................................................................... VI-5
70.0 APPENDIX VII .................................................................... VII-2

70.1 SCOPE ..................................................................................................................................................... VII-2
70.2 APPLICABLE DOCUMENTS ............................................................................................................................ VII-2
70.3 REQUIREMENTS......................................................................................................................................... VII-2
70.3.1 Equipment ................................................................................................................................... VII-2
70.3.2 Materials ..................................................................................................................................... VII-3
70.3.3 Required Procedures and Operations.......................................................................................... VII-3
70.3.4 Records ........................................................................................................................................ VII-3
70.3.5 Wire Preparation and Handling .................................................................................................. VII-3
70.3.5.1 Stripping Procedure ................................................................................................................................ VII-4
70.3.5.1.1 Strip Dimensions ................................................................................................................................ VII-4
70.3.5.1.2 Stripping Method ............................................................................................................................... VII-4
70.3.5.1.2.1 Shielded Conductor ................................................................................................................... VII-4
70.3.5.1.2.2 Conductor Extraction ................................................................................................................. VII-5
70.3.5.1.2.3 Conductor Stripping ................................................................................................................... VII-6
70.3.5.2 Post-Strip Inspection ............................................................................................................................... VII-8
70.3.5.3 Stripped Wire Strands ............................................................................................................................. VII-8
70.3.5.3.1 Stripped Wire Conductors ................................................................................................................. VII-8
70.3.5.3.2 Unstripped Insulation ........................................................................................................................ VII-8
70.3.5.3.3 Insulation Flash .................................................................................................................................. VII-8
70.3.5.3.4 Shields................................................................................................................................................ VII-8
70.3.5.3.5 Cleanliness ......................................................................................................................................... VII-8
70.4 QUALITY ASSURANCE PROVISIONS ................................................................................................................ VII-8
70.4.1 Responsibility for Inspection ....................................................................................................... VII-8
70.4.2 Monitoring Procedures for Equipment Used in Process .............................................................. VII-9
70.4.3 Monitoring Procedures for Materials .......................................................................................... VII-9
70.4.4 Certification ................................................................................................................................. VII-9
70.4.4.1 Maintenance of Certification Logs .......................................................................................................... VII-9
70.4.4.2 Personnel Certification ........................................................................................................................... VII-9
70.4.5 Test Methods............................................................................................................................... VII-9
70.4.5.1 Inspection Methods ................................................................................................................................ VII-9
70.4.5.1.1 Acceptance Criteria............................................................................................................................ VII-9
70.4.5.1.2 Rejection Criteria ............................................................................................................................. VII-10
70.5 PREPARATION FOR DELIVERY...................................................................................................................... VII-10
70.6 NOTES................................................................................................................................................... VII-10
70.6.1 Intended Use ............................................................................................................................. VII-10
70.6.2 Definitions ................................................................................................................................. VII-10
70.6.2.1 Circumference....................................................................................................................................... VII-10
70.6.2.2 Flash, Insulation .................................................................................................................................... VII-10
70.6.2.3 Usage Items .......................................................................................................................................... VII-10
xi
80.0 APPENDIX VIII .................................................................. VIII-2

80.1 SCOPE .................................................................................................................................................... VIII-2
80.2 CLASSIFICATION........................................................................................................................................ VIII-2
80.3 APPLICABLE DOCUMENTS ........................................................................................................................... VIII-2
80.3.1 Requirements ............................................................................................................................. VIII-3
80.3.2 Equipment .................................................................................................................................. VIII-3
80.3.2.1 Crimp Tools ............................................................................................................................................ VIII-3
80.3.2.2 Ratcheting .............................................................................................................................................. VIII-3
80.3.2.3 Indenters ................................................................................................................................................ VIII-4
80.3.2.4 Tool Identification .................................................................................................................................. VIII-4
80.3.2.5 Solvents .................................................................................................................................................. VIII-4
80.3.2.6 Heat Shrink Tubing Material .................................................................................................................. VIII-4
80.3.3 Required Procedures and Operations......................................................................................... VIII-4
80.3.3.1 General .................................................................................................................................................. VIII-4
80.3.3.1.1 Records ............................................................................................................................................. VIII-4
80.3.3.1.2 Hardware .......................................................................................................................................... VIII-4
80.3.3.1.3 Wire .................................................................................................................................................. VIII-4
80.3.3.1.4 Crimp Tool Calibration ...................................................................................................................... VIII-5
80.3.3.1.5 Facility Cleanliness ............................................................................................................................ VIII-5
80.3.3.1.6 Environmental Conditions ................................................................................................................ VIII-5
80.3.3.1.7 Controlled Temperature and Humidity ............................................................................................ VIII-5
80.3.3.1.7.1 Critical Environments................................................................................................................ VIII-5
80.3.3.1.7.2 Lighting ..................................................................................................................................... VIII-5
80.3.3.2 Cleaning ................................................................................................................................................. VIII-5
80.3.3.3 Crimp Assembly Requirements .............................................................................................................. VIII-5
80.3.3.3.1 Heat Shrink Sleeving ......................................................................................................................... VIII-5
80.3.3.3.1.1 General Requirements .............................................................................................................. VIII-5
80.3.3.3.1.2 Application of Heat Shrinkable Sleeving ................................................................................... VIII-5
80.3.3.3.2 Contact-Conductor Combinations .................................................................................................... VIII-6
80.3.3.3.3 Insulation Clearance ......................................................................................................................... VIII-6
80.3.3.3.4 Contact Crimping .............................................................................................................................. VIII-7
80.3.3.3.4.1 Crimping Type I - Standard Contacts ........................................................................................ VIII-7
80.3.3.3.4.2 Crimping Type II - Reduced Crimp Barrel Contacts ................................................................... VIII-7
80.3.3.3.4.3 Crimping type III - shielded cables ............................................................................................ VIII-8
80.3.4 Recommended Procedures and Operations ............................................................................. VIII-10
80.3.5 Certification .............................................................................................................................. VIII-10
80.3.5.1 Personnel Certification ........................................................................................................................ VIII-10
80.3.5.1.1 Special Skills Requirements ............................................................................................................ VIII-10
80.3.5.2 Certification Records ............................................................................................................................ VIII-10
80.4 QUALITY ASSURANCE PROVISIONS ............................................................................................................. VIII-10
80.4.1 Responsibility for Inspection .................................................................................................... VIII-10
80.4.2 Monitoring Procedures for Equipment Used in Process ........................................................... VIII-11
80.4.2.1 Certification and Calibration ................................................................................................................ VIII-11
80.4.2.2 Sealing .................................................................................................................................................. VIII-11
80.4.2.3 Calibration Interval .............................................................................................................................. VIII-11
80.4.3 Monitoring Procedures for Materials ....................................................................................... VIII-11
80.4.4 Test Methods............................................................................................................................ VIII-11
80.4.4.1 Number of Samples ............................................................................................................................. VIII-11
80.4.4.2 Visual and Mechanical Inspection ........................................................................................................ VIII-11
80.4.4.2.1 Crimp Acceptance Criteria .............................................................................................................. VIII-12
80.4.4.2.2 Crimp Rejection Criteria.................................................................................................................. VIII-12
80.4.4.3 Crimp Tensile Strength ......................................................................................................................... VIII-13
80.4.4.3.1 Test Sample Requirements ............................................................................................................. VIII-13
80.4.4.3.2 Tensile Strength Testing ................................................................................................................. VIII-13
80.4.4.3.2.1 Test Samples ........................................................................................................................... VIII-13
80.4.4.3.2.2 Testing Procedures ................................................................................................................. VIII-13
80.4.4.3.3 Twinax Contacts Electrical Continuity ............................................................................................. VIII-14
xii
80.4.4.3.4 Twinax Socket Contact Separation Force........................................................................................ VIII-14

80.4.4.3.5 Twinax Center Pin Alignment Procedure ........................................................................................ VIII-15
80.4.4.3.6 Socket Contact Separation Force .................................................................................................... VIII-15
80.4.4.3.7 Data Recording ............................................................................................................................... VIII-16
80.5 PREPARATION FOR DELIVERY..................................................................................................................... VIII-16
80.6 NOTES.................................................................................................................................................. VIII-16
80.6.1 Intended Use ............................................................................................................................ VIII-16
80.6.2 Definitions ................................................................................................................................ VIII-16
80.6.3 Usage items.............................................................................................................................. VIII-16
80.6.3.1 Insulation Whiskers .............................................................................................................................. VIII-16
80.6.3.2 Birdcaging ............................................................................................................................................ VIII-16
90.0 APPENDIX IX ...................................................................... IX-2

90.1 SCOPE ...................................................................................................................................................... IX-2
90.2 CLASSIFICATION.......................................................................................................................................... IX-2
90.2.1 Applicable Documents .................................................................................................................. IX-2
90.2.1.1 Government Documents .......................................................................................................................... IX-2
90.3 REQUIREMENTS.......................................................................................................................................... IX-2
90.3.1 Equipment .................................................................................................................................... IX-2
90.3.1.1 Hand Tools ............................................................................................................................................... IX-3
90.3.1.1.1 Tool Calibration and Identification ..................................................................................................... IX-3
90.3.2 Materials ...................................................................................................................................... IX-3
90.3.2.1 Solvents .................................................................................................................................................... IX-4
90.3.2.2 Heat Shrink Tubing Material .................................................................................................................... IX-4
90.3.3 Required Procedures and Operations........................................................................................... IX-4
90.3.3.1 General .................................................................................................................................................... IX-4
90.3.3.1.1 Records ............................................................................................................................................... IX-4
90.3.3.1.2 Hardware ............................................................................................................................................ IX-4
90.3.3.1.3 Uncalibrated Tools .............................................................................................................................. IX-4
90.3.3.1.4 Assembly Facilities .............................................................................................................................. IX-4
90.3.3.1.5 Cleaning .............................................................................................................................................. IX-5
90.3.3.1.6 Storage and Handling ......................................................................................................................... IX-5
90.3.3.2 Part Assembly Requirements ................................................................................................................... IX-5
90.3.3.2.1 Heat Shrink Sleeving ........................................................................................................................... IX-5
90.3.3.2.2 Shrink Sleeving: Conductor Application .............................................................................................. IX-5
90.3.3.2.3 Shrink Sleeving: General Application .................................................................................................. IX-5
90.3.3.2.4 Contact Crimping ................................................................................................................................ IX-6
90.3.3.2.5 Threaded Fasteners ............................................................................................................................ IX-6
90.3.3.3 ORU Connector Configurations ................................................................................................................ IX-6
90.3.3.3.1 Connector Preparation ....................................................................................................................... IX-6
90.3.3.3.2 Connector Parts and Accessories ........................................................................................................ IX-6
90.3.3.3.2.1 Contacts ...................................................................................................................................... IX-7
90.3.3.3.2.2 Grommet Sealing Plugs ............................................................................................................... IX-7
90.3.3.3.2.3 Backshells ................................................................................................................................... IX-7
90.3.3.3.2.4 Insertion/Extraction Tools .......................................................................................................... IX-7
90.3.3.4 Assembly Processes ................................................................................................................................. IX-8
90.3.3.4.1 Crimping ............................................................................................................................................. IX-8
90.3.3.4.2 Contact Insertion ................................................................................................................................ IX-8
90.3.3.4.2.1 Conditioning Of SSQ 22680-20-4-4s Socket Contact .................................................................. IX-9
90.3.3.4.2.2 Tools ........................................................................................................................................... IX-9
90.3.3.4.3 Contact Removal............................................................................................................................... IX-10
90.3.3.4.4 Grommet Sealing Plug Insertion ....................................................................................................... IX-10
90.3.3.4.4.1 SSQ Grommet Sealing Plug Insertion ........................................................................................ IX-10
90.3.3.4.4.2 Military grommet sealing plug insertion .................................................................................. IX-10
90.3.3.4.5 Power Connectors - No Shield Braids ............................................................................................... IX-11
90.3.3.4.6 EMI Type Backshells.......................................................................................................................... IX-12
90.3.3.4.6.1 Overall Shield Braid Only .......................................................................................................... IX-12
90.3.3.4.6.2 Individual Shielded Wire Braids Only ........................................................................................ IX-14
xiii
90.3.3.4.6.3 Shielded Wires And Outer Shield Braid .................................................................................... IX-16

90.3.4 Certification ................................................................................................................................ IX-19
90.3.4.1 Test Methods ......................................................................................................................................... IX-19
90.3.4.1.1 Visual Inspection ............................................................................................................................... IX-19
90.3.4.1.2 Contact Retention Test ..................................................................................................................... IX-19
90.3.4.1.3 Contact Sizes 16 And Larger ............................................................................................................. IX-19
90.3.4.2 Contact Size 20 and Smaller and Concentric Twinax Contacts ............................................................... IX-20
90.3.4.3 Certification Records .............................................................................................................................. IX-23
90.4 QUALITY ASSURANCE PROVISIONS ............................................................................................................... IX-23
90.4.1 Responsibility for Inspection ...................................................................................................... IX-23
90.4.2 Monitoring Procedures for Equipment Used in Process ............................................................. IX-23
90.4.2.1 Certification and Calibration .................................................................................................................. IX-23
90.4.3 Monitoring Procedures For Materials ........................................................................................ IX-23
90.4.3.1 Connector Contact Separation Force (sizes 22, 20, 16, 12 and TWX) .................................................... IX-23
90.4.3.1.1 Test Procedure, Connector ............................................................................................................... IX-23
90.4.3.1.1.1 Test Equipment......................................................................................................................... IX-23
90.4.3.1.1.2 Test Procedure.......................................................................................................................... IX-24
90.4.3.1.2 Alternate Method (TWX Socket Contact only).................................................................................. IX-24
90.4.4 Torque Verification ..................................................................................................................... IX-26
90.4.4.1 Contact Strain Relief Test ....................................................................................................................... IX-26
90.4.4.1.1 Test Equipment:................................................................................................................................ IX-26
90.4.4.1.2 Test Procedure:................................................................................................................................. IX-26
90.4.4.2 Twinax Socket Contact Separation Force ............................................................................................... IX-27
90.4.4.2.1 Test Procedure.................................................................................................................................. IX-27
90.4.4.3 Twinax Center Pin Alignment Procedure ............................................................................................... IX-28
90.4.4.3.1 Test Equipment:................................................................................................................................ IX-28
90.4.4.3.2 Test Procedure:................................................................................................................................. IX-28
90.4.5 Rework ....................................................................................................................................... IX-28
90.4.5.1 Plating Defects ....................................................................................................................................... IX-28
90.4.5.2 Data Recording....................................................................................................................................... IX-29
90.5 PREPARATION FOR DELIVERY....................................................................................................................... IX-29
90.6 NOTES.................................................................................................................................................... IX-29
90.6.1 Intended Use .............................................................................................................................. IX-29
90.6.2 Definitions .................................................................................................................................. IX-29
90.6.2.1 Usage Items ........................................................................................................................................... IX-29
100.0 APPENDIX X ........................................................................ X-2

100.1 IN-PROCESS CONTACT INSPECTION .................................................................................................................. X-2
100.1.1 Inspection at Assembly.................................................................................................................. X-2
100.1.1.1 Prior to Crimping ....................................................................................................................................... X-2
100.1.1.2 After Crimping ........................................................................................................................................... X-2
100.1.2 Prior to Connector Assembly ......................................................................................................... X-3
100.1.3 After Connector Assembly ............................................................................................................. X-3
100.1.4 EMI Spring ..................................................................................................................................... X-4
100.1.4.1 Visual Inspection ....................................................................................................................................... X-4
100.1.4.2 EMI Spring Replacement ........................................................................................................................... X-4
100.1.5 Visual Aids ..................................................................................................................................... X-4
100.2 TESTING..................................................................................................................................................... X-4
100.2.1 Pin Contact Alignment .................................................................................................................. X-4
100.2.2 Test Equipment ............................................................................................................................. X-5
100.2.2.1 Solutions for Test Toll Cleaning ................................................................................................................. X-5
100.2.2.2 Aligning Tools ............................................................................................................................................ X-5
100.2.2.3 Test Procedure .......................................................................................................................................... X-6
100.2.2.4 Socket Contact Proper Engagement Test Procedure ................................................................................ X-6
100.2.2.4.1 Test Equipment .................................................................................................................................. X-7
100.2.2.4.1.1 Solutions for Test Tool Cleaning ................................................................................................ X-7
100.2.2.4.2 Aligning Tools ..................................................................................................................................... X-7
xiv
100.2.2.4.3 Test Procedure ................................................................................................................................... X-7

100.2.2.5 Twinax Contact Testing ............................................................................................................................. X-8
100.2.2.5.1 Inspection Procedure for Concentric Twinax Pin Contacts ................................................................ X-8
100.2.2.5.2 Test Procedure ................................................................................................................................... X-8
100.2.2.5.2.1 Inspection Procedure for Concentric Twinax Socket Contacts ................................................ X-10
110.0 MATERIAL USAGE AGREEMENT ...............................................2
xv
LIST OF FIGURES
Figure 6-1 Contact Resistance ........................................................................................................................... 6-21
Figure 6-2 Physical Envelope Connector Plug, Shell Size 1 ................................................................................. 6-22
Figure 6-3 Physical Envelope Connector Receptacle, Shell Size 1 ...................................................................... 6-23
Figure 6-4 Physical Envelope Plug, Shell Size 2 .................................................................................................. 6-24
Figure 6-5 Physical Envelope Connector Receptacle, Shell Size 2 ...................................................................... 6-25
Figure 6-6 Physical Envelope for Connector Plug, Shell Size 1, FRAM ................................................................ 6-26
Figure 6-7 Physical Envelope for Connector Receptacle, Shell Size 1, FRAM ...................................................... 6-27
Figure 6-8 Plug Receptacle Mated Configuration............................................................................................ 6-28
Figure 6-9 Contact Insert Arrangement A .......................................................................................................... 6-29
Figure 6-10 Contact Insert Arrangement B ........................................................................................................ 6-30
Figure 6-11 Contact Insert Arrangement C ........................................................................................................ 6-31
Figure 6-12 Contact Insert Arrangement D ........................................................................................................ 6-32
Figure 6-13 Contact Insert Arrangement E ........................................................................................................ 6-33
Figure 6-14 Contact Insert Arrangement F ........................................................................................................ 6-34
Figure 6-15 Contact Insert Arrangement G ........................................................................................................ 6-35
Figure 6-16 Contact Insert Arrangement J ......................................................................................................... 6-36
Figure 6-17 Contact Insert Arrangement K ........................................................................................................ 6-37
Figure 6-18 Test Pins ......................................................................................................................................... 6-38
Figure 6-19 Random Vibration (for Table 6-2 ORU Class Connector(s) Classification) ........................................ 6-39
Figure 6-20 Random Vibration (for Table 6-3 FRAM Connector(s) Classification) .............................................. 6-39
Figure 6-21 Transfer Impedance Measurement ................................................................................................ 6-40
Figure 6-22 Shielding Effectiveness Measurement ............................................................................................ 6-41
Figure 6-23 Test Circuits .................................................................................................................................... 6-42
Figure 10-1 Backshell Rectangular, 90, Power, Size 1 .......................................................................................... I-5
Figure 10-2 Backshell Rectangular, Straight, Power, Size 1 ................................................................................... I-6
Figure 10-3 Backshell, Round, 90, EMI, Size 1 ..................................................................................................... I-7
Figure 10-4 Backshell, Round, Straight, EMI, Size 1 .............................................................................................. I-8
Figure 10-5 Backshell, Round, 90, EMI, Size 2 .................................................................................................... I-9
Figure 10-6 Backshell, Round, Straight, EMI, Size 2 ........................................................................................... I-10
Figure 10-7 Backshell, Rectangular, 45, Power, Size 1 ...................................................................................... I-11
Figure 10-8 Backshell, Round, 30 , EMI, Size 1 .................................................................................................. I-12
Figure 10-9 Backshell, Round, 30, EMI, Size 2 .................................................................................................. I-13
Figure 10-10 Backshell, Round, Straight, Size 1, FRAM, Plug .............................................................................. I-14
Figure 20-1 Contact, Electrical Connector, Socket, Crimp Type (Sizes 0,4) ........................................................... II-7
Figure 20-2 Contact, Electrical Connector Socket, Crimp Type Dimensions (Size 0, 4) ......................................... II-8
Figure 20-3 Contact, Electrical Connector Socket, Crimp Type, (Sizes 22 to 12) ................................................... II-9
Figure 20-4 Contact, Electrical Connector, Socket, Crimp Type Dimensions, (Sizes 22 to 12) .......................... II-10
Figure 20-5 Contact, Electrical Connector, Pin, Crimp Type (Size 0, 4) ......................................................... II-11
Figure 20-6 Contact, Electrical Connector, Pin, Crimp Type, Dimensions, (Sizes 0, 4) .................................. II-12
Figure 20-7 Contact, Electrical Connector, Pin, Crimp Type, (Sizes 22 to 12) ...................................................... II-13
Figure 20-8 Contact, Electrical Connector, Pin, Crimp Type, Dimensions, (Sizes 22 to 12) ................................. II-14
Figure 20-9 Contact, Electrical Connector, Socket, Crimp Type Concentric Twinax, Size 8, Part No. SSQ22680-20-
CTS .......................................................................................................................................................... II-15
Figure 20-10 Contact, Electrical Connector, Socket, Crimp Type Concentric Twinax, Size 8 ............................... II-16
Figure 20-11 Contact, Electrical Connector, Pin, Crimp Type Concentric ........................................................... II-17
Figure 20-12 Contact, Electrical Connector, Pin, Crimp Type Concentric Twinax, Size 8 .................................... II-18
Figure 20-13 Contact, Electrical Connector, Socket, Crimp Type Concentric Twinax, Size 8, Part No. SSQ22680-
20-CTS-2 .................................................................................................................................................. II-19
Figure 20-14 Contact, Electrical Connector, Socket, Crimp Type, Concentric Twinax, Size 8, Part No. SSQ 22680-
20-CTS-2 .................................................................................................................................................. II-20
xvi
Figure 20-15 Contact, Electrical Connector, Pin, Crimp Type (Size 8) ................................................................. II-21
Figure 20-16 Contact, Electrical Connector, Pin, Crimp Type (Size 8) Dimensions .............................................. II-21
Figure 20-17 Contact, Electrical Connector Socket, Crimp Type (Size 8) ............................................................ II-22
Figure 20-18 Contact, Electrical Connector Socket, Crimp Type Dimensions (Size 8) ......................................... II-22
Figure 20-19 CONTACT, ELECTRICAL, CONNECTOR, FIBER OPTIC SIZE 16 .......................................................... II-23
Figure 20-20 Contact, Electrical Connector, Socket, Crimp Type, Size 12, SSQ22680-20-12-12S-1 ..................... II-25
Figure 20-25 Contact, Electrical Connector, Socket, Crimp Type Concentric Twinax, Size 8, SSQ22680-20-CTS-2 .. II-
27
Figure 30-1 Protective Cover, Size 1, Plug (P/N SSQ 22680-30-001) Non-ESD Cover ........................................... III-6
Figure 30-2 Protective Cover, Size 1, Receptacle (P/N SSQ22680-30-002) .......................................................... III-7
Figure 30-3 Protective Cover, Size 2, Plug (P/N SSQ22680-30-003) Non-ESD Cover ............................................ III-8
Figure 30-4 Protective Cover, Size 1, Receptacle (P/N SSQ22680-30-004) .......................................................... III-9
Figure 30-5 Blind Mate, Dummy Connector, Size 1, Plug, (P/N SSQ22680-30-005) ........................................... III-10
Figure 30-6 Blind Mate, Dummy Connector, Size 1 Receptacle ........................................................................ III-11
Figure 30-7 Blind Mate, Dummy Connector, Size 2, Plug, ................................................................................. III-12
Figure 30-8 Blind Mate, Dummy Connector, Size 1, Receptacle ....................................................................... III-13
Figure 30-9 EMI Band (P/N SSQ22680-30-008) ................................................................................................. III-14
Figure 30-10 ESD Protective Cover, Receptacle ................................................................................................ III-15
Figure 30-11 ESD Protective Cover, Plug .......................................................................................................... III-16
Figure 30-12 EVA Friendly, Dummy Connector, Size 1, Receptacle ................................................................... III-17
Figure 30-13 EVA Friendly, Dummy Connector Size 2 Receptacle ..................................................................... III-18
Figure 30-14 EVA FRIENDLY, DUMMY CONNECTOR, SIZE 1, PLUG .................................................................... III-19
Figure 30-15 EVA Friendly, Dummy Connector Size 2 Plug ............................................................................... III-20
Figure 40-1 Insertion, Removal Tool, Plastic, Sizes 8 Twinax through 0 .............................................................IV-6
Figure 40-2 Insertion, Removal Tool, Plastic, Size 20 through 12 ........................................................................IV-7
Figure 40-3 Insertion, Removal Tool, Metal, Size 22 ..........................................................................................IV-8
Figure 40-4 Extraction Tool, Metal, Sizes 8 through 0 ........................................................................................IV-9
Figure 40-5 Insertion Tool, Metal, Sizes 20-12 .................................................................................................. IV-10
Figure 50-1 Grommet Sealing Plugs, Sizes 0, 4, 8 .................................................................................................V-4
Figure 50-2 Grommet Seal Plugs, Sizes 12, 16, 20, 22 ..........................................................................................V-5
Figure 60-1 Definition of Non Repairable Connector Surfaces ...........................................................................VI-6
Figure 70-1 Wire Dimension References ........................................................................................................VII-11
Figure 70-2 Insulation Removal.......................................................................................................................VII-12
Figure 70-3 Conductor Extraction from Shield .................................................................................................VII-13
Figure 70-4 Examples of Wire Stripping .........................................................................................................VII-14
Figure 80-1 Contact to Wire Insulation Clearance ..........................................................................................VIII-20
Figure 80-2 Shrink Sleeving Application (Braids) ............................................................................................VIII-21
Figure 80-3 Shrink Sleeving Application (Conductors) ....................................................................................VIII-22
Figure 80-4 Contact to Wire Insulation Clearance ..........................................................................................VIII-23
Figure 80-5 ORU Twinax Contact Components ...............................................................................................VIII-24
Figure 80-6 Cable, Wire and Braid Preparation(steps 2 through 4) ...............................................................VIII-27
Figure 80-7 Intermediate Contact Crimping (step 5) ......................................................................................VIII-28
Figure 80-8 Outer Contact Crimping (steps 6 and 7) .......................................................................................VIII-30
Figure 80-9 Wire Preparation for Crimp Tensile Test .....................................................................................VIII-31
Figure 80-10 1 oz Drop Weight .......................................................................................................................VIII-32
Figure 80-11 Aligning Tool FA22680-1 for SSQ22680-20-CTP-TWINAX...........................................................VIII-33
Figure 90-1 Engagement Aid, Part Number FA220-4-10 .................................................................................... IX-9
Figure 90-2 Seating Test, Tool Probe for Socket Contacts................................................................................. IX-22
Figure 90-3 FA22680-40, Drop Weight Gage Socket Contact ............................................................................ IX-26
Figure 90-4 Physical Envelope-Typical Connector ............................................................................................ IX-30
xvii
Figure 90-5 Typical Connector, Shell Size 2 ...................................................................................................... IX-31

Figure 90-6 Pressure Plate and Retaining Screws ............................................................................................. IX-32
Figure 90-7 Typical Contact Insertion ............................................................................................................... IX-32
Figure 90-8 Contact-Insertion Tool Alignment.................................................................................................. IX-33
Figure 90-9 Contact Extraction ......................................................................................................................... IX-34
Figure 90-10 SSQ22680 End Seal Plug Insertion ............................................................................................... IX-35
Figure 90-11 Typical Rectangular Backshell ...................................................................................................... IX-36
Figure 90-12 Backshell and Shrink Tubing Insertion ......................................................................................... IX-37
Figure 90-13 Alignment of Rectangular Backshell ............................................................................................ IX-38
Figure 90-14 Alignment of Shrink Sleeving ....................................................................................................... IX-39
Figure 90-15 Backshell with Circular Opening .................................................................................................. IX-40
Figure 90-16 Typical Backshell FRAM with Circular Opening ............................................................................ IX-41
Figure 90-17 Circular Backshell Insertion ......................................................................................................... IX-42
Figure 90-18 Circular Backshell, FRAM ............................................................................................................. IX-43
Figure 90-19 Insulation Strip Lengths ............................................................................................................... IX-44
Figure 90-20 Braided Shield Trimming ............................................................................................................. IX-45
Figure 90-21 Braid Preparation ........................................................................................................................ IX-46
Figure 90-22 EMI Clamping Band Preparation .................................................................................................. IX-47
Figure 90-23 Alignment of Shield and Backshell ............................................................................................... IX-48
Figure 90-24 Typical Band Clamping Tool ......................................................................................................... IX-49
Figure 90-25 Orientation of EMI Clamping Band and Tool ................................................................................ IX-50
Figure 90-26 Compression of EMI Clamping Band ............................................................................................ IX-51
Figure 90-27 Cutting Excess EMI Clamping Band .............................................................................................. IX-52
Figure 90-28 Shrink Sleeving and Clamp Positioning ........................................................................................ IX-53
Figure 90-29 Completed Backshell Circular Type ........................................................................................... IX-54
Figure 90-30 Individual Shield Preparation ...................................................................................................... IX-55
Figure 90-31 Alignment of Individual Wire Shield ............................................................................................ IX-56
Figure 90-32 Clamping Individual Shields ......................................................................................................... IX-57
Figure 90-33 Overall Braid and Individual Shield .............................................................................................. IX-58
Figure 90-34 Clamping Overall Braid and Shields ............................................................................................. IX-59
Figure 90-35 Seating Test Tool ......................................................................................................................... IX-60
Figure 90-36 Strain Relief Inspection Tool, Part Number FA22680-2S For ........................................................ IX-61
Figure 90-37 Strain Relief Inspection Tool, Part Number FA22680-2P for SSQ22680-20-CTS-TWX Contact Pin IX-62
Figure 90-38 0.50 oz Drop Weight, FA22680-4 ................................................................................................. IX-63
Figure 90-39 Contact Separation Force Test Adapter ....................................................................................... IX-64
Figure 100-1 EMI SRING .................................................................................................................................... X-11
Figure 100-2 POWER PIN CONTACT VISUAL AID ................................................................................................ X-12
Figure 100-3 POWER SOCKET CONTACT VISUAL AID ........................................................................................ X-13
Figure 100-4 TWINAX CONTACT VISUAL AID ..................................................................................................... X-14
Figure 100-5 TYPICAL POSITION OF SOCKET CONTACT IN CONNECTOR RECEPTACLE CAVITY .......................... X-15
xviii
LIST OF TABLES
Table 6-1 Approved Source(s) of Supply ............................................................................................................. 6-2
Table 6-2 ORU CONNECTOR(S) CLASSIFICATION ................................................................................................. 6-3
Table 6-3 EXTERNAL CARRIER CONNECTOR(S) CLASSIFICATION .......................................................................... 6-3
Table 6-4 CONTACT RESISTANCE ......................................................................................................................... 6-4
Table 6-5 CONNECTOR DEMATING ELECTRICAL LOADS ....................................................................................... 6-5
Table 6-6 CONTACT ENGAGING AND SEPARATING FORCE ................................................................................. 6-5
Table 6-7 CONTACT RETENTION .......................................................................................................................... 6-6
Table 6-8 CONTACT INSERTION AND REMOVAL FORCES ..................................................................................... 6-6
Table 6-9 LAUNCH VIBRATION TEST REQUIREMENTS FOR ORU CONNECTORS ................................................... 6-7
Table 6-10 LAUNCH VIBRATION TEST REQUIREMENTS FOR FRAM CONNECTORS ............................................... 6-7
Table 6-11 WIRE INSULATION SIZE ..................................................................................................................... 6-8
Table 6-12 TENSILE STRENGTH ............................................................................................................................ 6-8
Table 6-13 QUALIFICATION INSPECTION (CONTACTS) ......................................................................................... 6-9
Table 6-14 QUALIFICATION INSPECTION (PLUG AND RECEPTACLE) 1 ................................................................ 6-10
Table 6-15 ORU CONNECTOR QUALIFICATION INSPECTION (MATED PAIR) ....................................................... 6-11
Table 6-16 FRAM CONNECTORS QUALIFICATION INSPECTION (MATED PAIR) .................................................. 6-13
Table 6-17 FINAL INSPECTION .......................................................................................................................... 6-13
Table 6-18 REQUIREMENT/INSPECTION CROSS REFERENCE ............................................................................. 6-14
Table 6-19 Optical Performance Requirements ................................................................................................. 6-20
Table 10-1 BACKSHELL CROSS REFERENCE ........................................................................................................... I-3
Table 10-2 BACKSHELL APPROVED SOURCE(S) OF SUPPLY ................................................................................... I-4
Table 20-1 CONTACTS APPROVED SOURCE(S) OF SUPPLY .................................................................................. II-4
Table 20-2 CONTACT NOMENCLATURE ............................................................................................................... II-5
Table 20-3 FINAL INSPECTION (CONTACTS) ......................................................................................................... II-6
Table 30-1 CONNECTOR ACCESSORY CROSS REFERENCE ................................................................................... III-4
Table 30-2 CONNECTOR USE ACCESSORY APPROVED SOURCE(S) OF SUPPLY .................................................... III-5
Table 40-1 CONTACT INSERTION AND REMOVAL TOOL APPROVED SOURCE(S) OF SUPPLY ...............................IV-4
Table 40-2 CONTACT INSERTION AND REMOVAL TOOL UTILIZATION CROSS REFERENCE ..................................IV-5
Table 50-1 GROMMET SEALING PLUGS APPROVED SOURCE(S) OF SUPPLY .........................................................V-3
Table 50-2 GROMMET SEALING PLUGS UTILIZATION CROSS REFERENCE ............................................................V-3
Table 80-1 CRIMP TOOLS FOR SIZE 4 AND LARGER CONTACTS .......................................................................VIII-16
Table 80-2 CRIMP TOOLS FOR SIZE 12 AND SMALLER CONTACTS ..................................................................VIII-17
Table 80-3 TOOLS for REDUCED BARREL CONTACTS ......................................................................................VIII-17
Table 80-4 TOOLS for TWINAX CONTACTS .....................................................................................................VIII-18
Table 80-5 HEAT SHRINK TUBING MATERIAL .................................................................................................VIII-18
Table 80-6 CRIMP TENSILE STRENGTH............................................................................................................VIII-19
Table 90-1 Part Number ................................................................................................................................... IX-25
Table 100-1 CONTACT PIN ACCEPTABLE FOR ALIGNING TOOLS ........................................................................... X-6
Table 100-2 SOCKET CONTACT ENGAGEMENT TOOLS ......................................................................................... X-7
Table 100-3 TWINAX CONTACT TEST TOOLS ....................................................................................................... X-8
xix
LIST OF APPENDICES
APPENDIX I BACKSHELLS I-1

APPENDIX II CONTACTS, ELECTRICAL CONNECTOR, CRIMP, REMOVABLE II-1
APPENDIX III CONNECTOR USE ACCESSORIES III-1
APPENDIX IV TOOLS, INSERTION AND REMOVAL, CRIMP CONTACTS IV-1
APPENDIX V GROMMET SEALING PLUGS V-1
APPENDIX VI SSQ REPAIR PROCEDURES, REQUIREMENTS FOR VI-1
APPENDIX VII STRIPPING OF ELECTRICAL WIRE AND CABLE INSULATION VII-1
APPENDIX VIII CRIMPING OF ELECTRICAL CONNECTIONS VIII-1
APPENDIX IX ASSEMBLY PROCEDURES FOR CONNECTORS, RECTANGULAR (ORU), SPACE
QUALITY IX-1
APPENDIX X SSQ22680 CONNECTOR INSPECTION PROCEDURES X-1
APPENDIX XI APPLICABLE FORMS XI-1
xx
1.0 SCOPE
1.1 Purpose
The purpose of this Specification Control Drawing (SCD) is to establish the performance,
design, manufacturing, and test verification requirements for a class S-level, rectangular, self
aligning, blind mate, electrical plug and receptacle connectors, contacts and accessories for use
in the Electric Power System (EPS) of the Space Station.
1-1
2.0 Applicable documents

The following documents of the exact issue shown form a part of this SCD to the extent specified
herein. The effective issue of those documents not specifically identified by change letter or date
shall be the latest issue in effect on the date of contract. In the event of conflict between the
documents referenced herein and contents of this SCD, this SCD shall take precedence.
2.1 Government Documents
SPECIFICATIONS
Federal
QQ-A-200/8 Aluminum Alloy 6061, Bar, Rod, Shapes, Tube and Wire, Extruded
QQ-A-250/11 Aluminum Alloy 6061, Plate and Sheet
QQ-N-290 Nickel Plating, (Electro deposited)
Military
MS 27488 Plug, Sealing, Electrical Connector
MIL-H-6088 Heat Treatment of Aluminum Parts
MIL-H-6875 Heat Treatment of Steel, General Specification For
MIL-S-7742 Screw Threads, Standard, Optimum Selected Series, General Specification For
MIL-B-7883 Brazing of Steels, Copper Alloys, Nickel Alloys, Aluminum and
Aluminum Alloys
MIL-A-8625 Anodic Coatings, For Aluminum and Aluminum Alloys
MIL-S-8879 Screw Threads, Controlled Radius Root with Increased Minor
Diameter, General Specification For
MIL-C-22520 Crimping Tools, Terminal Hand or Power Actuated Wire Termination and Tool
Kits, General Specification For
MIL-I-23053/13 Insulation Sleeving, Electrical, Heat Shrinkable, Fluoroelastomer, Flexible
MIL-C-26074 Coating, Electroless Nickel, Requirements For
MIL-C-39029 Contact, Electrical Connector, General Specification For
MIL-G-45204 Gold Plating, Electro Deposited
DOD-STD-100 Military Standard Engineering Drawing Practices
DOD-STD-1000 Military Specification - Drawing Engineering and Associated Lists
MIL-STD-105 Sampling Procedures and Tables for Inspection by Attributes
MIL-STD-129 Marking for Shipment and Storage
MIL-STD-454 Standard General Requirements for Electronic Equipment
MIL-STD-490 Specification Practices
MIL-STD-794 Parts and Equipment, Procedures for Packaging and Packaging of
MIL-STD-810 Environmental Test Methods and Engineering Guidelines
MIL-STD-889 Dissimilar Metals
2-1
MIL-STD-970 Standards and Specifications, Order of Preference

MIL-STD-1246 Product Cleanliness Levels and Contamination Control Program
MIL-STD-1285 Marking of Electrical and Electronic Parts
MIL-STD-1344 Test Methods for Electrical Connectors Dated 1-Sep-1977
MIL-STD-1595 Qualification of Aircraft, Missile and Aerospace Fusion Welders
MIL-STD-45662 Military Standard Calibration Systems Requirements
MIL-Q-9858 Quality Program Requirements
2.2 Other Publications
SP-R-0022 Specification for Vacuum Stability of Polymeric Materials for
Spacecraft Application
MSFC-SPEC-504 Specification; Welding, Aluminum Alloys
MSFC-SPEC-522 Design Criteria for Controlling Stress Corrosion Cracking
MSFC-HDBK-527 Materials Selection List for Space Hardware Systems
NHB 8060.1 Flammability, Odor, and Offgassing Requirements and Test
Procedures for Materials in Environment that Supports Combustion
NASA-TM-86556 Lubrication Handbook for the Space Industry, Part A: Solid
Lubricants, Part B: Liquid Lubricants
JSC 09604 Government Furnished Equipment Material Selection List and Materials
Documentation Procedures
SSQ21636 Connectors and Accessories, Electrical, Rectangular, Rack and Panel, Space
Quality, General Specification for
SSQ21654 Cable, Single Fiber, Multimode, Space Quality, General Specification for
SSQ 21655 Cable, Electrical, MIL-STD-1553 Data Bus, Space Quality, General
Specification for
SPECIFICATIONS
ASTM-E-595 Total Mass Loss and Collected Volatile Condensable Materials from
Outgassing in a Vacuum Environment
AMS-4218 Aluminum Alloy Castings, 7.0S1 - 0.35Mg, A356.0-T61P, Solution and
Precipitation Heat Treated
RM2432 Wire, Cross-linked Ethylene Tetraflouroethylene
RM2589 Cable, Electrical, Two Conductor, Shielded
9RE2412 Connector, Rectangular (ORU)
2-2
3.0 Requirements
3.1 Item Definition

The connectors, accessories, and contacts specified herein are used to interconnect electrical
power, control power, and communication/control to Orbital Replacement Units (ORUs) and
Flight Releasable Attachment Mechanism (FRAM) in a manned Space Station application.
The connectors, contacts and accessories shall be designed for continuous operation in low
earth orbit space environment. They are intended to mate electrically and mechanically as
specified in Table 6-2. The connector shall be designed with the appropriate Electromagnetic
Interference (EMI) shielding.
3.1.1 Part Number
Complete part numbers for each part covered by this specification shall be as follows:
a. Plug and receptacle connector part numbers shall be in accordance with Table 6-1.
b. Backshell part numbers shall be in accordance with Appendix I, Table 10-2
c. Contact part numbers shall be in accordance with Appendix II, Table 20-1.
d. Connector Use Accessories part numbers shall in accordance with Appendix III,
Table 30-2
e. Insertion and removal tool part numbers shall be in accordance with Appendix IV,
Table 40-1
f. Grommet sealing plug part numbers shall be in accordance with Appendix V, Table 50-1
3.1.2 Connector Identification
a. Connector shall be identified in accordance with paragraph 3.3.3 herein. Nomenclature

connector receptacle or connector plug shall appear on the same line or below
Buyer part number. Connector part number shall appear on the connector shell
assembly. The Connector part numbers shall be as follows:
SSQ 22680-XXX-X where
SSQ 22680 SSQ specification identifier for the ORU connector family and related
accessories.
-XXX Connector part number in accordance with Table 6-1.
-X Connector Configuration Identifier, applicable only when a Class 1 change
is incorporated.
b. Individual piece parts used in the connectors and procurable as discrete items are
backshells, electrical contacts and connector use accessories. These parts shall be
identified as specified in the applicable Appendix.
3-1
3.1.3 Standard Tolerances
Unless otherwise specified, tolerances on:

Angles = 30, Decimals .XX = .03, Decimals .XXX = .010.
3.1.4 Appendix Description
Appendix I Backshells
Appendix II Contacts, Electrical Connector, Crimp, Removable
Appendix III Connector Use Accessories
Appendix IV Tools, Insertion and Removal, Crimp Contacts
Appendix V Grommet Sealing Plugs
Appendix VI SSQ Repair Procedures, Requirements for
Appendix VII Stripping of Electrical Wire and Cable Insulation
Appendix VIII Crimping of Electrical Connectors
Appendix IX Assembly Procedures for Connectors, Rectangular, (ORU), Space
Quality
Appendix X SSQ22680 Connector Inspection Procedures
Appendix XI Applicable Forms
3.2 Characteristics
3.2.1 Electrical Performance
3.2.1.1 Contact Resistance

The maximum voltage drop of any pair of mated contacts across y-y as specified in Figure 6-1
shall be in accordance with Table 6-4 when tested as specified in 4.8.1.
3.2.1.2 Dielectric Withstanding Voltage
The dielectric withstanding voltage when tested as specified in 4.8.2 shall not cause any
evidence of electrical breakdown, corona, and disruptive discharge or exceed current leakage
of one (1) milliampere (mA).
3.2.1.3 Insulation Resistance
The insulation resistance shall be measured contact to contact and contact to shell, in
accordance with 4.8.3, as follows:
a. The connector insulation resistance at room temperature shall be greater than 5000
megohms at 500 Volts (V, dc).
b. The connector insulation resistance at 200C temperature extreme shall be greater than
1,000 megohms at 500 Volts (V, dc).
c. Four hours prior to completion of the last humidity test cycle the connector Insulation
Resistance shall be 100 megohms minimum at 500 Volts (V, dc).
3-2
3.2.1.4 Shell to Shell Conductivity

The DC resistance of a mated connector pair shall not exceed 2 m, when tested as specified
in 4.8.4a and 1.5 m per 4.8.4b.
3.2.1.5 Size 8 Concentric Twinax Cavity Grounding
When tested in accordance with 4.8.5 the maximum potential drop between the size 8
concentric Twinax outer body and the connector mounting flange shall not exceed 10.0 mV.
3.2.1.6 Connector Current Rating
The electrical current rating of any contact or group of contacts is governed by the heating
effects of the electrical load and ambient temperature. The connector may have any
combination of electrical loading and ambient environment provided the shell, contacts, or
insert temperature does not exceed + 200C (+392 F) maximum, when tested in accordance
with 4.8.6. Current shall be as specified in Table 6-4.
3.2.1.7 Connector De-mating Under Electrical Load
The connector shall withstand 10 de-mating cycles under electrical load as specified in Table
6-5 when tested in accordance with paragraph 4.8.7. The connector contact shall show no
signs of melting, oxidation, discoloration, and pitting that would be detrimental to the
performance of the contact. The connector shall meet the requirements of paragraph 3.2.1.1
and 3.3.10 after cycling.
3.2.2 Physical Characteristics
See Figures 6-2 to 6-6 for physical envelope and Figures 6-9 to 6-17 for contact arrangement.
3.2.2.1 Weight
The maximum weight of each connector half (excluding contacts, protective cover, and
backshell) shall be in accordance with Table 6-2.
3.2.2.2 Center of Gravity
The center of gravity of the connector shall be as shown in Figures 6-6 when determined in the
three-reference axis of Figures 6-2 to 6-5.
3.2.2.3 Connector Mating Sequence
Connector mating sequence shall be: Shells - EMI Seal - Contacts - Interfacial seal.
3.2.2.4 Contact Separation Force
The required forces for contacts engagement/separation when engaged to the specified length
in accordance with Figure 6-18 shall be in accordance with the contact sizes in Table 6-6, when
tested as specified in 4.8.8.
3.2.2.5 Contact Retention
When tested as specified in 4.8.9, the contact(s) of the unmated connector shall withstand in
both directions an axial load as specified in Table 6-7 without dislodging or damaging the
contacts. Under applied load, the axial displacement of the contacts shall not exceed .012 inch.
In production, contact retention tests shall be performed as in process test for each insert
assembly. The clip shall be capable of retaining a contact under a minimum load of Table 6-7
3-3
in the direction tending to remove contact. For the in process test, contacts or simulated
contacts shall be inserted into the insert assembly one time only.
3.2.2.6 Insert Retention
Unmated connectors shall retain their inserts in the proper location in the shell and there shall
be no evidence of cracking, breaking, separation from the shell or loosening of parts when
tested as specified in 4.8.10.
3.2.2.7 Insert Bond Integrity
The insert grommet bonded assembly shall be subjected to the leakage test as specified in
4.8.11. There shall be no evidence of leakage between each contact cavity and all other contact
cavities and the external surfaces of the insert assembly. The test shall be conducted using the
complete insert assemblies in their final form.
3.2.2.8 Contact Insertion and Removal Force
The force required for contact insertion or removal into an unmated half shall be in accordance
with Table 6-8, when tested as specified in 4.8.12.
3.2.2.9 Durability
The connector pairs, when suitably mounted with one connector half on a floating plate, shall
be capable of engagement or separation without binding, degradation or jamming during 500
mating and de-mating cycles tested as specified in 4.8.13. Throughout durability test the
mating force shall not exceed by more than 30% the force measurements during the first 10
cycles. The connector shall meet the requirements of 3.2.1.1, 3.2.1.2 at the completion of the
test. The connector with fiber optic insert (insert J) shall meet additional Induced Attenuation
requirement as specified in paragraph 3.3.24. The optical loss measurements of the fiber optic
termini shall meet the requirements of paragraph 3.3.24 and Table 6-19, Item 1 before the test.
The optical loss measurements of the fiber optic termini during the test shall not exceed the
value of Table 6-19, Item 3, but maximum change in Induced Loss measurements shall not
exceed the value of Table 6-19, Item 6.
3.2.3 Reliability
3.2.3.1 Mean Time Between Failure (MTBF)

The connector MTBF shall be no less than 10 million hours excluding limited life effects such
as thermal cycling, radiation, plasma, and atomic oxygen.
3.2.3.2 Design Life
The connector shall be designed for an on-orbit operating life of 20 years minimum.
3.2.3.3 Storage Life
The connector shall be designed for a storage life of 10 years minimum.
3.2.3.4 Accelerated Aging
3.2.3.4.1 Connector Accelerated Aging
When tested in accordance with 4.8.14.1 connectors shall withstand without degradation a
minimum of 1000 hours at 200C.
3-4
3.2.3.4.2 Contact Twinax Accelerated Aging
When tested in accordance with 4.8.14.2 contact Twinax shall withstand without degradation a
minimum of 1000 hours at 200C.
3.2.4 Maintainability
The connector shall require no preventive maintenance or refurbishment during the operating
life of 20 years.
3.2.5 Environmental conditions
The connector shall be capable of meeting the performance requirements of this SCD during
and after exposure to any combination of the following environments:
3.2.5.1 Ground environment
The connector shall withstand all pertinent ground environmental conditions for the location
involved in fabrication, storage, assembly, testing, and transportation.
3.2.5.1.1 Temperature
The ground operating and non-operating connector temperatures shall not exceed temperature
limits specified in 3.2.5.2.1.
3.2.5.1.2 Humidity
a. Operating - From 25% to 70%

b. Non-operating - The connector shall show no signs of degradation and meet
the requirement of 3.2.1.3c after exposure to the humidity test as specified in
4.8.15.
3.2.5.1.3 Pressure
a. Operating - From 85.5 to 104.1 kPa (12.4 psi to 15.1 psi).

b. Non-operating - From 85.5 to 104.1 kPa (12.4 psi to 15.1 psi).
3.2.5.1.4 Shock
Non-operating - The connector shall show no evidence of cracking, breaking, loosening of

parts or damage of any kind, after exposure to an induced shock environment as defined in
4.8.16.
3.2.5.1.5 Salt Spray (Corrosion)
The connector shall show no exposure of base metal due to corrosion when tested as specified
in 4.8.17.
3.2.5.2 Launch and Orbit Environment
The connector shall meet the performance requirements during and after exposure to any
combination of the following launch and orbit environmental conditions.
3-5
3.2.5.2.1 Temperature
3.2.5.2.1.1 Temperature for ORU Connector(s) (Table 6-2)

The connector may have any combination of electrical loading and ambient environment
provided the shell, contacts, or insert temperature maintained within the temperature limits
from -65C to +200C (-85F to + 392F).
3.2.5.2.1.2 Temperature for FRAM Connector(s) (Table 6-3)
The connector may have any combination of electrical loading and ambient environment
provided the shell, contacts, or insert temperature is maintained within the temperature limits.
The limits for the K connector configuration is from 104C to +200C (-155F to + 392F)
and from 104C to +150C (-155F to + 302F) for the J connector configuration.
3.2.5.2.2 Humidity
Operating - relative humidity of 25% to 75%, at a temperature of +16C to +32C,

(+61 F to +90 F)
3.2.5.2.3 Pressure
a. The connector shall operate in three pressure environments:

1) From 99.9 to 102.7 kPa (14.5 psi to 14.9 psi)
-11 -12
2) 1.931 x 10 kPa (2.8 x 10 psi)
-11 -12
3) Pressure change from 104.1 to 1.931 x 10 kPa (15.1 psi to 2.8 x 10 psi)
and backward. The pressure rate of change shall be 5.24 kPa/sec
(0.76 psi/sec) minimum.
3.2.5.2.4 Random Vibration
3.2.5.2.4.1 Random Vibration for ORU Connector(s) (Table 6-2)

Non-operating - Both, mated and unmated connectors shall withstand, without damage of any
kind, the application of random vibration, as defined in Table 6-9 and Figure 6-19 as specified
in 4.8.18.
3.2.5.2.4.2 Random Vibration for FRAM Connector(s) (Table 6-3)
Non-operating Both, mated and unmated connectors shall withstand, without damage of any
kind, the application of random vibration, as defined in Table 6-10 and Figure 6-20, when
tested as specified in 4.8.18. The connector shall meet the requirements of 3.2.1.1 (room
temperature), 3.2.1.2 (sea level and room temperature), 3.2.1.3a, and 3.3.22f after completion
of the test. The connector with fiber optic insert (insert J) shall meet additional Optical Loss
(Substitution Loss) requirement as specified in paragraph 3.3.25. The maximum optical loss
shall not exceed Optical Performance requirement of Table 6-19, Item 1 before Vibration. The
maximum change in Substitution Loss measurements shall not exceed the value specified in
Table 6-19, Item 7 when measured after vibration test.
3-6
3.2.5.2.5 Atomic Oxygen
All nonmetallic materials used in connector assembly shall show no evidence of weight loss in
14 2
excess of 0.2% when exposed to a direct Atomic Oxygen flux of 3.6 x 10 AO/cm sec at
impact energies of 4.2 eV to 4.5 eV for 30 hours. Shell and Backshell assemblies shall show no
signs of degradation due to Atomic Oxygen flux specified above for 30 years lifetime.
3.2.5.2.6 Radiation
The connector shall meet the requirements of 3.2.3 under exposure to charged particle
7
radiation. The maximum total dose for the 30 year mission life is 3 x10 rads (external
4
environment), and 3 x 10 rads for the connector components retained by the connector
housing.
3.2.5.2.7 Plasma
The connector shall meet requirements of 3.2.3 under exposure to plasma environment. The
6 3
reference plasma is 3 x 10 ions/cm with a temperature of .1 to .2 eV. The plasma is
essentially oxygen ions and electrons. Successful completion of dielectric withstanding voltage
test of 4.8.2b will satisfy this requirement.
3.2.5.2.8 Thermal Cycling, Vacuum Conditions
3.2.5.2.8.1 Thermal Cycling, Vacuum conditions for ORU Connector(s) (Table 6-2)
A fully wired mated connector shall be subjected to vacuum thermal cycling with a
temperature excursion of -65C to +200C (-85F to +392F), when tested as specified in
4.8.19. The connector shall meet the requirements of 3.2.1.1 (room temperature), 3.2.1.2 (sea
level, room temperature), 3.2.1.3a, and 3.3.22f after completion of the test.
3.2.5.2.8.2 Thermal Cycling, Vacuum Conditions for FRAM Connector(s) (Table 6-3)
A fully wired mated connector shall be subjected to vacuum thermal cycling with a
temperature excursion of 104C to +200C (-155F to +392F), except for the J configuration
which shall be subjected to a temperature excursion of 104C to +150C (-155F to +302F),
when tested as specified in 4.8.19. The connector shall meet the requirements of 3.2.1.1 (room
temperature), 3.2.1.2 (sea level and room temperature), 3.2.1.3a, and 3.3.22f after completion
of the test. The connector with fiber optic insert (insert J) shall meet additional Optical Loss
(Substitution Loss) requirement as specified in paragraph 3.3.25. The maximum optical loss
shall not exceed Optical Performance requirement of Table 6-19, Item 1 before the test. The
maximum change in Substitution Loss measurements shall not exceed the value specified in
Table 6-19, Item 7 when measured after the test.
3.3 Design and Construction
The connector(s), plug/receptacle shall be designed and constructed to meet all the
requirements of this SCD. The connector shall withstand handling incident to installation,
mate, and unmate without deleterious damage to either plug or receptacle. The following
features shall be incorporated into the design of connectors:
a. No static charge buildup.
3-7
b. Safety requirements with respect to exposed corners/edges, holes, screws,

bolts, securing pins, for connector designs shall be observed.
3.3.1 Materials, Processes, and Parts
All materials, processes, and parts used in connector fabrication shall be selected by
considering the operational requirements of this SCD and the design engineering properties of
the candidate materials. The operational requirements shall include, but not be limited to,
operational temperature limits, loads, radiation, atomic oxygen, plasma, contamination, and life
expectancy.
Properties to be considered in material selection include tensile properties, fracture toughness,
flammability and offgassing characteristics, corrosion, stress corrosion, thermal and
mechanical fatigue properties, vacuum outgassing, etc.
3.3.1.1 Process Specification
A list of all material and process specifications, utilized in connector construction shall be
submitted to the Buyer for evaluation in accordance with 4.11.6.
3.3.1.2 Controlling Documents
All M&P shall be documented by standards and specifications to preclude unauthorized
changes. Seller shall select standards and specifications from government, industry, and
company sources in accordance with MIL-STD-970, except the NASA documents, which shall
take precedence.
3.3.1.3 Special Material Problems
a. Polyvinylchloride shall not be used.
b. Lubricants containing chloro-fluoro components shall not be used with
aluminum if shear stresses can be imposed.
c. Single component liquid locking compounds, which do not cure in an oxygen-
containing environment, shall not be used unless approved by the procuring
activity.
3.3.1.4 Metals
The criteria of MSFC-SPEC-522 and MSFC-HDBK-527 shall be used to select metallic
materials to control stress corrosion cracking. Metallic materials shall meet the requirements
of NHB 8060.1 as applicable.
a. Aluminum - Maximum use shall be made of those alloys, heat treatments, and
coatings, which minimize susceptibility to general corrosion, pitting, inter-
granular and stress corrosion cracking of MSFC-SPEC-522A and MSFC-
HDBK-527F. The following aluminum alloys shall not be used: 2014-T6,
2024-T3, 2024-T4, 2024-T6, 5083-H32, 5083-H38, 5086-H34, 5086-H38,
5456-H32, 5456-H38, 7075-T6, 7079-T6, 7178-T6.
3-8
b. Heat treatment of aluminum alloy parts shall meet the requirements of MIL-H-
6088. Heat treatments not included in MIL-H-6088 may be used with the
approval of the procuring activity, if sufficient test data is available to
conclusively demonstrate that the specific heat treatment improves the
mechanical and/or physical properties.
c. High strength alloy steels heat treated at or above 180 Ksi may not be used
without approval of the Buyer.
d. Heat treatment -- Steel parts shall be heat treated to meet the requirements of
MIL-H-6875.
e. Corrosion Resistant Steel -- Caution shall be exercised in using 400 series
stainless steels to minimize hydrogen embrittlement, corrosion, and stress
corrosion.
f. All precipitation hardening steel parts shall be aged at temperatures of 1000
degrees Fahrenheit and above. Exceptions may be made for particular
applications (e.g., springs) for those steels, such as 17-7PH, which develop
maximum resistance to stress corrosion with certain aging treatments below
1000 degrees Fahrenheit. Precipitation hardening steels shall also conform to
the requirements of MSFC-SPEC-522.
3.3.1.5 Nonmetallic materials
a. Environmental Compatibility
As a general requirement for all nonmetallic materials, the Supplier shall
obtain data or analyses as necessary to meet the requirements of the most
recent issue of NASA document NHB 8060.1. Flammability, Odor, and
Offgassing Requirements and Test Procedures for Materials in the
Environments Which Support Combustion.
b. Elastomeric components shall have long term resistance to aging, low
temperature, ozone, heat aging, polymer reversion, and lubricants.
c. NASA TM-86556 shall be used in the design and application of lubricants for
connector assembly.
d. Elastomeric materials shall be cure dated for tracking purposes.
3.3.1.6 Processes
a. The welding of aluminum alloys for high strength applications shall meet the
requirements of MSFC-SPEC-504. Alternate welding specifications and
supporting data are subject to approval by the Buyer. As a minimum
requirement, welding operators shall be qualified in accordance with MIL-STD-
1595.
3-9
b. Weld repair is limited to the repair of welding defects in a production weld as

revealed by inspection. Weld repair does not include the correction of
dimensional deficiencies by weld buildup or buttering of parts in areas where
the design did not provide a welded joint. All weld repairs shall be fully
documented to facilitate the Buyers review on request. The quality of repair
welds shall be confirmed by 100 percent inspection of both surface and
subsurface using visual, dimensional, and nondestructive techniques.
c. Brazing shall meet the requirements of MIL-B-7883. Subsequent, fusion-welding
operations in the vicinity of brazed joints or other operations involving high
temperatures which might affect the brazed joint are prohibited. Brazed joints
shall be designed for shear loading and shall not be relied upon for strength in
tension for structural parts.
d. Soldering shall not be used.
3.3.1.7 Non-Magnetic Materials
All materials, components, and parts shall be non-magnetic. The relative permeability of the
connector with contacts installed but unwired shall be two (2) maximum, when tested as
specified in Method 3006 of MIL-STD-1344.
3.3.1.8 Dissimilar Metals
The selection of metals shall be in accordance with MIL-STD-889.
3.3.1.9 Moisture and Fungus Resistance
Materials used in the construction of the connectors shall be fungus inert, when tested as
specified in 4.8.20. The materials listed in Table 4-I, Group I of MIL-STD-454, requirement 4
need not be tested for fungus resistance prior to use.
3.3.1.10 Ozone Exposure
The connector shall show no evidence of cracking of the dielectric material or other damage
due to ozone exposure, when tested as specified in Method 1007.1 of MIL-STD-1344.
3.3.1.11 Manufacturing and Inspection Contamination Control
The Seller shall establish plans and procedures for the control of dust and chemical
contamination.
3.3.1.12 Corrosion Prevention and Control
Only those alloys rated A for corrosion in MSFC-HDBK-527/JSC 09604 and stress
corrosion cracking in MSFC-HDBK-527 may be used. An exception is the aluminum alloys
with a B rating for corrosion which can be used but require an approved coating.
3.3.1.13 Cleanliness
Connector plug and connector receptacle shall be cleaned to a minimum level 750 as defined in
MIL-STD-1246 prior to connector delivery.
3.3.1.14 Surface Outgassing
Materials shall be compatible with the combined environment in which they are employed. All
materials used in the item shall meet the requirements of SP-R-0022 with acceptance criteria of
having a total mass loss (TML) of less than 1% and a collected volatile condensable material
3-10
(CVCM) of less than 0.1% when tested per ASTM-E-595. In lieu of individual testing, the
mated connector assembly may be tested for total mass loss (TML) using the same test
procedure and acceptance criteria specified herein.
3.3.1.15 Flammability
The materials used in the connector assembly shall be nonflammable or self-extinguishing
when tested as specified in test 1 of NHB 8060.1, or the mated connector assembly shall be
nonflammable or self extinguishing when tested as specified in test 10 of NHB 8060.1. Tests
shall be conducted in a 10.2 psi absolute pressure of 30% oxygen and 70% nitrogen
atmosphere.
3.3.1.16 Toxicity
The connector materials or the mated connector assembly shall meet the odor and toxicity
requirements of NHB 8060.1, tests 6 and 7.
3.3.2 Electromagnetic Interference
3.3.2.1 EMI Transfer Impedance (10 kHz to 100 MHz)

When tested as specified in 4.8.21.1, the mated connector equipped with appropriate backshells
shall exhibit minimum transfer impedance of 70 dB over the frequency range from
10 kHz to 100 MHz
3.3.2.2 EMI Shielding Effectiveness (100 MHz to 1 GHz)
When tested as specified in 4.8.21.2, the mated connector equipped with appropriate backshells
shall exhibit a minimum shielding effectiveness of 50 dB over the frequency range from 100
MHz to 1 GHz.
3.3.3 Identification and Product Marking
3.3.3.1 Connector and Accessories Marking

Unless otherwise specified in applicable appendix, each connector and accessory procured to
the requirements of this specification shall be permanently and legibly marked per MIL-STD-
1285 with the following information as a minimum:
a. The manufacturers name, symbol, or trademark.
b. The manufacturers part number.
c. The manufacturers cage code number.
d. A four digit date code indicating the year and week of manufacture.
e. A 4 digit serial number, (connector, receptacle and connector, plug only)
applied as follows: 0XXX - assigned to connectors supplied by Cooper
Industries (formerly G&H Technology), Cage Code 99447. 1XXX -
assigned to connectors supplied by Smiths Connectors (formerly Sabritec),
Cage Code 58795.
f. SSQ SCD part number
g. Connector nomenclature in accordance with Figures 6-2 to 6-7.
3-11
All identification marking on metal surfaces (except contacts) shall be electrochemical etched,
laser etched, or impression stamped. A suitable ink or paint may be used for contact and
contact insertion, removal tool identification.
3.3.3.2 Contact Location Identification
Contact locations shall be identified as indicated in Figures 6-9 to 6-17. All the positions shall
be identified on the front and rear faces of the insert except where space limitations make this
impractical. Location of contact identifying characters shall be in close proximity to the holes
but need not be placed exactly where indicated on Figures 6-9 to 6-17. Cavity number random
marking is optional.
3.3.3.3 Identification and Product Marking, Retrofit Connectors
Retrofit connectors are connectors that have been reworked to the latest flight configuration,
which required a part number change. When the currently defined space available for
connector remarking is inadequate or not accessible for the complete new part number or the
remarking process may damage the connector surface, the following alternative is acceptable:
a. Do not line out the part number.
b. Add to the SSQ part number a new configuration identifier -X, where -X is a
connector configuration identifier in accordance with paragraph 3.1.2.
a. Example: -1 for the SSQ22680-012-1, location on the connector shell is optional.
c. Add to the manufacturer part number a new configuration identifier XX, where XX
is the last character in the second set of the three characters in the connector manufacturer
part number.
a. Example: 13 for the 1089-1000-013, location on the connector shell is optional,
but near the SSQ connector identifier.
d. The marking method shall be in accordance with 3.3.3.1 of this SCD.
3.3.4 Workmanship
Workmanship shall be of the highest quality attainable consistent with sound engineering and
design practices. All corners shall be broken and shall be smooth. Shell surfaces of connectors
and accessories shall be free from porosity, blowholes and cracks. Poor quality finishes,
assembly, exposed flash, sharp burrs, or contaminants shall be cause for rejection.
3.3.4.1 Defect Criteria
Base metal material shall not be exposed, except for allowances as specified in Appendix VI,
and shall be cause for rejection. Surface irregularities and imperfections, which meet
workmanship requirements herein, and do not inhibit form, fit, or function over the expected
life of the part, are acceptable. Plated-over irregularities such as nicks, dings, tool marks and
surface blemishes that may occur in the manufacturing process, do not exceed drawing
tolerances, and do not expose base metal material shall not be the sole cause for rejections.
Plated irregularities are not to be used for the purpose of measuring surface finish and flatness
3.3.4.2 Wire Sealing Member (Rear Grommet) Defect Criteria
Surface irregularities and imperfections, which do not inhibit form, fit, or function, are
acceptable.
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3.3.5 Interchangeability
All connector(s), contacts and accessories having the same SSQ part number shall be directly
and completely interchangeable with respect to installation and performance.
3.3.6 Safety
Safety shall be ensured through provision of appropriate design features, materials and parts
selections, and safety factors to protect personnel/crewmembers from electrical or mechanical
hazard. The following safety considerations are to be included in the design criteria as
applicable:
3.3.6.1 Mechanical Safety Criteria
The connector plug and connector receptacle shall meet the following mechanical safety
criteria:
a. Exposed corners and edges shall be smooth and have .02 minimum radii unless
otherwise specified.
b. Holes - Holes that are uncovered and are round or slotted in the range of 10.0 to
25.0 millimeter (mm) (0.4 to 1.0 in.) shall be avoided.
c. Screws and Bolts - Screws or bolts with more than two exposed threads shall be
capped to protect against the sharp threads.
d. Burrs - Exposed surfaces shall be free of burrs.
3.3.7 Polarization
a. Polarization of the same size connector shells shall be accomplished by means

of integral key(s) and suitable matching keyway(s) on the counterpart.
Polarization shall prevent mating of connectors of different insert arrangements.
Polarization shall be accomplished before the contact pins engage or touch the
socket insert face. Visual means of proper polarization shall be defined.
Protective covers shall mate to their counterpart without regard to the
polarization.
b. Visual indicator shall be designed to assure proper connector installation.
3.3.8 Angular Connect and Disconnect Capability
3.3.8.1 Angular Connect and Disconnect Capability, ORU Connectors (Table 6-2)
The connector pairs, when suitably mounted with one connector half on a floating plate, shall
be capable of engagement or separation without; binding, degradation or jamming; and
exceeding the force limits of Table 6-2 by more than 20 %. The two connector mounting
flanges shall be capable of engagement or separation when positioned such that the connector
data A, B and C of Figures 6-2 to 6-5 are displaced from their true position by angles of up to
10 degrees combined with 0.12 inch linear misalignment. Successful completion of actuation
force to mate or de-mate test of Par. 4.8.22a will satisfy this requirement.
3-13
3.3.8.2 Angular Connect and Disconnect Capability, ORU Connectors, FRAM Connector(s) (Table 6-3)
The connector pairs, when suitably mounted with a connector plug on a floating plate similar
to a FRAM mounting mechanism, shall be capable of engagement or separation without;
binding, degradation or jamming; and exceeding the force limits of Table 6-3, by more than
20%. The connector plug mounting flange shall be capable of engagement or separation when
positioned such that the connector center line, as defined by data A, B, and C of Figure 6-6, is
displaced from its true position by the angle of 1 combined with 0.165 Inch linear
misalignment. Successful completion of actuation force to mate or de-mate test of Par. 4.8.22a
shall satisfy this requirement.
3.3.9 Contact Protection, Connector Mating (Scoop Proof)
Connector plug shall have the pins recessed in relation to the shell so that the engaging edge of
the shell of the counterpart mating connector shall not touch the plug contacts in the worst
misalignment conditions of paragraph 3.3.8.
3.3.10 Actuation Force to Mate or De-mate
3.3.10.1 Actuation Force (Room Temperature)

Connector actuation force shall be in accordance with Table 6-3, when tested as specified in
4.8.22 (a) and (b).
3.3.10.2 Actuation Force (Differential Temperature) for FRAM Connector(s) (Table 6-3)
The connector pairs exposed to a differential temperature of 122C (220F) shall be capable
of engagement without binding, jamming, or any kind of damage when tested in accordance
with paragraph 4.8.22.c. During differential temperature mate connector actuation force shall
not exceed by more than 60% the force measurements at ambient condition. Connector with
Insert J shall meet Optical Substitution Loss requirement of paragraph 3.3.25 and Table 6-19,
Item 1 prior to the test. Within 60 minutes following completion of the engagement and prior
to demating, the connectors shall meet Optical Substitution Loss requirement of paragraph
3.3.25 for fiber optic termini and paragraph 3.2.1.1 Contact Resistance for electrical contacts
(Table 6-4, after conditioning). The maximum change in substitution loss measurements shall
not exceed requirement of Table 6-19, Item 7 when measured after completion of test.
3.3.11 Shell Design
The connector(s) plug/receptacle shall be of solid shell design and shall positively retain insert
assemblies. It shall be so constructed that the inserts cannot be removed without the use of
tools. The shell design shall be blind mate and shall be chamfered at the mating surfaces.
3.3.12 Shell Material
The shell shall be made of aluminum alloy 6061-T6511 in accordance with QQ-A-200/8 or
QQ-A-250/11.
3.3.13 Finish
Shell and backshell assemblies shall be conductive nickel plated per MIL-C-26074, class 4 to a
minimum 0.0015 inch thickness. All other aluminum parts shall be anodized in accordance
with MIL-A-8625, type III or other suitable hard anodizing process to meet the performance
3-14
requirements specified herein. Minor defects on non-functioning surfaces can be treated in

accordance with Appendix V. Minor defects are defined in Appendix V. All other metal parts
of the connector shall be made of corrosion-resistant material or be protected to meet the
performance requirements specified herein.
3.3.14 Backshell
The backshell shall be a separate component or assembly, which can be suitably attached to the
connector shell. The backshell must be removable and shall not distort or bind any of the
contacts or wires to cause improper operation. EMI backshell shall contain provisions for
termination of the cable shield. The physical characteristics and dimensions are referenced in
Appendix I.
3.3.14.1 Backshell Material
The backshell shall be made of aluminum alloy 6061-T6511 or T651 as defined by QQ-A-
200/8 or QQ-A-250/11, A356.0-T61 as defined by AMS-4218.
3.3.15 Insert Face Seal
The insert face seal of the plug shall be a resilient material bonded to the insert with individual
pin barrier. The pin barrier projections shall seal in their respective lead in chamfers of the hard
face socket insert. The insert face seal shall provide individual contact seals in the mated
condition to ensure circuit isolation between each contact and contact to shell.
3.3.16 Wire Sealing Member (Rear Grommet)
A wire-sealing member shall be provided on the rear of both the plug and receptacle and it
shall not be removable from the connector. It shall be designed to provide sealing to meet the
environmental requirements of this specification when using any combination of wires of outer
diameters within the range shown in Table 6-12, or any combination of wires and sealing
plugs.
3.3.17 Grommet Sealing Plugs
See Appendix V for physical characteristics and dimensions. The same sealing plugs shall be
capable of being used in both connector plugs and receptacles. Sealing plugs shall be made of
material Fluorinated Ethylene Propylene (FEP) in accordance with MS 27488. The quantity of
the sealing plugs to be supplied with each connector unit package shall be in accordance with
Appendix V.
3.3.18 Inserts
a. Receptacle insert assemblies shall have a rigid dielectric front face. Contact
cavities shall be designed for recessed contacts.
b. Plug insert assemblies shall have a resilient interfacial seal on the front end.
Contact cavities shall be designed for exposed pin contacts (front end). Size 22
contact cavities can be designed for either exposed contacts (pin or socket).
3-15
c. The insert shall be designed and constructed with proper sections and radii so that
they will not chip, crack or break during normal assembly or service. Hollow-
type inserts shall not be used. No metal lattice material shall be used between the
contacts.
d. Complete electrical and physical isolation of each mated pair of contacts from
every other pair of mated contacts and shell shall be provided when the plug is
mated to the receptacle.
e. Positive locking of the contacts in the insert shall be provided.
f. The insert shall permit individual insertion and removal of contacts without
removing the insert.
g. Insertion of the contacts into and removal of the contacts from the insert shall be
accomplished from the rear of the plug and receptacle.
h. The alignment of the contacts in the plug shall meet the requirement of 3.3.10.1
when tested as specified in 4.8.22a. and 3.3.10.2 when tested as specified in
4.8.22.c.
i. The alignment of the contacts in an assembled receptacle shall allow for the
contact float of .0025 to .0075 inch from true alignment position as shown in
Figure 6-9 to 6-17, when tested as specified in 4.8.22a.
j. The installation of the rigid dielectric part of insert assembly shall be limited to
one position only. If keys and keyways are used, they shall not interfere with
environmental sealing of insert assembly to shell, nor affect the true position
location of the contact cavities within the shell.
k. The contact position shall be permanently designated in contrasting color on the
front and rear faces of the insert assemblies. The interface marking of the inserts
shall not be raised or recessed on any sealing surface, except the interface rubber
seal. The marks on this seal may be .010 inch maximum deep and located in
valleys between holes. After qualification testing, the marking shall remain
legible on all samples.
3.3.19 EMI Spring
An EMI spring shall be provided around each insert housing on the receptacle shell to ensure
electrical grounding to the mating plug shell and to meet the EMI requirements specified
herein. The EMI spring shall form an integral part of the receptacle shell, and shall, in
connector mating, make contact to plug shell prior to electrical contact mating.
3.3.20 Threads and Fasteners
Screw threads shall be in accordance with MIL-S-7742 or MIL-S-8879 for fastener ultimate
tensile strengths below 160,000 pounds per square inch (psi). MIL-S-8879 shall be used for
fastener ultimate tensile strengths of 160,000 psi or greater. External threads in accordance
with MIL-S-8879 for fastener tensile strengths of 160,000 psi and greater shall be produced by
a single thread-rolling process after final heat treat.
3-16
3.3.21 Fastener Torque
Torque values for the threaded fasteners shall be in accordance with Appendix VIII, Assembly
procedures for Connectors, Rectangular, (ORU), Space Quality.
3.3.22 Contacts
See Appendix II for physical characteristics and dimensions.

a. Contacts shall be low insertion force type designed for crimp termination and shall
be qualified to this specification. Concentric Twinax contacts shall be capable of
being crimped to the wire sizes 22 and 24 and shall meet the applicable
requirements of this specification and MIL-C-39029/90 and /91. The quantity of
contacts to be supplied with each connector unit package shall consist of a full
complement of contacts plus eight spare contacts for size 12 and smaller, and seven
spare contacts for size 4 and larger. Two spare TWXs are required. Ten contacts of
part no. SSQ22680-20-12-16X to be supplied with Type C connectors. Fiber optic
contacts will not be supplied with the connector unit package.
b. Wire barrels shall be designed in accordance with applicable Figures of Appendix II
and shall conform to Table 6-4. Crimping tool shall be in accordance with
Appendix VIII.
c. Contact bodies shall be machined of solid rod stock using conductive material. The
contacting surface of the pin contacts and socket contacts shall be smooth within 32
micro-inches, rms.
d. The contacts shall be finished with 50 micro-inch minimum of durable gold in
accordance with MIL-G-45204 type II, grade C, Class I as a minimum over a nickel
underplate per QQ-N-290, 20 micro-inch minimum thickness. Gold under-plate in
accordance with MIL-G-45204 of any type and grade is permitted. Finish thickness
shall be measured in accordance with MIL-C-39029, paragraph 4.7.18.1.
e. The engaging end of the pin contact shall be of a suitable configuration to allow for
directing and centering of the pin in a mating socket contact.
f. Termination tensile strength: When tested as specified in 4.8.23, the wire shall not
pull out of the contact or break within the contact, nor shall the contact break or
become distorted to the extent it is unfit for further use before the minimum tensile
strength, as specified in Table 6-12, is reached.
g. Contact arrangement: Contact arrangement shall be as shown in Figures 6-9 to 6-17.
h. Installation and removal tools: Tools required for the assembly and disassembly of
the pin and socket contacts into their connector inserts shall be in accordance with
Appendix IV. Quantity of tools shall be in accordance with Appendix IV.
3.3.23 Connector Use Accessories
See Appendix III for physical characteristics and dimensions.
3-17
3.3.23.1 Protective Covers

Connectors shall be provided with protective covers. The protective covers shall meet the
following requirements:
a. Protect the plugs and receptacles from moisture.
b. Protect against damage to sealing surfaces, threads, and pins.
c. Be resistant to abrasion, chipping, or flaking.
d. Be permanently marked by bright colors.
e. Be maintained at a level of cleanliness equivalent to the plugs or receptacles on
which they are used.
f. Be made of material that is compatible with the connector material.
g. Be provided with restraining devices. Pressure sensitive tape shall not be used to
satisfy this requirement.
h. There shall be no static charge build-up.
i. Installation / removal shall be accomplished using one hand. There shall be no
damage to the connector (EMI spring in particular) during installation or
removal when tested as specified in 4.8.25.
3.3.23.2 Dummy Connectors
Dummy connectors shall provide a proper mating interface to a plug or a receptacle regardless
of polarization or insert arrangement. Paragraph 3.3.8 is applicable.
3.3.23.2.1 EVA Friendly Dummy Connectors
EVA friendly dummy connectors shall meet the following requirements:

a. Dummy connectors shall be compatible with the astronaut-gloved hand during
extravehicular activity (EVA).
b. Installation/removal shall be accomplished using one hand.
c. Provide electrostatic discharge (ESD) protection. Successful completion of
shell-to-shell conductivity as specified in paragraph 3.2.1.4 when tested in
accordance with 4.8.4.b will satisfy this requirement.
d. The axial installation/removal force shall not exceed 10 pounds.
e. Protect connector front face from the environment in accordance with 3.2.5.2.
f. Be resistant to abrasion, chipping, or flaking.
g. Be maintained at a level of cleanliness equivalent to the plugs or receptacles on
which they are used.
h. Dummy connectors metal surfaces shall be anodized in accordance with MIL-
A-8625, Type III or other suitable hard anodize process to meet the
performance requirements specified herein. The surfaces that provide shell to
shell conductivity of 3.2.1.5 shall be nickel-plated in accordance with 3.3.13.
3-18
3.3.23.2.2 Blind Mate Dummy Connectors
Blind mate dummy connectors shall meet the following requirements:

a. Provide electrostatic discharge (ESD) protection. Successful completion of shell-to-
shell conductivity as specified in paragraph 3.2.1.4 when tested in accordance with
4.8.4.b will satisfy this requirement.
b. Protect connector front face from the environment in accordance with 3.2.5.2.
c. Sealing surfaces, threads, and pins shall be protected against damage.
d. Be resistant to abrasion, chipping, or flaking.
e. Be maintained at a level of cleanliness equivalent to the plugs or receptacles on which
they are used.
f. Dummy connectors metal surfaces shall be nickel-plated in accordance with 3.3.13.
3.3.24 Induced Attenuation
The maximum attenuation deviation under any condition shall be in accordance with Table 6-
19. Neither the initial nor the final power measurement shall exceed the loss limitation listed
in the Table 6-19 when tested IAW paragraph 4.8.28.4. This test procedure shall be used to
measure the additional loss caused by certain tests and test environments. This procedure shall
be used to determine the relative change in attenuation of the test article.
3.3.25 Substitution Loss
The maximum loss and the maximum loss deviation per pair of optical termini when measured
IAW paragraph 4.8.28.5 shall be IAW Table 6-19. This optical loss measurement procedure
shall be used to measure the attenuation of optical links. This procedure shall be used to
determine the absolute loss of a test article.
3-19
4.0 QUALITY ASSURANCE PROVISIONS

Sellers Quality Assurance Program shall demonstrate recognition of Buyers quality
requirements and shall show evidence of an organized approach to the attainment of a quality
product. The Quality Assurance Program shall assure quality throughout all areas of
Contract/Purchase Order (C/PO) performance.
When Buyers C/PO includes a Quality System Flysheet as a requirement, Sellers contractual
commitment for a Quality Assurance Program shall be in accordance with that Flysheet. When
Buyers C/PO does not include a Quality System Flysheet as a requirement, Sellers
contractual commitment for a Quality Assurance Program shall, as a minimum, be in
accordance with MIL-Q-9858A, Quality Program Requirements. Unique part requirements
shall be defined by all paragraphs of this SCD. Buyers C/PO shall be the governing document
in the event of any conflict between the C/PO and the requirements set forth in the Quality
Assurance Program Specification and the SCD. In the event of any conflict between the
Quality Assurance Program Specification and the SCD, the SCD shall take precedence.
4.1 Responsibility for Inspection
The Supplier shall be responsible for the performance of all inspections and tests required to
verify that connectors offered for acceptance conform to the requirements of the Suppliers
engineering documentation for the connector and as set forth in this section. The Supplier may
use his own facilities or any laboratory with approval by the Buyer for performing the
verifications. The Buyer and the Government source inspection reserves the right to perform
any inspections necessary to assure the connector is in conformance with requirements of this
SCD.
4.1.1 Test Equipment and Inspection Facilities
Test and measuring equipment and inspection facilities of sufficient accuracy, quality, and
quantity to permit performance of the required inspection shall be established and maintained
by the Supplier. The establishment and maintenance of a calibration system to control the
accuracy of the measuring and test equipment shall be in accordance with MIL-STD-45662.
4.1.2 Standard Test Conditions
Unless otherwise specified, all measurements shall be made within the following ambient
conditions:
a. Temperature: +15C to +30C (+590F to +86F).
b. Atmospheric pressure: 73.33 to 106.66 Kpa (10.6 to 15.5 psi).
c. Relative humidity: 10% to 80%.
4.2 Baseline Configuration Control
Suppliers shall prepare a Process Baseline Control Plan in accordance with 4.11.9.3.
4.3 Baseline Control Deviations
After final approval of the Baseline Control Document any requests for deviation from the
requirements of this specification with regard to engineering documentation and critical
manufacturing procedures as defined in 4.11.9.3b shall be submitted in accordance with 4.11.8.
4-1
4.4 Supplier Traceability Requirements

4.4.1 Serialization and Date Code
4.4.1.1 Connectors and Accessories

Each Connector shall be marked in accordance with 3.3.3 and applicable Figure. The serial
number shall be in order of production. Each connector accessory shall be marked in
accordance with 3.3.3 and applicable Appendix.
4.4.1.2 Contacts
Each contact and unit package shall be marked in accordance with paragraph 20.3.2 of
Appendix II.
4.4.1.3 Tools
Accountable tools shall be marked with a tool number and after calibration, when applicable,
each tool shall have a calibration tag or sticker affixed to the tool or the tool container.
4.4.2 Purge Capability
Serial Numbers, Date Codes and lot Numbers shall provide the means for data linkage and
retrieval between the devices in stock or installed in equipment and the fabrication processes
and materials used such that standard devices may be identified to the smallest quantity
possible, thus minimizing the number of devices requiring replacement. The seller shall
maintain the applicable records until directed otherwise by the Buyer.
4.4.3 Critical Materials and Processes
The traceability system may be by lot control or similar methods that control and identify the
critical materials and processes. The following identifies the items considered critical and for
which traceability is mandatory:
a. Inserts - Materials and Assembly
b. Contact Retention Clips
c. Contacts
d. Plug Housing
e. Receptacle Housing
f. Final Assembly
g. Other - Any Material or Process designated by the Buyer and/or Seller as
critical to operational performance.
4.5 Classification of Inspection
The inspection and testing of the connector shall be classified as follows:
a. Qualification Inspection (Paragraph. 4.6)
b. Acceptance Inspection (Paragraph. 4.7).
4.6 Qualification Inspection
Qualification inspection shall consist of the following:
4-2
4.6.1 Analysis In Accordance With Table 6-18
4.6.2 Examination In Accordance With Table 6-18
4.6.3 Qualification by Similarity
Qualification may be granted by the Buyer, on the basis of similarity, to connectors or contacts
which differ only in minor details from those submitted for qualification testing. Qualification
is contingent on the degree of similarity and successful evaluation of test data submitted to
validate the difference.
4.6.4 Qualification Tests
Unless otherwise specified, the qualification tests shall consist of those tests specified in Tables
6-13 to 6-17 and in sequence listed. The qualification tests will be performed by Seller, or at a
laboratory approved by the procuring activity in accordance with paragraph 4.8, when
specified on the contract or purchase order, and when it considers such testing necessary to
determine the acceptability of the connectors.
4.6.4.1 Qualification Test Samples
The qualification test samples shall consist of plugs, receptacles, protective caps, contacts and
associated accessory hardware that has been obtained from production lot and has successfully
passed final inspection. The test samples shall be wired as specified in 3.3.22b and Table 6-4,
using wires in accordance with RM2432 or equivalent. Twinax contact test samples shall be
divided into two equal groups: one group shall be wired using RM2589-001 cable or
equivalent, the second group shall be wired using NDBC-TFE-22-2SJ-75 cable per SSQ21655
or equivalent. The test connectors with the insert J shall be assembled with Fiber Optic Termini
Part Numbers NRP-F-16X (ref. Appendix II herein) terminated to the single fiber cable Part
Number NFOC-2FFF-1GRP-1 per SSQ21654. Each part shall be serialized and identified as
qualification test sample. Connectors submitted for mated qualification test shall be paired and
each connector half-serialized and identified as qualification test sample. Connector pairing
shall be maintained throughout all tests and examinations. The quantity of test samples shall be
as specified in Tables 10, 11, and 14.
4.6.4.2 Qualification Objective
Qualification inspections and tests determine if the construction, design, materials, and
processes employed in the manufacture of the connectors and contacts inspected allow the
connectors and contacts to comply with the requirements of this drawing.
4.6.4.3 Qualification Rejection
There shall be no failures in any examination or test of the connectors, accessories or contacts
submitted for qualification inspection. If any failure occurs, the testing of the failed hardware
shall be stopped. The Buyer shall be notified by the Supplier in accordance with 4.10.1.
Failure analysis shall be performed in accordance with 4.10.2 which shall include
recommended changes to be made in the connectors, accessories or contacts. The supplier
shall continue with the qualification testing of hardware which is not affected by the failure
unless directed in writing otherwise by the buyer.
4-3
4.6.4.4 Disposition of Qualification Sample Units

Unless otherwise specified in the purchase contract, connectors or contacts, subjected to
qualification inspection, shall be delivered to the Buyer in a container marked Qualification
samples - do not use .
4.7 Acceptance Inspections
Acceptance inspections shall consist of these examinations and tests:
a. Periodic inspections (4.7.3)
b. Final inspection (4.7.4) Note: Sequence of inspections / tests is optional, except
Dielectric Withstanding Voltage (DWV) shall precede Insulation Resistance test
(IR).
4.7.1 Acceptance Objective
Acceptance inspections and tests are intended to ensure compliance of production connectors
and contacts with the requirements of this drawing.
4.7.2 Acceptance Rejection
4.7.2.1 Connector Acceptance Rejection

There shall be no failures in any examination or test of the connectors, submitted for
acceptance. If any failure occurs, the Buyer shall be notified by the Supplier in accordance
with 4.10.1. Failure analysis shall be performed in accordance with 4.10.2. Final inspection
need not be held up, after such failure, for the rest of the connector lot submitted to final
inspection, while the Supplier is investigating the cause of the failure and instituting corrective
action. Final acceptance of connectors or the contacts related to the failure shall not be made
until it is determined that the items meet all requirements of this drawing and Buyers
approval.
4.7.2.2 Contact Acceptance Rejection
The contacts submitted for final inspection shall pass the acceptance requirements in
accordance with Appendix II, paragraph 20.4.1. If failure occurs, Rocketdyne shall be notified
by the Supplier in accordance with 4.10.1. Failure analysis shall be performed in accordance
with 4.10.2. Final acceptance of the contact inspection lot related to the failure shall not be
made until it is determined that it meets all requirements of this drawing and Buyers approval.
4.7.3 Periodic Inspection
If a qualified source has been inactive, or for other reasons has not supplied Buyer with
connectors or contacts for a period of 2 years or greater, periodic inspection of the source may
be required. The inspection criteria will be determined at the time a periodic inspection is
deemed necessary and may include tests of sufficient magnitude and duration to ensure that the
connectors and contacts continue to comply with the requirements of this drawing.
4.7.4 Final Inspection
As a minimum, each connector shall be 100 percent inspected in accordance with Table 6-17
and/or applicable Appendix.
4-4
The wires used in Final Inspection shall be in accordance with RM2432 and RM2589
specifications, or equivalent. Nickel coated wires, TFE, FEP Teflon or Cross-linked modified
ETFE Tefzel insulated wires per MIL-W-22759 specification are equivalent to RM2432 wires.
MIL-C-17/176 Shielded, Twisted Pair Cable is equivalent to RM2589 Cable.
4.8 Test Methods
4.8.1 Contact Resistance
a. Contact resistance at room temperature.

With the pin contact engaged as shown (see Figure 6-1), voltage drop of each
mated pair shall be measured across y-y in accordance with Method 3004.1 of
MIL-STD-1344 after the contact temperature has stabilized at 25C 3C.
Voltage drop measurement connections shall be permanent connections.
b. Contact resistance at elevated temperature.
As specified in 4.8.1.a with the following exception: The contact temperature
shall be stabilized at 200C 3C (392F 5F).
4.8.2 Dielectric Withstanding Voltage
Dielectric Withstanding Voltage, (Sea Level, Room Temperature)

a. Wired mated and unmated connectors shall be tested in accordance with Method 3001.1
of MIL-STD-1344. The following details and exceptions shall apply:
1) The magnitude of the mated connector test voltage shall be 1800 VAC/RMS minimum.
2) The magnitude of unmated connector halves test voltage shall be 1300 VAC/RMS
minimum.
3) For final inspection, test harnesses may be used in performing this test.
b. Dielectric withstanding voltage, (high temperature, high altitude).
Wired mated connectors shall be tested in accordance with Method 3001.1 of
MIL-STD-1344, test condition IV, V, and VI. The following details and exceptions
shall apply:
1) The magnitude of the mated connector test voltage shall be 800 VAC/RMS
minimum.
2) The test chamber shall be a thermal-vacuum chamber.
3) The test sample shall be stabilized at 200C + 3C (392F 5F) elevated
temperature and specified pressure for 30 minutes prior to being subjected to
specified tests.
4) The pressure rate change shall be the maximum obtainable when the
barometric-pressure test chamber as specified in the latest, buyer-approved
qualification test procedure, is used.
5) The leads of all test circuits shall be brought out through the walls of the
chamber.
4-5
4.8.3 Insulation Resistance
a. Insulation resistance at room temperature.

Wired mated connectors, connector plugs, and connector receptacles shall be tested as
specified in Method 3003.1 of MIL-STD-1344. The insulation resistance shall not be
less than the values specified in 3.2.1.3a. The insulation resistance after humidity test
shall not be less than the value specified in 3.2.1.3c. The following details and
exceptions apply:
1) For final inspection testing, test harnesses may be used in performing this test.
2) Connectors shall be mated when tested after environmental testing specified in
Table 6-15 for insert arrangements A-G, and Table 6-16 for insert arrangements J
and K, for mated pair.
b. Insulation Resistance at Elevated Temperature
Mated connectors shall be tested as specified in Method 3003.1 of MIL-STD-1344.
The insulation resistance shall not be less than the value specified in 3.2.1.3b. The
insulation resistance shall be measured after stabilizing the mated connectors at the
specified temperature for a minimum of 30 minutes.
4.8.4 Shell to Shell Conductivity
Mated connectors shall be subjected to the test specified in Method 3007 of MIL-STD-1344.
The dc resistance of the mated connectors shall be measured as follows:
a. For Qualification Test
1) From a point on the rear end of the receptacle backshell to a point on the
mounting flange of the plug.
2) From a point on the rear end of the plug backshell to a point on the
mounting flange of the receptacle.
b. For Final Inspection
1) From the rear end of the connector plug/receptacle to a point on the
mounting flange of the mating connector plug/receptacle.
4.8.5 Size 8 Concentric Twinax Grounding
Unmated connectors, with size 8 concentric Twinax contacts installed, shall be tested in
accordance with method 3007 of MIL-STD-1344. The following details and exceptions
shall apply:
a. Points of measurements. Front surface of connector mounting flange and size 8
concentric Twinax outer body (0.1 inch maximum from rear edge of the contact)
b. To facilitate testing, voltage probes may be so positioned as to include a reasonable
length of cable, provided the resistance of the additional length of cable is subtracted
from the resistance value obtained.
4-6
4.8.6 Connector Current Rating
A test current specified in Table 6-4 shall be applied to each contact of wired, mated connector
assembly. Connectors shall be mounted by normal means, and held together by fixture, which
simulates the connector mounting box. The following details shall apply:
a. Insert arrangement of type A to be tested.
b. The altitude test chamber shall consist of a suitably sealed chamber with
necessary vacuum pump equipment to maintain a reduced pressure of 1.3 x 10-6
kPa (1.9 x 10-7 psi) or lower and a means to maintain temperature +100C to
+106C (+212F to +223F).
c. The length of the wires terminated to the contacts is 14 inches maximum. The
wire ends shall be terminated to the leads of all test circuits that are brought in
through the walls of the chamber.
d. The test sample shall be stabilized at specified pressure and temperature for 30
minutes prior to testing.
e. Connector temperature shall be recorded 15 minutes after it was stabilized since
the application of the test current.
4.8.7 Connector De-mating Under Electrical Load
The purpose of this test is to determine the effects of subjecting connectors and contacts to 10
de-mating cycles under electrical loads simulating the de-mating process of ORUs on orbit.
The test voltages and corresponding test currents shall be applied between each wired contact
and each adjacent contact as specified in the Table 6-5. When type D connector to be tested,
the test voltage and corresponding test current shall be applied between two size 20 contacts
and one size 16 contact. The following details shall apply:
a. Connectors shall be mounted in the tester carefully aligned, and fully mated and
unmated the number of cycles specified.
b. One mated pair of type A connector and one mated pair of type D
connector shall be tested.
c. Electrical load shall be applied during de-mating part of the cycle only.
d. At the completion of 10 cycles, connector contacts shall be visually examined
for signs of melting, oxidation, discoloration, and pitting that would be
detrimental to the performance of the contact and may be caused by arcing.
e. At the completion of 10 cycles, contact resistance test as specified in 4.8.1a and
actuation force to mate or de-mate test as specified in 4.8.22b shall be
performed.
4.8.8 Contact Separation Force
Sockets shall be mounted in a suitable fixture for applying gradually increasing loads for the
engagement and separation of the test pins specified in 3.2.2.4. The test shall be performed in
accordance with Method 2014 of MIL-STD-1344, Procedure I using applicable test pin in
4-7
accordance with Figure 6-18. The depth of the engagement shall be in accordance with Figure
6-18.
4.8.9 Contact Retention
The contact retention shall be tested as specified in Method 2007.1 of MIL-STD-1344. The
following details and exceptions shall apply:
a. The test shall be performed on 50 percent of each size of the contact
compliment, but not less than three contacts per size in each connector half.
b. Contact retention shall be verified by completely inserting and removing
specified number of contacts of each connector half 10 times.
c. An applicable axial load shall be applied along the longitudinal axis of
individual contacts in the direction tending to displace the contacts to the rear,
and then, to the front.
4.8.10 Insert Retention
Unmated connectors shall be tested in accordance with Method 2010 of MIL-STD-1344 with
the following details:
a. Axial load to be applied: 75 psi + 5 psi for duration of two (2) minutes
minimum.
b. Connectors may be wired.
4.8.11 Insert Bonding Integrity
Insert assemblies shall be tested as specified by either paragraph a or b.

a. Test method 1
The complete insert assembly shall be immersed one inch below the surface of a
compatible fluid. A pressure differential of 9 1 psi shall be applied between
each contact cavity and all other contact cavities and the insert assembly outside
surfaces. The pressure differential shall be maintained for a minimum period of
three seconds and any indication of air leakage shall be cause for rejection.
b. Test method 2
The complete insert assembly shall be conditioned such that all contact cavities
and all voids opening into the cavities are filled with a compatible conductive
fluid. The insert assemblies with the conductive fluid remaining inside shall
then be subjected to an electrical continuity test between each contact cavity and
all other contact cavities and the insert assembly outside surfaces. Indication of
continuity shall be cause for rejection.
4.8.12 Contact Insertion and Removal Force
Unmated connectors shall be tested in accordance with Method 2012.1 of MIL-STD-1344 with
the following details:
a. The test shall be performed on 50 percent of each size of the contact compliment, but
not less than three contacts per size in each connector half.
4-8
b. Contact installation and removal tools as specified in 3.3.22h.

4.8.13 Durability
The wired plugs and receptacles shall be tested in accordance with Method 2016 of
MIL-STD-1344. The following details and exceptions shall apply:
a. The mating and de-mating shall be accomplished so that the plug and receptacle are
completely separated during each test. When connectors with J insert are tested, one
mated pair of Fiber Optic contacts shall be subjected to induced attenuation test IAW
4.8.26.4 test procedure. The optical surfaces shall be inspected before and after the test
using a 100 power minimum microscope before and after the 500 cycles. The
observations shall be recorded.
b. Contact resistance as specified in 4.8.1a, dielectric withstanding voltage as specified in
4.8.2a, insulation resistance as specified in 4.8.3a, and actuation force to mate or de-
mate as specified in 4.8.22b shall be measured after completion of the test. For inserts
with Fiber Optic contacts (J insert), one mated pair of Fiber Optic contacts shall meet
the requirements of paragraph 3.3.24 Induced Attenuation when the first mate is
complete. The Induced Attenuation testing as specified in paragraph 3.3.24 shall be
repeated every 10 cycles during first 100 cycles and every 100 cycles after that.
c. The optical surfaces can be cleaned (up to three times for each subset of mating cycles)
if the optical performance exceeds the requirements of 3.3.24. Minor damage such as
scratches or abraded finishes at non-optical surfaces or at surfaces not used as part of
the contact alignment guides shall not be cause for failure
d. Optical surfaces shall remain unaffected by the 500 mating cycles. There shall be no
evidence of scratching, pitting, cracks or chips on the optical surface that adversely
affects optical performance of the fiber optic contacts.
4.8.14 Accelerated Aging
4.8.14.1 Connector Accelerated Aging

Mated connectors with full complement of contacts shall be subjected to the temperature life
test in accordance with Method 1005.1 of MIL-STD-1344. The following details and
exceptions apply
a. Temperatures that are specified in 3.2.3.4.1 are connector internal temperatures.
4-9
b. One mated connector shall be subjected to the conditions of 3.2.3.4.1a. A

second mated connector of the same type shall be subjected to the conditions of
3.2.3.4.1b
c. Dielectric withstanding voltage as specified in 4.8.2a, insulation resistance as
specified in 4.8.3a, contact resistance as specified in 4.8.1a, and termination
tensile strength as specified in 4.8.23 shall be measured after completion of the
test.
4.8.14.2 Contact Twinax Accelerated Aging
This test shall be performed after contact final inspection. Mated contacts shall be
subjected to the following accelerated aging test:
a. Contact temperatures in accordance with 3.2.3.4.2
b. Two mated contact pairs shall be subjected to the conditions of 3.2.3.4.2a, and
two mated contact pairs shall be subjected to the conditions of 3.2.3.4b.
c. For each condition one mated contact pair shall be terminated to RM2589-001
or equivalent cable and the other mated pair to NDBC-TFE-22-2SJ-75 cable
per SSQ21655 or equivalent.
d. Dielectric withstanding voltage, insulation resistance, contact resistance, and
termination tensile strength in accordance with MIL-C-39029/95 and/96 shall
be measured after completion of the test.
4.8.15 Humidity
Wired plugs and receptacles with protective covers on shall be subjected to the
humidity test specified in Method 1002.2 of MIL-STD-1344. The following details and
exceptions shall apply:
a. Test procedure- Type II.
b. Four hours prior to finishing the last cycle and while the connectors are still
subjected to high humidity; the insulation resistance test shall be performed in
accordance with 3.2.1.3c.
c. After completion of the test:
1) Shut off the humidity chamber, open the door and allow the test articles
to air dry for 24 hours.
2) Remove test articles from the chamber, remove the protective covers and
visually examine the connector cavity for the presence of condensed
moisture and or signs of corrosion. The presence of condensed moisture
or corrosion constitutes a test failure.
3) Proceed to the specified post test functional testing.
4.8.16 Shock
Mated connectors, connector plugs, and connector receptacles shall be tested in accordance
with MIL-STD-1344, Method 2004.1, Condition F.
The following details shall apply to both test procedures:
4-10
a. Unmated connectors shall be tested with the protective covers installed.

b. Connectors shall be mounted by normal means, and held together by fixture,
which simulates the connector mounting box.
c. Connectors shall be fully wired. The connector wire bundle shall be clamped
to the connector-mounting fixture 12 to 18 inches from the rear of the
connector backshell.
4.8.17 Salt Spray (Corrosion)
Unmated connectors with protective covers shall be tested in accordance with Method 1001.1
of MIL-STD-1344, condition B. The following details and exceptions shall apply:
a. The samples shall not be mounted but shall be suspended from the top of the
chamber using waxed twine or string, glass rods, or glass cord.
b. Wire ends must be protected to prevent salt migration.
4.8.18 Vibration
Mated connectors, connector plugs, and connector receptacles shall be subjected to a vibration
test in the following sequence:
a. The resonant frequencies shall be determined by varying the frequency of
applied sinusoidal vibration through the range of 10 to 2000 Hz at the rate of 1
octave/min. with sufficient amplitude to excite the item in each of three
mutually perpendicular axes.
b. Random vibration per 3.2.5.2.4 along each of three mutually perpendicular
axis for a duration as specified in Tables 6-9 and 6-10. All mated and
unmated connectors shall be fully wired. The connector wire bundle shall be
clamped to the connector-mounting fixture 12 to 18 inches from the rear of
the connector backshell. The test fixture shall be designed so that resonant
vibration inherent in the fixture within the frequency range specified for the
test shall be minor. The magnitude of the applied vibration shall be monitored
on the test fixture near the specimen mounting points. The test specimen
mounting interface is the same for both mated and unmated connectors and
shall simulate as closely as possible the normal mounting of the connector.
c. DWV as specified in 4.8.2.a, IR as specified in 4.8.3a and Shell to Shell
Conductivity as specified in 4.8.4.a shall be measured after completion of the
test. For the fiber optic insert (J insert), additional Optical Loss (Substitution
Loss) test shall be performed IAW, paragraph 4.8.26.5.
4.8.19 Thermal Cycling, Vacuum Conditions
Wired, fully mated connectors shall be subjected to 24 continuous temperature cycles at the
temperature extremes specified in 3.2.5.2.8. There shall be no visible physical damage such as
cracking, peeling, or splitting of resilient, hard dielectric, or metal parts. The following details
shall apply:
4-11
a. The altitude test chamber shall consist of a suitably sealed chamber with
necessary vacuum pump equipment to maintain a reduced pressure 0.0001
Torr (0.0133 Pa) max, and means to maintain temperature extremes as
specified. The time for reduction of chamber pressure from ambient to the
specified reduced pressure shall be at least 10 minutes to allow sufficient time
in the region of critical pressure.
b. Temperature stability has been achieved when the rate of change is no more
than 5.4F/hour (3C/hour).
c. The test sample consists of a mated plug and receptacle assembled with the
full complement of wired contacts. The connector plug wire bundle shall be
clamped to the connector thermally controlled mounting fixture 12 inches
from the rear of the connector backshell. Connectors shall be maintained in
mated position by a suitable fixture.
d. A minimum of 24 temperature cycles shall be used. During the first full cycle
the connector shall be thermally stabilized for at least 12 hours at both
temperature extremes. The temperature extremes for ORU connector(s)
(Table 6-2) are -65C (85F) and +200C (+392F), for the K connector
configuration -104C (-155F) and +200C (+392F) and for the J connector
configuration -104 0C (-155 0F) and +150 C (+302 F). During subsequent
cycles, shorter dwell times may be used that are equivalent to those required
to reach internal equilibrium during the first cycle but not less than one hour.
Transition shall be at a rate no less than 1.0F (0.56C) per minute.
e. Dielectric withstanding voltage as specified in 4.8.2a, insulation resistance as
specified in 4.8.3a, contact resistance as specified in 4.8.1a, and termination tensile
strength as specified in 4.8.23 shall be measured upon completion of the final cycle.
For the fiber optic insert (J insert), additional Optical Loss (Substitution Loss) test
shall be performed IAW paragraph 4.8.26.5
(Note) Temperatures specified above are internal connector temperatures.
4.8.20 Moisture and Fungus Resistance
Wired plugs and receptacles, with the protective covers on, shall be subjected to the fungus test
in accordance with Method 508.4-3 of MIL-STD-810. The following details shall apply:
a. Duration: 28 days minimum.
b. Acceptance criteria: MIL-STD-810, Method 508.4-1, Amount of Growth - None,
Grade 0.
c. Similarity data may be used.
4.8.21 Electromagnetic Radiation
4.8.21.1 Transfer Impedance Measurements

The procedure used to measure connector shell EMI transfer impedance for the frequency
range of 10 kHz to 100 MHz is shown in Figure 6-22. Current at these frequencies is driven,
end to end, through the shell of the mated connector set by attachment of wide copper straps at
each end of the backshells. A single center unshielded conductor is passed through the entire
4-12
assembly and is terminated at one end by a 50 ohm coaxial load and the other end by a 50 ohm
cable to the 50 ohm input impedance of the EMI test receiver. These last two connections are
accomplished via type N coaxial receptacles mounted to flat plate flanges which in turn are
bolted over the EMI backshell end opening. The measurement shall consist of first obtaining a
reference voltage expressed in dB reading by connecting the signal generator directly to the
EMI test receiver. The same generator is then connected to the current driving straps referred
to above and the EMI test receiver is connected to the coaxial receptacle opposite the end
terminated with a 50 ohm load. This reading is expressed in dB below the reference reading
and is equivalent to transfer impedance in dB below 50 ohms. This procedure is repeated and
measurements are to be taken for 5 frequencies spread evenly across the test band.
4.8.21.2 Shielding Effectiveness Measurement
The procedure used to measure the connector shell EMI shielding effectiveness for the
frequency range of 100 MHz to 1 GHz is shown in Figure 6-22. A length of 22 AWG bare
wire is to be suspended above the copper ground plane between two type N coaxial
connectors. Each of these connectors is mounted to an L shaped bracket, which in turn is
clamped to the copper ground plane. The distance between the connectors is set equal to the
length of the mated test connector set. This test wire is terminated at one end with a 50-ohm
coaxial load and the other end with a EMI receiver/analyzer. The test wire is to be radiated
with a reference field from a source antenna 1 meter away. A reference reading is taken at
each frequency to be tested. The test wire assembly is then replaced with the mated test
connector. A reading is then taken on the receiver/analyzer at each test frequency used for the
unshielded test wire. The difference in the readings between the test wire levels and the mated
test connector levels in dB is defined as the shielding effectiveness. This procedure is to be
followed for each frequency tested. Shielding effectiveness measurements are to be made at
100, 200, 400, 600, 800, and 1000 MHz for both vertical and horizontal antenna polarizations.
4.8.22 Actuation Force to Mate or De-mate
a. Actuation force to mate or de-mate qualification test procedure

Connectors shall be tested in accordance with Method 2013.1 of MIL-STD-
1344. The following details shall apply:
1) Connector plug and connector receptacle shall be mounted in the fixture,
which simulates, as closely as possible, the normal mounting of the
connector. Connector shall be fully wired. The connector wire bundles
shall be clamped to the connector-mounting fixture 12 to 18 inches from the
rear of the connector backshells.
2) After performing 10 cycles at a rate of 300 cycles maximum per hour, the
mating and de-mating force for the next 3 cycles shall be recorded and shall
not exceed the requirement of 3.3.10. (Cycle is defined as one complete
mating and de-mating process.)
3) The mating/de-mating process shall be accomplished at worst case angular
connect and disconnect capability of 3.3.8. The actuation force to mate or
de-mate shall not exceed the requirement of 3.3.8.
4-13
4) Contact resistance in accordance with 4.8.1a, dielectric-withstanding voltage

as specified in 4.8.2a, and insulation resistance as specified in 4.8.3a shall be
performed prior to the last de-mating process.
5) Successful completion of this test will satisfy the requirements of 3.3.18h
and 3.3.18i.
6) Connector force measurements shall not include any external forces that
may be exerted by the mounting fixture.
b. Actuation force to mate or de-mate final inspection test procedure
Connectors shall be tested in accordance with Method 2013.1 of MIL-STD-
1344. The following details shall apply:
1) Connector plug and connector receptacle shall be mounted in a suitable
fixture.
2) The mating de-mating process shall be repeated three times. The mating and
un-mating force for the last cycle shall be recorded.
3) The actuation force to mate or de-mate shall not exceed the requirement of
3.3.10.
4) Connector force measurement shall not include any external forces that may
be exerted by the mounting fixture.
c. Differential Temperature
Connectors, plug and receptacle, shall be mated and demated at a differential
temperature of 122 C (220 F). Temperature stability has been achieved when the
rate of change is no more than 3 C/hour (5.4 F/hour) (this rate of change shall apply
to all subsequent temperature stabilization steps). Thermal conditioning shall be
maintained during mate / de-mate cycles. The following details apply:
1) Delta Temperature Test (Low):
a. Perform actuation force to mate or de-mate in accordance with 4.8.22b. The
following details shall apply:
1) When fully mated, the relative position of the connector shells shall be
measured, recorded, and visually marked for the reference. Subsequent
mate sequences are complete when the connector shells reach this visual
indicator within +0 to 0.020 inches.
2) While fully mated perform Substitution Loss test IAW paragraph
4.8.26.5.
b. Stabilize connector plug at 104 C (-155 F) and the connector receptacle at
+18 C (+65 F). Mate and de-mate the connectors. Record the mate and de-
mate forces.
c. Stabilize connector plug at 104 C (-155 F) and the connector receptacle at
-104C (-155 F). Mate and de-mate the connectors. Record the mate and de-
mate forces. Connector shells may be in physical contact during stabilization.
4-14
d. Stabilize connector plug at +18 C (+65 F) and the connector receptacle at

104 C (-155 F). Mate and de-mate the connectors. Record the mate and de-
mate forces.
e. Mate connectors and allow them to stabilize at room temperature. Perform
DWV in accordance with 4.8.2a, IR in accordance with 4.8.3a, Shell to Shell
Conductivity in accordance with 4.8.4, and Contact Resistance Test in
accordance with 4.8.1a, (on a minimum of 50 percent of each size contact in
the connector). For J connector, perform additional Substitution Loss test
IAW paragraph 4.8.26.5.
f. Perform actuation force to mate or de-mate in accordance with 4.8.22b.
Connectors shall be visually examined for damage that would affect
connector performance.
2) Delta Temperature Test (High):
a. Stabilize the connector plug at +138 C (+ 280F) and the connector
receptacle at +15.5C (+60F). Mate and de-mate the connectors. Record the
mate and de-mate forces.
b. Stabilize the connector plug at +138 C (+ 280F) and the connector
receptacle at +138C (+280F). Mate and de-mate the connectors. Record the
mate and de-mate forces. Connector shells may be in physical contact during
stabilization.
c. Stabilize the connector plug at +15.5C (+60F) and the receptacle
temperature at +138C (+280F). Mate and de-mate the connectors. Record
the mate and de-mate forces.
d. Repeat steps e, and f of paragraph c.1.
4.8.23 Termination Tensile Strength
4.8.23.1 Termination Tensile Strength Qualification Test Procedure

Crimped contact wire assemblies shall be subjected to the tensile strength test in accordance with
Method 2003.1 of MIL-STD-1344. TWX cable assemblies shall be subjected to the tensile
strength test in accordance with MIL-C-39029/95 and /96. The un-terminated ends of the TWX
cable assemblies shall be stripped and twisted together to facilitate equal load distribution to all
TWX components. The following details shall apply:
a. Quantity:
1) See Table 6-13, (for contact qualification test).
2) 20 percent of each contact size, but no less than 2, (for connector qualification
test).
b. Crimping tool: see 3.3.22b.Yab
c. Measurement: see Table 6-12.
4-15
4.8.23.2 Termination Tensile Strength Final Inspection Test Procedure

Crimped contact wire assemblies shall be subjected to the tensile strength test in accordance with
Method 2003.1 of MIL-STD-1344. TWX cable assemblies shall be subjected to the tensile
strength test in accordance with MIL-C-39029/95 and /96. The un-terminated ends of the TWX
cable assemblies shall be stripped and twisted together to facilitate equal load distribution to all
TWX components. The following details shall apply:
a. Quantity: see Appendix II.
b. Crimping tool: see 3.3.22b.
c. Measurement: see Table 6-12.
4.8.24 EVA Dummy Connectors Axial Installation / Removal Force
Connectors shall be tested in accordance with Method 2013.1 of MIL-STD-1344. The following
details shall apply:
a. Connector plug and connector receptacle shall be mounted in the fixture, which
simulates, as closely as possible, the normal mounting of the connector.
Connectors may not be wired for this test.
b. EVA Dummy connector shall be installed and removed on / from mating
connector 10 times using one hand.
c. Mating / de-mating force for the following 3 cycles shall be accomplished using
appropriate force gage.
4.8.25 Protective Cover Easy Installation / Removal
4.8.25.1 Installation / Removal Test

The purpose of this test is to demonstrate that the protective cover design is in compliance with
the requirements of Paragraph 3.3.23.1i. The following details apply:
a. Perform a minimum of 10 installation / removal cycles (plug and receptacle).
b. Installation / removal shall be accomplished by one hand.
c. There shall be no damage to the connector, specifically EMI spring.
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4.8.25.2 Protective Cover Storage Test (Connector Receptacle only)

Set aside a connector receptacle with installed protective cover in a secure area for three (3) days
minimum. After time is completed, remove protective cover using one hand. Visually examine
connector and EMI spring for any damage or other attributes that would affect EMI spring
performance or connector mating.
4.8.26 Fiber Optic Cable Assembly Power Loss Test
The fiber optic cable assembly power loss shall be tested using the following method.
4.8.26.1 Test Equipment
The test equipment shall consist of both a light source and an optical power meter.
4.8.26.1.1 Light Source
RIFOCS CP1763, 1300 + 30 nm LED Source with ST adapter is the standard light source for
this test. Verify the LED Light Source is within calibration date prior to the test.
4.8.26.1.2 Optical Power Meter
TEKTRONIX TOP2200 with ST adapter is the standard optical power meter for this test. Verify
the Optical Power Meter is within calibration date prior to the test
4.8.26.2 Test Sample
The following definitions are given to support the procedures listed in this section:
a. Optical Power Loss Test Cable Assembly (TC) - The Optical Power Loss Test Cable
shall consist of a mated pair of fiber optic termini in SSQ22680 connector per Figure 6-
23, each half shall be terminated a four (4) feet in length of SSQ21654 cable, and is
terminated with ST connectors at both ends. Label the source end "A" and the detector
end "B"
b. Reference Cable Set - The reference cable consists of three cables S, R, and D
constructed from a single SSQ 21654 cable with ST connector at each end. The R cable
shall be eight (8) feet long. Each reference cable set component shall be clearly marked
with the power loss value derived during final testing at the completion of the cable
assembly. The R cable segment that is plugged into Light source shall be identified as
Ref. 1. The R cable segment that is plugged into Power Metter shall be identified as
Ref. 2.
Notes:
1. Keep all cables in ESD protective bag to protect cables assembly prior to testing.
2. Handle with care: when securing cables use the widest strap and the widest bend
radius. Use minimal force when manipulating cables.
4.8.26.3 Optical Test Set Cleaning
a. Clean each optical surface of the Power Loss Test Cable Assembly (TC) and Reference
Cable set using a clean lint free wipe wetted with N-Propyl alcohol followed by a clean
lint free wipe (dry).
b. Using clean, dry compressed air, blow the connector on the source and detector.
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c. Using clean, dry compressed air, blow the adapter on the LED Light Source and the
Optical Power Meter.
d. Inspect the mating face of Fiber Optic termini using power scope with 100 minimum
magnification if required. There shall be no evidence of scratching, pitting, cracks or
chips on the optical surface. Minor damage such as scratches or abraded finishes at non-
optical surfaces or at surfaces not used as part of the contact alignment guides shall not be
cause for failure.
e. When Fiber Optic cable is suspect use Laser Fault Finder DPA 310 for break detection.
4.8.26.4 Induced Attenuation
The Induced Attenuation loss (changes due to exposure to mechanical and environmental tests)
shall be measured and recorded when specified, and shall be performed IAW the following
procedure used as required for testing in the configuration as shown in Fig. 8. The optical loss
measurements shall meet the requirements specified in 3.3.24. The test article must remain
connected for the duration of the test.
4.8.26.4.1 Test Procedure
Verify proper performance by connecting to the optical interface and measuring the output light
with a calibrated power meter. The power level shall meet the requirement of the source
specification (Insertion loss of the test cable shall be 0.5 dB or less). The test set-up shall be
configured as shown in Figure 6-23.
a. Set source to continuous mode.
b. Clean optical surfaces of S and D cables IAW 4.8.26.3 procedure and install the
S cable into optical source and D cable into the optical detector.
c. Connect the S and the D reference cables as shown in Figure 6-23. Note the dB
power output of the reference cable(s). Press the Source button for dB mode. The
reading shall be 20 dB +/- 0.5 dB. Perform this four times, disconnecting the cables
from the meter each time.
d. Measure and record the final optical power of the three consecutive readings or of the
mean of the seven highest power measurements of ten measurement data set.
e. Press the [dB] or [Zero] button to store the new 0.00 dB reference value in the meter
(zero-out the meter)
f. Clean the connectors of S, R and D cables IAW 4.8.26.3 procedure and reconnect them
as shown in Figure 6-23. Unmate each junction (one junction at a time), clean the fiber
surfaces and remate until three consecutive matings agree to within 0.03 dB but not
more than ten times. If a cable does not meet the 0.03 dB requirement, the cable is
unacceptable and cannot be used for this procedure. Verify that the power
measurement is consistent with the optical loss history of the test article.
g. Press the [dB] or [Zero] button to store the new 0.00 dB reference value in the meter
(zero-out the meter).
h. Install the test article in the test chamber or on the test setup.
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i. Disconnect the reference cable and connect to the A connector of the Power Loss Test
Cable Assembly to the S cable and B connector of the Power Loss Test Cable
Assembly to the D cable as shown in Figure 6-23. Record the optical power
transmission (OPT) reading.
j. Disconnect the Power Loss Test Cable Assembly from the S and D reference
cables, clean fiber surfaces IAW 4.8.26.3 procedure (one junction at the time), and
reconnect. Unmate each junction (one junction at the time), clean the fiber surfaces and
remate until three consecutive matings agree to within 0.03 dB but not more than ten
times. If a cable does not meet the 0.03 dB requirement, the cable is unacceptable and
cannot be used for this procedure. Verify that the power measurement is consistent
with the optical loss history of the test article.
k. Measure and record the final optical power of the three consecutive readings or of the
mean of the seven highest power measurements of ten measurement data set and
calculate the mean value.
l. Make subsequent power readings as required.
Under no circumstances shall the optical test setup be disconnected and care must be taken to
minimize disturbances to the test setup except for the test environment.
4.8.26.5 Substitution Loss
The substitution loss (changes in the attenuation of the optical links) shall be measured and
recorded when specified, and shall be performed IAW the following procedure used as
required for testing in the configuration as shown in Figure 6-23. T he optical loss
measurements shall meet the requirements specified in 3.3.25. This method is intended to
determine the optical power loss of a mated pair of fiber optic termini when installed in an
appropriate connector as it is installed in an optical link.
Verify proper performance by connecting to the optical interface and measuring the output
light with a calibrated power meter. The power level shall meet the requirement of the source
specification (Insertion loss of the test cable shall be 0.5 dB or less). The test set-up shall be
configured as shown in Figure 6-23.
a. Set source to continuous mode.
b. Clean optical surfaces of S and D cables IAW 4.8.26.3 procedure and install the
S cable into optical source and D cable into the optical detector
c. Connect the S and the D reference cables as shown in Figure 6-23. Note the dB
power output of the reference cable(s). Press the Source button for dB mode. The
reading shall be 20 dB +/- 0.5 dB Perform this four times, disconnecting the cables
from the meter each time.
d. Measure and record the final optical power of the three consecutive readings or of the
mean of the seven highest power measurements of ten measurements data set.
e. Press the [dB] or [Zero] button to store the new 0.00 dB reference value in the meter
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f. Clean the source, detector, S, R and D cables IAW paragraph 4.8.26.3 and connect as
shown in Figure 6-23. Un-mate each junction (one at a time), clean and repeat until three
consecutive power readings agreed within 0.03 dB but not more than ten times. If a
cable does not meet the 0.03 dB requirement, the cable is unacceptable and cannot be
used for this procedure. Verify that the power measurement is consistent with the
optical loss history of the test article.
g. Press the [dB] or [Zero] button to store the new 0.00 dB reference value in the meter
h. Clean the connectors of the Power Loss Test Cable Assembly and replace the R cable.
Connect the A connector to the S cable and B cable to the D cable.
i. Un-mate each junction (one at a time), clean and re-mate each junction to the A and B
connectors. Repeat until three consecutive readings agreed within 0.03 dB but not more
than ten times. If a cable does not meet the 0.03 dB requirement, then the cable is
unacceptable and cannot be used for this procedure. Record the mean power of the three
power readings or discard the high and low values (those that deviate more that 0.10 dB
from the mean of the remaining data) from the data set and calculate the mean of the
data remaining.
j. Disconnect only the test article from the S and D cables and perform the environmental
or mechanical test.
4.9 Destructive Physical Analysis (DPA)
DPA will not be required except in the presence of concern regarding manufacturer or part type
design or problem/failure history, which could be verified or eliminated by appropriate DPA
investigation.
4.9.1 Connectors
A sample of each connector configuration randomly selected from any production lot by the
Buyer shall be submitted to the Buyer for DPA after successful completion of a final inspection.
4.9.2 Contacts
The following contacts randomly selected from each lot shall be submitted to the Buyer for
DPA:
a. 5 contacts of size 12 and smaller.
b. 2 contacts of size 4 and larger.
c. 1 TWX pin contact and 1 TWX socket contact of each configuration.
4.9.3 Accessories
A sample of each accessory configuration randomly selected from any production lot by the
Buyer shall be submitted to the Buyer for DPA.
4.10 Connector Failures
4.10.1 Failure Reporting Notification
Failures as specified in 4.10.2 shall be reported within 5 working days in Sellers format.
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4.10.2 Failure Analysis
A failure analysis shall be performed in accordance with 4.11.3 on each connector, accessories or
contact having failed during qualification inspection, final inspection, Buyer receiving
inspection, DPA, and direction by the Buyer to analyze failure trends or generic problems. The
failure analysis shall isolate the cause(s) of failure and yield adequate conclusions to initiate a
plan for corrective action to eliminate the cause of failure, and to prevent recurrence of the type
of failure mode reported. The failure analysis shall be approved by the Buyer.
4.11 Documentation and Data
The specific documentation products to be delivered or made available to the Buyer shall be as
follows:
4.11.1 Test Procedures
4.11.1.1 Qualification Test Procedure

4.11.1.1.1 Scope
The purpose of the Qualification test procedure is to ensure the safe, effective, and economic
conduct of the testing of electrical connectors, contacts and accessories.
4.11.1.1.2 Data Description
The test procedure shall provide in detail the information needed by the test engineers to perform
a specific test or series of tests in order to achieve the required test results.
The test procedure shall include, but not be limited to, the items below. The items are listed in
their preferred order:
a. Title page shall contain document number, title, and latest revision date or letter,
Supplier approval, and a cross-reference between the Suppliers part number(s)
and the Buyer part number(s).
b. Table of contents
c. The Scope shall include the purpose of the document, and its arrangement.
d. Test plan shall include test schedule, and test sequence in accordance with 4.6.4.
e. Description of the test samples:
1) Identification of test samples in accordance with 4.6.4.1
2) A general description of the test samples including photographs.
f. References
g. Conditions and Tolerances shall be specified in accordance with 4.1.2 and 4.8
h. Quality control verification of data shall be as specified.
i. Test Equipment and inspection facilities must be specified by the Supplier. It
must be calibrated in accordance with 4.1.1.
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j. Test procedures. A separate section of test directions shall be provided for each
test required by the SCD. The test directions shall include the name of test, a
complete list of test equipment, methods of mounting of test samples, and step by
step procedures for testing. Locations of monitoring devices shall be specified.
Sketches of test setups, schematics of nonstandard test equipment and detailed
schedules of individual tests shall be provided. Special warnings or precautions as
necessary during functional or environmental testing shall also be included.
k. Data recording requirements, including accuracy.
Format
l. Supplier format acceptable pending Buyer approval.
m. Maintenance
The Supplier shall establish and maintain the procedure.
4.11.1.2 Final Inspection Test Procedure
4.11.1.2.1 Scope
Final Inspection Test Procedure provides the instructions for tests and inspections to be
conducted for determining acceptability of connectors, contacts and accessories to be furnished
to the Buyer.
4.11.1.2.2 Data Description
Final Inspection Test Procedures shall be prepared as working documents in accordance with
4.7b, containing sufficient details so that it may be used for conducing the tests to which they
apply. The document shall include the following information as a minimum:
a. Title page shall contain document number, title, and latest revision date or letter,
Supplier approval, and a cross-reference between the Suppliers part number(s)
and the Buyer part number(s).
d. Description of the test article:
1) Identification of test article by name and part number
2) A general description of the test article giving the normal use or function of the
article.
3) A drawing of the article, to assist in defining size, form and other pertinent
configuration information.
e. References
f. Conditions and Tolerances shall be specified in accordance with 4.1.2 and 4.8
g. Test equipment and inspection facilities must be specified by the Supplier. It must be
calibrated in accordance with 4.1.1.
h. Test set-up
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The test set-up explanation shall include the following:

1) A description of the test article(s) to be tested and of the test equipment required shall
be included. Any pretest positioning of controls and components shall be described.
2) Diagrams/drawings providing complete test set-up shall be incorporated or
referenced.
3) Any visual or special inspection of the article, required prior to conduct of the test,
shall be defined.
i. Test Procedure
Test Procedure shall contain a clear step-by-step plan to be followed in the final
inspection testing of the test article. The level of detail shall be such that the statement
may be used as direct and adequate instructions to a technician experienced in the type of
testing described but not necessarily knowledgeable of the item to be tested. Special
warnings or precautions as necessary during functional or environmental testing shall
also be included.
j. Test sequence shall be in accordance with 4.7b.
k. Data recording requirements, including accuracy.
l. Quality Assurance Provisions shall be in accordance with 4.0.
m. Maintenance
n. Supplier format acceptable pending buyer approval.
4.11.2 Acceptance Data Package ( ADP )
4.11.2.1 Scope
Acceptance data package provides the documentation needed by the using activity to put the
connector to use.
4.11.2.2 Data Description
The ADP shall be arranged according to the following format and contain information necessary
to assist the Buyer in controlling, maintaining, statusing and using the end item.
a. The title page shall contain:
Deliverable item Buyer part number, name, and serial number.
Contract number.
Supplier name.
A cross-reference between the Suppliers part number and the SSQ SCD part number.
b. Index page
This page identifies the type of hardware, associated data, and applicable
sections contained in the ADP as follows:
1) Deliverable item Buyer part number, name, and serial number
2) Content of the applicable data with an explanation for any missing data.
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3) Appropriate deliverable data package approval signatures and date.

c. Recognized commercial shipping documents
This form is required for all shipments and shall include the appropriate quality control
validation and shall include:
1) Deliverable item Buyer part number, name, and serial number
2) Quantity shipped
3) Shortage/open work
d. Final inspection report
Final inspection (4.7.4) documentation shall show clearly that tests were conducted in
accordance with specified requirements. The Supplier shall certify that each connector,
accessories or contact meets all applicable drawing requirements.
e. Notes/Comments
Unusual phenomena (occurrence, difficulty, or questionable condition during fabrication
and testing)
f. Waiver/Deviation Record
Buyer approved waivers and deviations to the contract authorizing hardware delivery
with existing variations, as applicable to the physical parameters of the item being
delivered.
g. Format
Supplier format acceptable pending Buyer approval
4.11.3 Failure Analysis Report
4.11.3.1 Scope
This document establishes the requirements for failure reports, including content, format, and
maintenance.
The failure report shall include, as a minimum, the following information:
a. Failure report number
b. Date defect occurred
c. Lot number, lot size, and serial number (where applicable)
d. Connector, accessory or contact type designation
e. Test and/or examination at which defect was first noted
f. Failure mode
g. Criticality
h. Cause of failure
i. Corrective action taken or to be taken
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j. Effect of failure on other connectors, backshells or contacts in the inspection lot

k. Purchase order or contracts affected
l. Format
m. Maintenance
n. The Supplier is responsible for correcting any errors or omissions discovered by
either party after submittal of the test report.
4.11.4 Qualification Test Report
4.11.4.1 Scope
This document establishes the requirements for Test Report, including content, format, and
maintenance.
The Test report shall contain a section, which states the test objectives, complete test data, and
explains how the results meet the objectives.
In addition, the Test report shall include, but not be limited to:
a. Title page shall contain document number, title, and latest revision date or letter, Supplier
approval, and a cross-reference between the Suppliers part number(s) and the Buyer part
number(s).
d. Description of the test samples
e. Certification of the fact that the test samples were in conformance with and tested to the
latest approved revision of the appropriate document with respect to design, construction,
materials and finishes, workmanship, marking, manufacturing processes and controls, test
procedures
f. References
g. Test techniques and procedures in accordance with 4.11.1
h. Layout of instrumentation system including types, accuracy and location
i. Summary of problems, hardware discrepancy and corrective actions
j. Dated and signed examination and test result data verifying that the samples complied
with all the qualification test requirements of SCD. This data shall include:
1) Measured or observed test conditions at the time of test or examination as required
2) All pertinent qualitative observations and quantitative values obtained by
measurement, including recordings, charts, photographs
3) Calculated values and sample calculations
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k. Appropriate Product Assurance Procedures (including calibration procedures) utilized

shall be summarized in a separate section of the report
l. Qualification test summary/status
m. Format
n. Maintenance
The Supplier is responsible for correcting any errors or omissions discovered by either
party after submittal of the test report.
4.11.5 Supporting Engineering Drawings, Analyses, Specifications, List and Data
4.11.5.1 Scope
This document establishes the requirement for providing to the Buyer when requested design
drawings, specifications, descriptive data, lists, and supporting analyses and data used to define
and/or substantiate the design.
4.11.5.2 Applicable documents
DOD-STD-100 Military Standard Engineering Drawing Practices
DOD-STD-1000 Military Specification - Drawing Engineering and Associated Lists
MIL-STD-490 Specification Practices
4.11.5.3.1 Analysis and Data
The reports shall include, but not be limited to, trade-off analysis; design analyses (loads,
stresses, thermal, structural, electrical, etc.); performance, design-to-cost. Specific content
requirements for design analyses, drawings and lists, and specifications are defined below:
a. The report shall be structured to separately cover each of the major subsections of the
design analysis task. The analysis report shall correlate the design requirements with the
Buyer specified requirements. The report shall include or reference all related data.
b. The report shall include, as appropriate and applicable, the following:
1) Objectives of the analysis/study.
2) Description of the items involved, including adequate drawings, to support the
analysis
3) Specification of design constraints and assumptions imposed on the analysis
4) Identification of source material used in the analysis
5) Results of the analysis shall include predicted performance related to requirements,
design impact, problems encountered or revealed
6) Conclusions
c. Format
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Supplier format acceptable pending Buyer approval.

4.11.5.3.2 Drawings and Lists
Drawings and associated lists shall be prepared to the requirements of DOD-D-1000, Drawings,
Engineering and associated Lists and DOD-STD-100 Engineering Drawing Practices.
a. Tailoring of DOD-D-1000 Requirements
Par. 6.2.1 Procurement Requirements shall be used
1) Drawings shall be prepared to the requirements of level 3, Production
2) The inch-pound system will be used except where mutually agreed upon by the Buyer
and the Supplier
3) Suppliers standards shall be acceptable
4) Part lists shall be prepared at every numbered assembly level, up to and including the
top assembly drawing
5) Control drawings in accordance with DOD-STD-100 shall be prepared as applicable
4.11.5.3.3 Specifications
a. The specifications shall be expressed in readily measurable terms, and shall specify the
requirements and Quality Assurance Provisions necessary to establish that the material or
process satisfies all applicable requirements, quantitatively in terms of measurable
physical properties with tolerances
b. The process controls delineated by the specifications shall reflect a defect prevention
program for the control of processes where uniform, high quality cannot be assured by
inspection of articles alone.(Example: bonding, coating, plating)
c. The specification shall include the following information as a minimum:
1) Process control definition including performance and control methods
2) Inspection methods definition
3) Process environments, defined for processes which must be conducted in special
environments, including the degree of control required
4) Identification of processing materials, equipment and their associated control
parameters
5) Identification of tests
d. Format
Supplier format acceptable pending Buyer approval.
4.11.5.4 Maintenance
a. Analyses and Data
The reports shall be updated to reflect changes in the analysis and/or supporting data as
required. The reports shall also be updated as a result of Supplier performance reviews
and/or subsequent direction by the Buyer. Subsequent reports shall be maintained current
with design progress.
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b. Drawings, lists and specifications

Changes and/or updating of drawings and specifications shall be accomplished in
accordance with the Suppliers configuration management system. Change documents
will be incorporated into their drawings/specifications prior to contract completion.
4.11.6 List of Materials and Processes
4.11.6.1 Scope
This document establishes content, format, and maintenance requirements for the list of materials
and processes employed in connector, contact and accessories fabrication.
A list of all materials and process specifications shall be submitted. The list shall contain the
following information:
a. Specification/procedure title and author
b. Identification of the revisions and updates used
c. Designation of which specifications and procedures are critical to fabrication, control,
and inspection of the contract end items. All critical processes/procedures shall be made
available to the Buyer for review.
d. A list of materials and process specifications shall comply with the applicable documents
and shall contain:
1) Detail part number
2) Next assembly part number
3) Change letter designation
4) Drawing source (Supplier or vendor)
5) Material form
6) Material manufacturer
7) Material specification
8) Process specification
9) Material code
10) Standard/commercial part number
11) Maximum and minimum temperature
12) Overall evaluation shall include corrosion, stress corrosion, cracking, flammability,
toxicity and thermal vacuum stability ratings from MAPTIS or MSFC HDBK 527
(JSC 09604).
13) Material code per MSFC HDBK 527 or MAPTIS
14) Weight (non-metallics only)
15) Surface area (non-metallics only)
e. Format
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Material Identification/Usage Form per Appendix IX

f. Maintenance
A list of materials and process specifications shall be updated to reflect changes as
required. The document shall also be updated as a result of Supplier performance reviews
and/or subsequent direction by the Buyer. Subsequent reports shall be maintained current
with design progress.
4.11.7 Engineering Change Proposals (ECPs)
4.11.7.1 Scope
This document provides the necessary information to analyze the proposed change and make an
informed decision on the ECP.
a. Minimum Change Proposal Documentation
Design changes submitted to the Buyer for acceptance shall be documented on ECPs
providing the following data as a minimum:
1) Change title, date, recommended priority (routine, urgent) and change classification
2) Change description
3) Serial number production effectivity
4) Justification and reason for the change
5) Parts affected
6) Impact on hardware certification. If certification/ re-certification is required, the
proposed method (test, analysis, similarity) shall be identified
7) Schedule impact
8) Cost impact(s)
9) Engineering materials and process specifications affected by the ECP
10) Engineering acceptance test specifications affected by the ECP
b. Format
4.11.8 Deviation/Waiver to Program Contract Requirement
4.11.8.1 Scope
This document establishes requirements for obtaining specific written authorization to accept an
item, which departs from contract requirements.
a. Deviations shall be submitted for all parts when the problem is identified prior to
manufacture.
1) Item name, Part number and serial number
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2) Effectivity of deviation
3) Quantity of items involved
4) Description of the proposed deviation and an explanation of the effect on
safety, maintainability, reliability, performance, weight, interface
requirements, and interchangeability
5) Number, title, and paragraph of the documented requirement from which
deviation is sought
6) Rationale for acceptance and assessment of risk involved
7) Effect on contract delivery schedule, if disapproved
8) Effect on contract cost
9) Approval signatures and dates
b. A waiver shall be submitted when the problem is identified during manufacture or after
submittal to inspection.
1) Item name, Part number and serial number
2) Quantity of items involved
3) Description of the proposed waiver and an explanation of the effect on safety,
maintainability, reliability, performance, weight, interface requirements, and
interchangeability
4) Number, title, and paragraph of the documented requirement from which
waiver is sought
5) Rationale for acceptance and assessment of risk involved
6) Effect on logistics
7) Corrective action required, if any
8) An estimate of commensurate reduction in contract cost if material is accepted
as is or with repair
c. Format
4.11.9 Quality Assurance Program Plan
4.11.9.1 Scope
Quality Assurance Program Plan shall contain the details for configuration baseline control. It
defines the procedure for establishing and maintaining control of the critical aspects of product
configuration. It also contains the Supplier baseline control documents that have been approved
by the Buyer.
4.11.9.2 Applicable Documents
All detail engineering, manufacturing, assembly and process drawings shall be identified. All
referenced Supplier specifications not normally available shall be made available on request.
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4.11.9.3 Baseline Control Document Requirements

The manufacturer of the product to be supplied to this specification shall prepare, implement and
maintain a Baseline Control Document (BCD) in accordance with following requirements:
a. Supplier drawing list, material specification and manufacturing procedure in effect and
approved at CDR shall be recorded in BCD. Changes required after CDR baseline
control has been established shall be submitted in accordance with 4.11.7.
b. Supplier Drawing List shall list Engineering top assembly drawings, sub-assembly
drawings, material specifications, and specific manufacturing procedures that are
designated as critical by the Buyer. The procedures currently designated critical are as
follows:
Insert components and insert assembly installation and bonding.
EMI components installation and securing to the shell.
Threaded insert installation.
Any manufacturing procedure designated by the Buyer and/or Seller as critical to
operational performance.
c. List of all manufacturing procedures other than those designated as critical above. This
list to be updated as required to add new, delete non-applicable or obsolete manufacturing
procedures.
d. List of the quality assurance program plan and related quality assurance documents on
which the Buyer approval is based, and the Supplier in-house procedure for control and
performance of rework. List to include document number, title of the document and
revision status.
e. Rework procedures
The manufacturers documentation for the control and performance of rework
f. Change control procedure
The manufacturers procedures for identifying and controlling changes to items defined
as critical. This shall identify the manufacturers system for compliance with 4.11.9.4
g. Buyer representative participation
BCD shall clearly identify, where applicable, those processes that require the
participation of the Buyer representative.
4.11.9.4 Change Control
The manufacturer shall designate a focal point (program manager when used) with responsibility
to identify major and minor changes with the qualifying activity. The manufacturers
configuration control system shall provide for review, by the program focal point, all changes to
the configuration baseline prior to implementation of the change. The program focal point shall
have the authority to delay implementation of any change to the product being supplied to this
specification until coordination with the Buyer is complete.
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4.11.9.4.1 Major Change Procedure
Any changes (class I or class II) to a critical item in accordance with 4.4.3 or critical procedure
in accordance with 4.11.9.3b is defined as major. Any class I change to a non-critical item is
defined as major. When a major change has been identified an ECP in accordance with 4.11.7
shall be submitted to the Buyer. The Buyer shall provide a written response within 20 working
days after receipt of the ECP, indicating approval, disapproval or identifying a delay in response,
the reason for delay and any additional information required from the manufacturer. The
changes shall not be implemented until Buyers approvals have been received.
4.11.9.4.2 Minor Change Procedure
Any class II change to a non-critical item is defined as minor. When a minor change has been
identified an ECP in accordance with 4.11.7 shall be submitted to the Buyer for concurrence on
classification. If there is no written Buyer response within 10 working days, the change may be
implemented.
4.11.9.5 Baseline Audits
Following configuration baseline approval, an audit team will periodically examine the
manufacturers facilities and equipment, review his critical processes and audit the
implementation of the baseline control. The date, location, time of audit and extent of
participation of manufacturer personnel required to accomplish the task will be established on a
schedule, which is mutually acceptable to the Buyer and the manufacturer. A current copy of the
suppliers BCD shall be made available for use in conducting the audit. Upon completion of the
audit, the manufacturer will be provided with a written report of the results of such an audit. A
schedule for correction of any significant deficiencies will be required for review and approval
by the Buyer.
4.11.9.6 Quality Survey by the Buyer
Seller shall permit Buyer to conduct quality audits, including audits of Sellers suppliers, as
required, to evaluate the degree of compliance with the Quality Assurance Program
Specification, SCD and C/PO. Seller shall make available to the Buyer at Sellers facility a copy
of each specification, instruction, procedure, record or special requirement deemed by the Buyer
to be necessary and pertinent to the conduct of the qualify survey. The sellers quality program
shall be verified by a Space Station EEE Parts Pre-award Survey.
Any corrective actions as a result of the survey shall be corrected, implemented and verified
prior to the start of manufacturing.
4.11.10 Document Cross-Reference
All documentation whether retained or submitted by the Supplier shall be cross-referenced to the
applicable contract or purchase order.
4.11.11 Record Retention
All records pertinent to a specific connector, backshell or contact shall be retained by the
Supplier for a minimum of five (5) years. Buyer must be notified prior to records being
destroyed.
4-32
5.0 PREPARATION FOR DELIVERY
5.1 General Requirements

The requirements specified herein govern the preparation for shipment and the transport of the
item to all Buyer and Government facilities. The methods of preservation, packaging, and
packing utilized for shipment shall adequately protect the item from damage or degradation in
reliability or performance due to the natural or induced environments encountered during
transportation and subsequent indoor storage. Packaging and packing shall be designed to
withstand the rough handling packaging requirements of MIL-STD-794.
Preservation and Packaging
Preservation and packaging shall be in accordance with the requirements of Level C of
MIL-STD-794. The Seller shall ensure that parts and materials are preserved and packaged in
accordance with applicable process documents.
5.2 Package Identification
Unit, intermediate, interior, and exterior container shall be marked in accordance with
MIL-STD-129. Identification information on the containers shall include:
Purchase Order Number
Part Number
Item Name
Manufacturer Type or Part Number
Date Control Number
Serial Number (if applicable)
Quantity
Manufacturer
5-1
6.0 NOTES
6.1 Connector Compatibility

Connectors specified in this SCD are directly and completely interchangeable with connectors of
the same insert arrangement specified in Rocketdyne SOCD 9RE2412 of Rockwell International.
6.1.1 Connector Assembly Procedures Applicability
Procedures specified in appendices VI through VIII are applicable to connectors specified in

Rocketdyne SOCD 9RE2412.
6.2 Approved Source(s) of Supply
Connector Approved Source(s) of Supply
Only the item described in this drawing when procured from the vendor(s) is approved by
the Buyer for use in the application(s) specified. A substitute item shall not be used
without prior approval by the Buyer. Identification of the approved source(s) of supply is
not to be construed as a guarantee of present or continued availability as a source of
supply for the item described on the drawing.
6-1
Table 6-1 Approved Source(s) of Supply
Approved Source(s) of Supply

SSQ22680 Part No. Cooper Industries Smiths Connectors
(formerly G&H Technology) (formerly Sabritec)
Part No 1 Part No 2
SSQ22680-001 1089-900-007 S018031-2013
SSQ22680-002 5 1089-1000-007 S018032-3001
SSQ22680-003 1089-900-002 S018031-2014
SSQ22680-004 5 1089-1000-008 S018032-3002
SSQ22680-005 1089-900-003 S018031-2015
SSQ22680-006 5 1089-1000-009 S018032-3003
SSQ22680-007 1089-900-004 S018031-2016
SSQ22680-008 5 1089-1000-010 S018032-3004
SSQ22680-009 1089-900-005 S018031-2017
SSQ22680-010 3 1089-1000-011 S018032-3005
SSQ22680-010-1 3
SSQ22680-010-2 5 1089-1000-013 S18032-3012
SSQ22680-011 1089-700-001 S018031-2018
SSQ22680-012 4 1089-800-003 S018032-3006
SSQ22680-012-1 4
SSQ22680-012-2 6 1089-800-006 S018032-3013
SSQ22680-013 1089-700-002 S018031-2019
SSQ22680-014 6 1089-800-004 S018032-3007
SSQ22680-015 1089-900-012 S018031-2020
SSQ22680-016 5 1089-1000-012 S018032-3008
SSQ22680-019 S018031-2172
SSQ22680-020 5 S018032-3017
SSQ22680-021 S018031-2173
SSQ22680-022 5 S018032-3018
NOTES:
1. Cooper Industries Inc (formerly G&H Technology) , 750 W. Ventura Blvd, Camarillo, CA 93010, (805)389-
5781, Cage Code 99447
2. Smiths Connectors (formerly Sabritec), 1550 Scenic Ave, Suite 150 Costa Mesa, CA 92626 714-371-1100,
Cage Code 58795
3. SSQ22680-010 and SSQ22680-010-1 are obsolete for new procurement and replaced with SSQ22680-010-2.
4. SSQ22680-012 and SSQ22680-012-1 are obsolete for new procurement and replaced with SSQ22680-012-2.
5. When inspected in accordance with paragraph 2.5 of Appendix X herein, and the EMI spring is found to be
damaged or non-compliant the connector shall be repaired in accordance with paragraph 60.2 of Appendix VI
herein. The part numbers identified by this note combined with Smiths Connectors (formerly Sabritec) Part
Number S109900-9006 is an approved flight configuration.
6. When inspected in accordance with paragraph 2.5 of Appendix X herein, and the EMI spring is found to be
damaged or non-compliant the connector shall be repaired in accordance with paragraph 60.2 of Appendix VI
herein. The part numbers identified by this note combined with Smiths Connectors (formerly Sabritec) Part
Number S109900-9007 is an approved flight configuration
6-2
Table 6-2 ORU CONNECTOR(S) CLASSIFICATION
SSQ 22680 Connector Mating Contact Insert Weight Force

Part No. Type Half Type Arrange (lbs) (Ref Only) (lbs)
-001 plug -002 pin A .65 60
-003 plug -004 pin B .70 60
-005 plug -006 pin C .71 69
-007 plug -008 pin D .75 60

-009 plug -010 pin E .74 77
-011 plug -012 pin F .58 60
-013 plug -014 pin G .60 60
-015 plug -016 pin A .65 60
-002 receptacle -001 socket A .62 60
-004 receptacle -003 socket B .71 60
-006 receptacle -005 socket C .70 69
-008 receptacle -007 socket D .75 60
1
-010 receptacle -009 socket E .73 77
-010-1 Receptacle -009 Socket E .73 77
-012 1 receptacle -011 socket F .55 60

-012-1 Receptacle -011 Socket F .55 60
-014 receptacle -013 socket G .56 60

-016 receptacle -015 socket A .62 60
Note 1: Configuration is obsolete for new procurement and is replaced with -010-1 and -012-1 respectively.
Table 6-3 EXTERNAL CARRIER CONNECTOR(S) CLASSIFICATION
SSQ22680 Connector Mating Contact Insert Weight (lbs) Mating Force

Part No. Type Half Type Arrangement (Ref Only) (lbs) Max
-019 Plug -020 Pin J 0.73 86

-021 Plug -022 Pin K 0.70 76
-020 Receptacle -019 Socket J 0.76 86
-022 Receptacle -021 Socket K 0.66 76
6-3
Table 6-4 CONTACT RESISTANCE
Wire Test Maximum Contact Voltage Drop

Contact Wire (mV)2
Barrel Current After
Size Size 25C 200C
Size Amperes Conditioning
0 0 0 150 48 58 68
0 4 4 80 53 60 75
4 4 4 80 53 60 75
8 8 8 46 60 70 85
12 12 12 23 57 65 81
12 16 16 13 68 77 95
16 16 16 13 68 77 95
20 20 20 7.5 75 84 107
22 22 22 5 99 113 141
Center 22 1 20 23 29
TWX1 Intermediate 22 1 20 23 29
Outer
12 75 90 137
Center 22 1 55 66 101
TWX1 Intermediate 22 1 55 66 101
Outer
12 75 90 137
NOTES:
1. Contact, electrical connector, concentric Twinax, size 8.
2. Values reflect maximum voltage drop after accelerated aging, thermal cycling and
durability tests.
6-4
Table 6-5 CONNECTOR DEMATING ELECTRICAL LOADS
Contact Size Test Voltage (Open) (v) Applied Current

(A)
.125 120
0 .25 60
.5 30
.125 4.4
16 .25 2.2
.5 1.1
.125 2.2
20 .25 1.1
.5 .54
Table 6-6 CONTACT ENGAGING AND SEPARATING FORCE
Initial After Conditioning (Durability)

Mating Min Separation Max Min Separation Max Engagement
End Min Pin Engagement Min Pin Max Pin
Size Diameter Max Pin Diameter Diameter
Diameter
Force (Ounces)
0 15 72 12 87
4 10 60 8 72
8 5 40 4 48
12 3 14 2.5 17
16 2 11 1.5 13
20 .7 5.0 .6 6
22 .7 4.0 .6 4.5
TWX MIL-C-39029/90 AND /91
6-5
Table 6-7 CONTACT RETENTION
Contact Size Pre-load 10% Load 10%

Pounds Pounds
0 3 75
4 3 60
8 3 25
TWX 3 25
12 3 25
16 3 25
20 3 15
22 3 10
Table 6-8 CONTACT INSERTION AND REMOVAL FORCES
Contact Size Insertion And Removal Forces

(Pounds, Maximum)
0 25
4 25
8 25
TWX 25
12 25
16 20
20 20
22 10
6-6
Table 6-9 LAUNCH VIBRATION TEST REQUIREMENTS FOR ORU CONNECTORS
Test Frequency Range Power Spectrum Density

20 Hz 0.05 G2/Hz
20 - 64 Hz +6 dB/oct
X, Y, Z Axis 64 - 366 Hz 0.5 G2/Hz
366-2000 Hz -7.5 dB/oct
X, Y, Z Axis Overall Acceleration 16.5 g (rms)
X, Y, Z Axis Duration: 3 min. per axis
Table 6-10 LAUNCH VIBRATION TEST REQUIREMENTS FOR FRAM CONNECTORS
Test Frequency Range Power Spectrum Density

20 Hz 0.025 G2/Hz
20 64 Hz 6.0 dB/oct
X, Y, Z Axis 64 366 Hz 0.26 G2/Hz
366 1100 Hz -5.5 dB/oct
1100 Hz .035 G/Hz
1100 - 2000 Hz -4.5 dB/oct
2000 Hz .014 G/Hz
X, Y, Z Axis Overall Acceleration 13.3 g (rms)
X, Y, Z Axis Duration 13.5 min. per axis
6-7
Table 6-11 WIRE INSULATION SIZE
Contact Size Wire Size Outer Diameter Of

Finished Wire (Inch)
0 0 .389-.555
4 4 .233-.360
6
8 8 .135 - .260
TWX RM2589-001 .124-.260
12 12 .074-.124
16
16 16 .056-.087
20
20/22 20 .048-.070
22
Table 6-12 TENSILE STRENGTH
Wire Barrel Size Wire Size Axial Load (Pounds)

Initial Condition Values After Conditioning1
0 0 630 567
4 4 360 325
8 8 288 259
12 12 104 85
16 16 42 38
20 20 21 16
22 22 12 10
TWINAX RM2589-001 MIL-C-39029/95 AND /96 MIL-C-39029/95 AND /96
TWINAX SSQ NDBC- MIL-C-39029/95 AND /96 MIL-C-39029/95 AND /96
TFE-22-2SJ-75
NOTES:
1. Conditioning includes thermal cycling, accelerated aging and temperature differential tests.
6-8
Table 6-13 QUALIFICATION INSPECTION (CONTACTS)
Requirement Test Number of

Examination or Test Paragraph Method Samples
Visual and Mechanical Appendix II Inspection Note 1
Inspection
Weight Appendix II Inspection Note 1
Contact Resistance 3.2.1.1 4.8.1 Note 1
Contact Separation Force 3.2.2.4 4.8.8 Note 1
Termination Tensile Strength 3.3.22f 4.8.23 Note 1
Finish Thickness 3.3.22d MIL-C-39029 Note 1
para. 4.7.18.1
TWX Qualification inspection 4.8.23.1 Note 1
Accelerated aging 3.2.3.4.2a 4.8.14.2 Note 1
3.2.3.4.2b 4.8.14.2
Note:
1. Ten contacts of size 12 and smaller, four TWX contacts, and four contacts of size 8
and larger shall be submitted for qualification inspection.
6-9
Table 6-14 QUALIFICATION INSPECTION (PLUG AND RECEPTACLE) 1
Examination or Test Requirement Paragraph Test Method

Final inspection 4.7.4 Table 6-17
Concentric Twinax Grounding 3.2.1.5 4.8.5
Contact retention 3.2.2.5 4.8.9
Contact Insertion/Removal Force 3.2.2.8 4.8.12
Humidity 3.2.5.1.2b 4.8.15
Moisture and Fungus Resistance 3.3.1.9 4.8.20
DWV 3.2.1.2 4.8.2a
Insulation Resistance 3.2.1.3a 4.8.3a
Vibration 3.2.5.2.4 4.8.18
DWV 3.2.1.2 4.8.2a
Shock 3.2.5.1.4 4.8.16
DWV 3.2.1.2 4.8.2a
Salt spray (corrosion) 3.2.5.1.5 4.8.17
Insert Retention 3.2.2.6 4.8.10
Insert Bond Integrity 3.2.2.7 4.8.11
Surface Outgassing 3.3.1.14 ASTM-E-595
Flammability (Note 2) 3.3.1.15 Test 1or 10 NHB 8060.1
Toxicity (Note 2) 3.3.1.16 Tests 6 & 7, NHB 8060.1
EVA Dummy Connectors Axial 3.3.23.2.1 b and d 4.8.24
Installation / Removal Force
NOTES:
1. One plug and one receptacle of insert arrangement type A, C, E, J and K shall be submitted for
qualification inspection.
2. Connector non-metallic insert assemblies used in connector assembly shall be subjected to the test.
3. The backshells to be used are as follows:
Part No SSQ22680-10-007 Backshells or equivalent with Type A connectors
Part No SSQ22680-10-010 Backshells or equivalent with Type C connectors
Part No SSQ22680-10-008 Backshells or equivalent with Type E connectors
Use EMI Backshell configurations for type J connectors
Backshell configurations for type K connectors are optional
6-10
Table 6-15 ORU CONNECTOR QUALIFICATION INSPECTION (MATED PAIR)
Examination Requirement Test Connector Type Test Samples (Note 1)

And Test Paragraph Method A C D E F G
Final Inspection 4.7.4 Table XV 1 2 3 4 1 2 3 1 1 2 3 1 2 3 1 2 3
Actuation Force 3.3.10 4.8.22a 1 1 1 1 1 1
to Mate or
Demate
Contact 3.3.18h, i 4.8.22a 1 1 1 1 1 1
alignment
Angular Connect 3.3.8 4.8.22a 1 1 1 1 1 1
and Disconnect
Non-Magnetic 3.3.1.7 3006, 1
Materials MIL-STD
-1344
Vibration 3.2.5.2.4 4.8.18 1 1 1 1 1 1
DWV 3.2.1.2 4.8.2a 1 1 1 1 1 1
Insulation 3.2.1.3a 4.8.3a 1 1 1 1 1 1
Resistance
Shell to Shell 3.2.1.4 4.8.4a 1 1 1 1 1 1
Conductivity
Shock 3.2.5.1.4 4.8.16 1 1 1 1 1 1
DWV 3.2.1.2 4.8.2a 1 1 1 1 1 1
Insulation 3.2.1.3a 4.8.3a 1 1 1 1 1 1
Resistance
Shell to Shell 3.2.1.4 4.8.4a 1 1 1 1 1 1
conductivity
Durability 3.2.2.9 4.8.13 1 1 1 1
Connector 3.2.1.6 4.8.6 2
Rating
Connector 3.2.1.7 4.8.7 1 1
De-mating
Under Electrical
Load
DWV 3.2.1.2 4.8.2b 2 2
Insulation 3.2.1.3b 4.8.3b 2 2

Resistance
6-11
Table 6-15 ORU CONNECTOR QUALIFICATION INSPECTION (MATED PAIR), (continued)
Examination Requirement Test Connector Type Test Samples (Note 1)

And Test Paragraph Method A C D E F G
1 2 3 4 1 2 3 1 1 2 3 1 2 3 1 2 3
Accelerated 3.2.3.4.1a 4.8.14.1 3 2
Aging (Note 1) 3.2.3.4.1b 4 3
Thermal 3.2.5.2.9 4.8.19 3 1
Cycling
vacuum
conditions
Ozone 3.3.1.10 1007.1, 1
Exposure MIL-
STD-1344
Electromagnetic 3.3.2.1 4.8.21.1 2 2
Interference 3.3.2.2 4.8.21.2 3 3
NOTES:
1. The backshells to be submitted for mated pair qualification test as follows:
SSQ22680-10-007 backshells or equivalent with Type A connectors
SSQ22680-10-010 backshells or equivalent with Type C connectors
SSQ22680-10-010 backshells or equivalent with Type D connectors
SSQ22680-10-008 backshells or equivalent with Type E connectors
SSQ22680-10-009 backshells or equivalent with Type F and G connectors
6-12
Table 6-16 FRAM CONNECTORS QUALIFICATION INSPECTION

(MATED PAIR)
Connector Type Test

Examination Requirement Test
Samples (Note 1)
or Test Paragraph Method J K
Final Inspection 4.7.4 Table 6-17 1 2 3 1 2 3
Vibration 3.2.5.2.4.2 4.8.18 1 1
Durability 3.2.2.9 4.8.13 1 1
Actuation Force 3.3.10.1 4.8.22a,c 2 2
to Mate or De-
mate
Thermal Cycling 3.2.5.2.8.2 4.8.19 2 2
Differential 3.3.10.2 4.8.22c 3 3
Temperature
Final Inspection 4.7.4 Table 6-17 1 2 3 1 2 3
Notes:
1. EMI type backshell configurations used for type J connectors.
2. Backshell configurations for type K connector are optional.
Table 6-17 FINAL INSPECTION
Examination or Test Requirement Verification Method

Paragraph
Visual and mechanical
inspection:
Physical dimensions Figure 6-1 Inspection
Figure 6-2
Marking 3.3.3 Inspection
Workmanship 3.3.4 Inspection
Weight 3.2.2.1 Inspection
Actuation force to mate or de- 3.3.10.1 4.8.22b
mate
DWV 3.2.1.2 4.8.2a
Shell to shell conductivity 3.2.1.4 4.8.4b
6-13
Table 6-18 REQUIREMENT/INSPECTION CROSS REFERENCE
Requirement Inspection Method

Requirement Title N/A Examination Analysis Test Test Method
3.1 Item Definition X
3.1.1 Part Number X
3.1.2 Connector Identification X
3.1.3 Appendix Description X
3.2 Characteristics X
3.2.1 Electrical Performance X
3.2.1.1 Contact Resistance X 4.8.1
3.2.1.2 Dielectric Withstanding X 4.8.2
Voltage
3.2.1.3 Insulation Resistance X 4.8.3
3.2.1.4 Shell to Shell X 4.8.4
Conductivity
3.2.1.5 Size 8 Concentric X 4.8.5
Twinax Cavity
Grounding
3.2.1.6 Connector Current X 4.8.6
Rating
3.2.1.7 Connector Demating X 4.8.7
Under Electrical
Stress
3.2.2 Physical Characteristics X
3.2.2.1 Weight X
3.2.2.2 Center of Gravity X
3.2.2.3 Connector Mating X
Sequence
3.2.2.4 Contact Separation X 4.8.8
Force
3.2.2.5 Contact Retention X 4.8.9
3.2.2.6 Insert Retention X 4.8.10
3.2.2.7 Insert Bond Integrity X 4.8.11
3.2.2.8 Contact Insertion and X 4.8.12
Removal Force
6-14
TABLE 6-18 REQUIREMENT/INSPECTION CROSS REFERENCE (Continued)

3.2.2.9 Durability X 4.8.13
3.2.3 Reliability X
3.2.3.1 Mean Time Between X
Failure (MTBF)
3.2.3.2 Design Life X
3.2.3.3 Storage Life X
3.2.3.4 Accelerated Aging X 4.8.14
3.2.3.4 Contact Twinax X 4.8.14.2
Accelerated Aging
3.2.4 Maintainability X
3.2.5 Environmental X
Conditions
3.2.5.1 Ground Environment X
3.2.5.1.1 Temperature X
3.2.5.1.2 Humidity X X 4.8.15
3.2.5.1.3 Pressure X
3.2.5.1.4 Shock X 4.8.16
3.2.5.1.5 Salt Spray (Corrosion) X 4.8.17
3.2.5.2 Launch and Orbit X
Environment
3.2.5.2.1 Temperature X
3.2.5.2.2 Humidity X
3.2.5.2.3 Pressure X X 4.8.2b
3.2.5.2.4 Random Vibration X 4.8.18
3.2.5.2.5 Atomic Oxygen X
3.2.5.2.6 Radiation X
3.2.5.2.7 Plasma X X 4.8.2b
3.2.5.2.8 Thermal Cycling X 4.8.19
Vacuum
Conditions
6-15

3.3.1.5 Nonmetallic Materials X
3.3.1.6 Processes X
3.3.1.7 Non-Magnetic Materials X MIL-STD-
1344
METHOD
3006
3.3.1.8 Dissimilar Metals X
3.3.1.9 Moisture and Fungus X X 4.8.20
Resistance
3.3.1.10 Ozone Exposure X MIL-STD-
1344,
METHOD
1007.1
3.3.1.11 Manufacturing and X
Inspection Contamination
Control
3.3.1.12 Corrosion Prevention X
and Control
3.3.1.13 Cleanliness X
3.3.1.14 Surface Outgassing X ASTM-E-595
3.3.1.15 Flammability X NHB8060.1,
TEST 6 OR 7
3.3.1.16 Toxicity X NHB8060.1,
TEST 6 & 7
3.3.2 Electromagnetic X
Interference
3.3.2.1 EMI Transfer Impedance X 4.8.21.1
(10 MHz to 100 MHz)
3.3.2.2 EMI Shielding Effectiveness X 4.8.21.2
(100 MHz to 10 GHz)
3.3.3 Identification and X
Product Marking
3.3.3.1 Connector and X
Accessories Marking
6-16

3.3 Design and Construction X
3.3.1 Materials, Processes, and X
Parts
3.3.1.1 Process Specification X
3.3.1.2 Controlling Documents X
3.3.1.3 Special Material Problems X
3.3.1.4 Metal X
3.3.3.2 Contact Location X
Identification
3.3.4 Workmanship X
3.3.5 Interchangeability X
3.3.6 Safety X X
3.3.6.1 Mechanical Safety X
Criteria
3.3.7 Polarization X X
3.3.8 Angular Connect and X X 4.8.22a
Disconnect Capability
3.3.9 Contact Protection, X
Connector Mating
(Scope Proof)
3.3.10 Actuation Force to X 4.8.22
Mate or Demate
3.3.11 Shell Design X X
3.3.12 Shell Material X
3.3.13 Finish X
3.3.14 Backshell X
3.3.14.1 Backshell Material X
3.3.15 Insert Face Seal X
3.3.16 Wire Sealing Member X
(Rear Grommet)
3.3.17 Grommet Sealing Plugs X
6-17

3.3.18 Inserts X
a X
b X
c X
d X
e X
f X
h X 4.8.25
g X
h X 4.8.22a
i X 4.8.22a
j X
k X
3.3.19 EMI Spring X X
3.3.20 Threads and Fasteners X
3.3.21 Fastener Torque X
3.3.22 Contacts X
a X
b X
c X
d X X MIL-C-39029
Par. 4.7.18.1
e X
f X 4.8.23
g X
h X
3.3.23 Connector Use Accessories X
3.3.23.1 Protective Covers
a X 4.8.15, 4.8.20
6-18

b X
c X
d X
e X
f X
g X
3.3.23.2 Dummy Connectors X
3.3.23.2.1 EVA Friendly Dummy X
Connectors
a X
b X 4.8.24
c X 4.8.24b
d X 4.8.24
e X 4.8.22a
f X
g X
3.3.23.2.1 Blind Mate Dummy X
Connectors
a X
b X X 4.8.18
c X
d X
e X
6-19
Table 6-19 Optical Performance Requirements
Item No Optical Performance Requirement dB
1 Unstressed mean 0.83
2 Unstressed Standard Deviation 0.33
3 Stressed mean 1.10
4 Stressed Standard Deviation 0.36
5 Maximum change in Induced Loss Measurements 0.40
6 Maximum change in Induced Before and After 0.30

Measurements
7 Maximum change in Substitution Loss Measurements 0.40
6-20
Figure 6-1 Contact Resistance
6-21
Figure 6-2 Physical Envelope Connector Plug, Shell Size 1
6-22
Figure 6-3 Physical Envelope Connector Receptacle, Shell Size 1
6-23
Figure 6-4 Physical Envelope Plug, Shell Size 2
6-24
Figure 6-5 Physical Envelope Connector Receptacle, Shell Size 2
6-25
Figure 6-6 Physical Envelope for Connector Plug, Shell Size 1, FRAM
6-26
Figure 6-7 Physical Envelope for Connector Receptacle, Shell Size 1, FRAM
6-27
Figure 6-8 Plug Receptacle Mated Configuration
6-28
Figure 6-9 Contact Insert Arrangement A
6-29
Figure 6-10 Contact Insert Arrangement B
6-30
Figure 6-11 Contact Insert Arrangement C
6-31
Figure 6-12 Contact Insert Arrangement D
6-32
Figure 6-13 Contact Insert Arrangement E
6-33
Figure 6-14 Contact Insert Arrangement F
6-34
Figure 6-15 Contact Insert Arrangement G
6-35
Shell Size Arrangement Number of Contact Contact Barrel Symbol

Type Contacts Mating End Size
Size
2 8 8
1 J 2 Fiber Optic 16
230 22 22
Notes:
1. Front face of the plug insert shown, receptacle opposite
2. Installation of two size 8 contacts is mandatory for proper plug to receptacle alignment.
Figure 6-16 Contact Insert Arrangement J
6-36
FRONT FACE OF PLUG INSERT SHOWN, RECEPTACLE OPPOSITE
SHELL ARRANGE NUMBER CONTACT CONTACT SYMBOL

SIZE MENT OF MATING BARREL
TYPE CONTACT END SIZE SIZE
S
6 8 8
1 K
40 12 12
42 20 20
Notes: Installation of two size 8 contacts, cavities 44 and 45 is mandatory for proper plug to receptacle alignment.
Figure 6-17 Contact Insert Arrangement K
6-37
Figure 6-18 Test Pins
6-38
P, G^2/Hz
Figure 6-19 Random Vibration (for Table 6-2 ORU Class Connector(s) Classification)
Figure 6-20 Random Vibration (for Table 6-3 FRAM Connector(s) Classification)
6-39
Figure 6-21 Transfer Impedance Measurement
6-40
Figure 6-22 Shielding Effectiveness Measurement
6-41
Figure 6-23 Test Circuits
6-42
I.
APPENDIX I BACKSHELLS
I-1
10.0 Appendix I
10.1 Scope
This Appendix covers connector backshells for electrical connectors conforming to SCD SSQ22680.
10.2 Part Numbers
The backshells shall be in accordance with Table 10-1 and shall be ordered by their part numbers
only. The part number shall have the following form:
SSQ22680-10-XXX
SSQ22680 Is the SSQ specification identifier for ORU connector family
and related accessories.
-10 Is the backshell identifier.
XXX Is the backshell part number per Table 10-1.
10.3 Applicable Documents
documents referenced herein and contents of this document, this document shall take precedence.
SPECIFICATION
SSQ22680 Connectors, Rectangular, (ORU)
10.4 Requirements
Unless otherwise specified, all connector provisions and requirements of SSQ22680, Paragraph 3
apply to this Appendix.
10.5 Physical characteristics
10.5.1 Weight
The maximum weight of each backshell shall be in accordance with Table 10-1.
10.5.1.1 Physical Envelope
The length of the protruding threads on the strain relief screws shall be limited to 3 threads
maximum when backshells are exposed to EVA.
10.5.1.2 Strain Relief Screw Length
Physical Envelope of each backshell shall be in accordance with Figures 10-1 through 10-10.
10.6 Quality Assurance Provisions
Unless otherwise specified, all applicable requirements of SSQ22680, Paragraph 4 apply to this
Appendix.
I-2
10.7 Preparation for Delivery

Unless otherwise specified, all applicable requirements of SSQ22680, Paragraph 5 apply to this
Appendix.
Table 10-1 BACKSHELL CROSS REFERENCE
Backshell Backshell Exit Hole Size Weight Figure

Part Number Type (REF
Only)
Rect. Round
SSQ22680-10-001 90, Power RE 1 .24 Fig. 10-1
SSQ22680-10-002 Straight RE 1 .18 Fig. 10-2
SSQ22680-10-003 90, EMI R 1 .31 Fig. 10-3
SSQ22680-10-004 Straight, EMI R 1 .25 Fig. 10-4
SSQ22680-10-005 90, EMI R 2 .28 Fig. 10-5
SSQ22680-10-006 Straight, Round, R 2 .22 Fig. 10-6

EMI
SSQ22680-10-007 45, Power RE 1 .21 Fig.10-7
SSQ22680-10-008 30, EMI R 1 .28 Fig.10-8
SSQ22680-10-009 30, EMI R 2 .26 Fig.10-9
SSQ22680-10-010 Straight Power RE 1 .21

SSQ22680-10-011 Strain Relief, R 1 Note 1
EMI Nut, Size 1
SSQ22680-10-012 Strain Relief, R 2 Note 2
EMI Nut, Size 2
SSQ22680-10-014 Straight, EMI R 1
Note 3
NOTES:
1. Identified as a strain relief in Figures 10-3, 10-4, and 10-8.
2. Identified as a strain relief in Figures 10-5, 10-6, and 10-9.
3. Backshell to be used with SSQ22680-019 and SSQ22680-021 only.

Only the item described on this drawing when procured from the vendor(s) is approved by
the NASA Space Station Program Office for use in the application(s) specified. A substitute
item shall not be used without prior approval by the NASA Space Station Program Office.
Identification of the approved source(s) of supply is not to be construed as a guarantee of
present or continued availability as a source of supply for the item described on the drawing.
I-3
Table 10-2 BACKSHELL APPROVED SOURCE(S) OF SUPPLY
Approved Source(s) of Supply

SSQ22680 Part Number Cooper Industries Smiths Connectors
(formerly G&H Technology) (formerly Sabritec)
Part Number 1 Part Number 2
SSQ22680-10-001 1089-610-001 S070012-0000
SSQ22680-10-002 1089-620-001 S070012-0006
SSQ22680-10-003 1089-630-001 S070012-0013
SSQ22680-10-004 1089-640-001 S070012-0007
SSQ22680-10-005 1089-650-001 S070012-0007.5
SSQ22680-10-006 1089-660-001 S070012-0008
SSQ22680-10-007 1089-670-001 S070012-0009
SSQ22680-10-008 1089-680-001 S070012-0010
SSQ22680-10-009 1089-690-001 S070012-0011
SSQ22680-10-010 1089-695-001 S070012-0012
SSQ22680-10-011 S070012-0016
SSQ22680-10-012 TBD
SSQ22680-10-014 1089-665-001
NOTE:
1. Cooper Industries Inc (formerly G&H Technology), 750 W. Ventura Blvd, Camarillo, CA 93010, (805) 389-
5781, Cage Code 99447
2. Smiths Connectors (formerly Sabritec), 1550 Scenic Ave, Suite 150 Costa Mesa, CA 92626 (714) 371-1100,
Cage Code 58795
I-4
Figure 10-1 Backshell Rectangular, 90, Power, Size 1
I-5
Figure 10-2 Backshell Rectangular, Straight, Power, Size 1
I-6
Figure 10-3 Backshell, Round, 90, EMI, Size 1
I-7
Figure 10-4 Backshell, Round, Straight, EMI, Size 1
I-8
I-9
Figure 10-6 Backshell, Round, Straight, EMI, Size 2
I-10
Figure 10-7 Backshell, Rectangular, 45, Power, Size 1
I-11
Figure 10-8 Backshell, Round, 30 , EMI, Size 1
I-12
I-13
Figure 10-10 Backshell, Round, Straight, Size 1, FRAM, Plug
I-14
II.
APPENDIX II
CONTACTS, ELECTRICAL CONNECTOR,
CRIMP, REMOVABLE
II-1
20.0 Appendix II
20.1 Scope
This appendix covers connector contacts for electrical connectors conforming to SCD SSQ22680.
20.1.1 Contact Part Numbers
Contacts shall be of the following part numbers, and shall be ordered by their part numbers only.
SSQ22680-20-XX-XXX-X, where:
SSQ22680 Is the SSQ specification identifier for ORU connector family and related accessories.
-20 Is the SSQ specification identifier for removable, crimp termination electrical
contacts as follows:
-XX Is the contact size per applicable figure (single digit used for contact size 4 and
larger) except for concentric Twinax which shall be identified by CT.
-XX (first two characters) Is the wire gauge the contact terminates to (single digit used for
wire gauges 4 and larger) except for concentric Twinax which shall have no
identifier.
X (third character) Is the contact type:
P - pin contacts.
S - socket contacts.
-X Contact configuration identifier, applicable only when a class 1 change is
incorporated.
SPECIFICATION
SSQ22680 Connectors, Rectangular, (ORU)
MIL-STD-105 Sampling Procedures and Tables for Inspection by Attributes
20.3 Requirements
Unless otherwise specified, all connector provisions and requirements of SSQ22680, paragraph 3
applies to this appendix.
20.3.1.1 Weight
The maximum weight of each contact type shall be in accordance with applicable figure of this
Appendix.
II-2

Physical Envelope of each contact type shall be in accordance with applicable figures of this
Appendix.
20.3.2 Marking
Each contact shall be permanently and legibly marked with the manufacturers symbol or trademark
and three color bands identifying the contact to a specific contact size and wire gauge the contact
terminates to in accordance with applicable figure of this Appendix. The package marking shall be
in accordance with paragraph 5.3 of SSQ22680 and appropriate nomenclature, as specified in Table
20-2.
Unless otherwise specified, all requirements of SSQ22680, Paragraph 4 apply to this Appendix
where applicable.
20.4.1 Final Inspection
20.4.1.1 Inspection Lot

An inspection lot shall consist of all contacts of the same parts number produced under the same
conditions, and offered for inspection at one time.
20.4.1.2 Inspection of Contacts for Delivery
As a minimum, each lot of product shall be inspected in accordance with Table 20-3.
20.4.1.3 Sampling Plan
Statistical sampling and inspection shall be in accordance with MIL-STD-105 for general Level II.
Unless otherwise specified, all requirements of SSQ22680, Paragraph 5 apply to this Appendix.
Only the item described on this drawing when procured from the vendor(s) is approved by the
NASA Space Station Program Office for use in the application(s) specified. A substitute item shall
not be used without prior approval by the NASA Space Station Program Office. Identification of the
approved source(s) of supply is not to be construed as a guarantee of present or continued
availability as a source of supply for the item described on the drawing.
II-3
Table 20-1 CONTACTS APPROVED SOURCE(S) OF SUPPLY
Part Number ITT Cannon Cooper Industries Trompeter Smiths Connector

Manufacturer (formerly G&H Manufacturer Manufacturer Part
3,5 4,5
Part Technology) Part Number Number
Number
1,5 Manufacturer Part
2,5
Number
SSQ22680-20-0-0P 1089-961-002 S102-2008-300
SSQ22680-20-0-0S 1089-1041-001 S126-0230-000
SSQ22680-20-0-4P S102-2009-300
SSQ22680-20-0-4S S126-0249-000
SSQ22680-20-4-4P S102-2010-300
SSQ22680-20-4-4S 1089-1043-001 S126-0231-000
SSQ22680-20-8-8P S102-2477-300
8
S22681-56-8-8 S126-0176-300
SSQ22680-20-12-12P 1089-965-001 S102-2011-300
SSQ22680-20-12-12S 1089-1171-001 S126-0232-000
SSQ22680-20-12- 1089-1171-001
12S-1
SSQ22680-20-12-16P S102-2012-300
SSQ22680-20-12-16S-1 1089-1172-001
SSQ22680-20-16-16P 1089-1087-001 S102-2013-300

7
SSQ22680-20-16-16S 1089-1073-001 S126-0233-000
SSQ22680-20-16-16S-1 1089-1173-001 S126-0347-000
SSQ22680-20-20-20P 1089-967-001 S102-2014-300

7
SSQ22680-20-20-20S 1089-1074-001 S126-0234-000
SSQ22680-20-20-20S-1 1089-1174-001 S126-0346-000
SSQ22680-20-22-22P 1089-968-001 S102-2015-300
SSQ22680-20-22-22S-1 1089-1175-001 S126-0345-000

7
SSQ22680-20-22-22S 1089-1075-001 S126-0235-000
SSQ22680-20-CTP 1089-964-001 305-0864-1

6
SSQ22680-20-CTS 1089-974-002 305-0864-3
6
SSQ22680-20-CTS-1 1089-974-003 305-0864-5
6
SSQ22680-20-CTS-2 1089-1164-001 305-0864-7
9
NRP-F-16P 031-9704-003
II-4
9
NRP-F-16S 031-9705-003
NOTES:
1. ITT Cannon, 666 E Dyer Road, Santa Ana, CA 92705, Cage Code 71468
2. Cooper Industries Inc. (formerly G&H Technology), 750 W. Ventura Blvd., Camarillo, CA 93010, (805) 484-
0543, Cage Code 99447.
3. Trompeter Electronics Inc., 299 Johnson Ave, Waseca, MN, 56093, (507) 833-8822, Cage Code 14949.
4. Smiths Connectors (formerly Sabritec) 1550 Scenic Ave, Suite 150 Costa Mesa, CA 92626 714-371-1100, Cage
Code 58795.
5. Approved sources of supply part numbers are given for reference only.
6. SSQ22680-20-CTS and SSQ22680-20-CTS-1 are obsolete for new procurement and is replaced with
SSQ22680-20-CTS-2.
7. Noted contact socket configurations are obsolete for new procurement and replaced with SSQ22680-20-XX-
XXS-1 matching configurations.
8. Noted Contact part numbers are originated in SSQ22681 Connector Specification.
Table 20-2 CONTACT NOMENCLATURE
Contact Part Number Contact Nomenclature
SSQ22680-20-0-0P Size 1/0 Crimp Pin Contact
SSQ22680-20-0-0S Size 1/0 Crimp Socket Contact
SSQ22680-20-0-4P Size 1/0 Crimp Pin Contact with 4 crimp barrel
SSQ22680-20-0-4S Size 1/0 Crimp Socket Contact with 4 crimp barrel
SSQ22680-20-4-4P Size 4 Crimp Pin Contact
SSQ22680-20-4-4S Size 4 Crimp Socket Contact

3
S22681-56-8-8 Size 8 Crimp Socket Contact

2
SSQ22680-20-12-12S-1 Size 12 Crimp Socket Contact
SSQ22680-20-12-16P Size 12 Crimp Pin Contact with 16 crimp barrel

2
SSQ22680-20-12-16S Size 12 Crimp Socket Contact with 16 crimp barrel
SSQ22680-20-12-16S-1 Size 12 Crimp Socket Contact with 16 crimp barrel

2

2
II-5

2
SSQ22680-20-CTP Size 8 Crimp Concentric Twinax Pin Contact

1
SSQ22680-20-CTS Size 8 Crimp Concentric Twinax Socket Contact
1
SSQ22680-20-CTS-1 Size 8 Crimp Concentric Twinax Socket Contact
1
SSQ22680-20-CTS-2 Size 8 Crimp Concentric Twinax Socket Contact
4
NRP-F-16P Size 16 Pin Fiber Optic Terminus
4
NRP-F-16S Size 16 Socket Fiber Optic Terminus
NOTES:
1. SSQ22680-20-CTS and SSQ22680-20-CTS-1 are obsolete for new procurement and is replaced with
SSQ22680-20-CTS-2.
2. Noted contact socket configurations are obsolete for new procurement and replaced with SSQ22680-20-XX-
XXS-1 matching configurations.
Table 20-3 FINAL INSPECTION (CONTACTS)

Examination or Test Requirement Test Number of
Paragraph Method Samples
Visual and Mechanical Inspection: 20.4.1
Physical Envelope 20.3.1.2 Inspection
Marking 20.3.2 Inspection
Workmanship 3.3.4 Inspection
Contact Resistance 3.2.1.1 4.8.1a 20.4.1
Contact Separation Force 3.2.2.4 4.8.8 20.4.1
Tensile Strength 3.3.22f 4.8.23.2 20.4.1
II-6
Figure 20-1 Contact, Electrical Connector, Socket, Crimp Type (Sizes 0,4)
II-7
Figure 20-2 Contact, Electrical Connector Socket, Crimp Type Dimensions (Size 0, 4)
II-8
Figure 20-3 Contact, Electrical Connector Socket, Crimp Type, (Sizes 22 to 12)
II-9
CONT CONT WIRE MATING A B C D E F G H I J K L

SIZE STL BARREL TEST PIN REF DIA DIA MIN .005 DIA DIA DIA MIN MIN
DIA DIA
-A- -B-
12 #12 .095 .182 .161 .100 .102 .151 .322

.093 .179 .158 .042 .098 .148 .088 .048
.880 .646 .036 .082 .044 .209
12 #16 .095 .182 .161 .100 .068 .103 .322
CRIMP POWERED
.093 .179 .158 .066 .101
16 #16 .0635 .1314 .113 .067 .068 .103 .263

.0615 .1299 .110 .066 .101
20 #20 .041 .1014 .078 .043 .032 .048 .070 .078 .260
.039 .0999 .076 .026 .046 .068 .072
22 #22 .0305 .870 .0704 .062 .033 .0636 .022 .0355 .048 -- .032 .141 .260
.0295 .0689 .060 .018 .0335 .046 .029
CONT WIRE BARREL U MIN DIA COLOR BANDS WGT (OZ)

SIZE
7 MAX
1ST 2ND 3RD 4TH 9
12 12 .118 RED ORANGE ORANGE BROWN .052
12 16 .118 RED ORANGE RED BROWN .052
16 16 .084 RED RED RED BROWN .032
20 20 .053 RED BROWN BROWN BROWN .015
22 22 .047 RED BLACK BLACK BROWN .009
The 4TH Band identifies SSQ22680-20-XX-XXX-1 configurations Shall Meet Contact

Separation Force IAW SSQ 22680 Par 3.2.2.4
.003 RAD. max. for all contact sizes
Minimum Dia. of hood lead-in
Hoods where used shall not exceed Dia. C (RFS)

5 All corners and fillet radii are .005 max
4 Point of first electrical engagement with a square nosed pin with a Dia. Within.0002 of the mating pin min. Dia
3 All diameters .005 A

2 All dimensions apply after plating
1 All dimensions are in inches
Notes: Unless otherwise specified
Figure 20-4 Contact, Electrical Connector, Socket, Crimp Type Dimensions, (Sizes 22 to 12)
II-10
Figure 20-5 Contact, Electrical Connector, Pin, Crimp Type (Size 0, 4)
II-11
Figure 20-6 Contact, Electrical Connector, Pin, Crimp Type, Dimensions, (Sizes 0, 4)
II-12
Figure 20-7 Contact, Electrical Connector, Pin, Crimp Type, (Sizes 22 to 12)
II-13
Figure 20-8 Contact, Electrical Connector, Pin, Crimp Type, Dimensions, (Sizes 22 to 12)
II-14
Figure 20-9 Contact, Electrical Connector, Socket, Crimp Type Concentric Twinax,
Size 8, Part No. SSQ22680-20-CTS
II-15
Figure 20-10 Contact, Electrical Connector, Socket, Crimp Type Concentric Twinax, Size 8
II-16
Figure 20-11 Contact, Electrical Connector, Pin, Crimp Type Concentric

Twinax, Size 8
II-17
Figure 20-12 Contact, Electrical Connector, Pin, Crimp Type

Concentric Twinax, Size 8
II-18
Figure 20-13 Contact, Electrical Connector, Socket, Crimp Type

Concentric Twinax, Size 8, Part No. SSQ22680-20-CTS-2
II-19
Figure 20-14 Contact, Electrical Connector, Socket, Crimp Type, Concentric Twinax,
Size 8, Part No. SSQ 22680-20-CTS-2
II-20
Figure 20-15 Contact, Electrical Connector, Pin, Crimp Type (Size 8)
C
CONTACT WIRE A B E F G H K 1ST 2ND 3RD
DIA I J
SIZE BARREL REF DIA +.005 DIA DIA DIA MIN BAND BAND BAND
-A-
.303 .1409 .865 .069 .180 .262 .044
8 #8 1.37 .486 .486 RED YELLOW YELLOW
.305 .1426 .875 .072 .183 .264 .047
Figure 20-16 Contact, Electrical Connector, Pin, Crimp Type (Size 8) Dimensions
II-21
Figure 20-17 Contact, Electrical Connector Socket, Crimp Type (Size 8)
Figure 20-18 Contact, Electrical Connector Socket, Crimp Type Dimensions (Size 8)
II-22
.574 .483
RED
.571 .473
BEFORE POLISHING BLUE
.141 .048 VIOLET

.135 .044
R .005 MAX .091

.038 .086
.020 R .055
.045
.06252 .363 .021

.06240 .0635
.347 .015
.0615
0.1750 mm .103 .130
0.1725 .127 .048
.101
.042
PIN ALIGNMENT TIP
.011 .103
R
.008 .101
.036 MIN
.008 .085
.002 .045
SHRINK SLEEVE
AS SUPPLIED
Figure 20-19 CONTACT, ELECTRICAL, CONNECTOR, FIBER OPTIC SIZE 16
COMPUTERSCALE: 4/1 DRAWING
GENERATED
D6FOPIN.DC2
SOCKET TERMINI
D6OPIN.DW2
II-23
1.160
1.115
WITH ALIGNMENT SLEEVE
ASSEMBLY INSTALLED
(FREE STATE)
RED
.194 BEFORE .420
.192 POLISHING BLUE
.400
(FREE STATE) VIOLET
.048
.108 .044
.102 .091
.011 .130 .086
R
.008 .127
.06252 .342 .021

.06240 .330 .015
.038 .114
R .005 MAX .048
.020 MAX
.042
O.D. OVER
SPRING
0.1750 mm (FREE STATE) COMPRESSION SPRING
.103
0.1725 .101
2-64 UNF-3A THREADS
.050 MIN FULL THREAD
SOCKET ALIGNMENT TIP
.020
4X
.010
.010
R
.004 .038
4X .036 MIN
.032
.112
.110
.100 .112
2X
.096 WRENCH FLATS .098
.277
.275 .008 .085
.002 .045
MATING END
ALIGNMENT SLEEVE ASSEMBLY SHRINK SLEEVE

(SHIPPED LOOSE PIECE) AS SUPPLIED
SCALE: 4/1
Figure 20-19 (Cond) CONTACT, ELECTRICAL, CONNECTOR, FIBER OPTIC SIZE 16

COMPUTER GENERATED DRAWING
D6FOPIN.DC2
D6FOSKT.DW2
SOCKET TERMINI
II-24
Figure 20-20 Contact, Electrical Connector, Socket, Crimp Type, Size 12, SSQ22680-20-12-12S-1
II-25
II-26
Figure 20-25 Contact, Electrical Connector, Socket, Crimp Type Concentric Twinax,
Size 8, SSQ22680-20-CTS-2
II-27
III. APPENDIX III

CONNECTOR USE ACCESSORIES
III-2
30.0 Appendix III
30.1 Scope
This Appendix covers connector use accessories for electrical connectors conforming to SCD
SSQ22680.
30.1.1 Part numbers
Connector use accessories shall be in accordance with Table 30-1 and shall be ordered by their part
numbers only. The part number shall have the following form:
SSQ22680-30-XXX
SSQ22680 Is the SSQ specification identifier for ORU connector
family and related accessories.
-30 Is the connector use accessories identifier
-XXX Is the connector use accessories part number per Table 30-1.

SPECIFICATION
SSQ 22680 Connectors, Rectangular, (ORU)
30.3 Requirements
Unless otherwise specified, all connector provisions and requirements of SSQ 22680, Paragraph 3
apply to this Appendix.
30.3.1.1 Weight
The maximum weight of each Connector use accessory shall be in accordance with Table 30-1
Physical Envelope of each connector use accessory shall be in accordance with Figures 30-1 through
30-15.
III-3
Table 30-1 CONNECTOR ACCESSORY CROSS REFERENCE
Connector Weight
Accessory Part Connector Accessory Type Size (Oz) (REF Fig.
Number Only)
SSQ22680-30-001 Protective Cover, Size 1, Plug 1 .06 Fig. 30-1
SSQ22680-30-002 Protective Cover, Size 1, Receptacle 1 .10 Fig. 30-2
SSQ22680-30-003 Protective Cover, Size 2, Plug 2 .03 Fig. 30-3
SSQ22680-30-004 Protective Cover, Size 2, Receptacle 2 .04 Fig. 30-4
SSQ22680-30-005 Blind Mate, Dummy Connector Size 1, 1 5.5 Fig. 30-5
Plug,
Receptacle,
Plug,
Receptacle,
SSQ22680-30-009 Band, EMI Fig. 30-9
SSQ22680-30-011 ESD Protective Cover, Size 1, Plug 1 .06 Fig. 30-11
SSQ22680-30-012 ESD Protective Cover, Size 1, Receptacle 1 .10 Fig.30-10
SSQ22680-30-013 ESD Protective Cover, Size 2, Plug 2 .03 Fig. 30-11
SSQ22680-30-014 ESD Protective Cover, Size 2, Receptacle 2 .04 Fig.30-10
SSQ22680-30-015 EVA Friendly, Dummy Connector Size 1, 1 3.2 Fig. 30-12
Receptacle,
Receptacle,
Plug,
Plug,
III-4
30.6 Approved source(s) of supply

Only the item described on this drawing when procured from the vendor(s) is approved by the
NASA Space Station Program Office for use in the application(s) specified. A substitute item
shall not be used without prior approval by the NASA Space Station Program Office.
Identification of the approved source(s) of supply is not to be construed as a guarantee of
present or continued availability as a source of supply for the item described on the drawing.
Table 30-2 CONNECTOR USE ACCESSORY APPROVED SOURCE(S) OF SUPPLY

SSQ22680 Manufacturer Manufacturer Part Manufacturer Name
Part Number Cage Code Number (Reference and Address
Only)
SSQ22680-30-001 (Note 1) 99447 1089-950-001 Cooper Industries
(formerly G&H
Technology)
SSQ22680-30-002 (Note 1) 99447 1089-1050-001 750 W. Ventura Blvd.
SSQ22680-30-003 (Note 1) 99447 1089-950-002 Camarillo, CA 93110
SSQ22680-30-004 (Note 1) 99447 1089-1050-002 (805)484-0543
SSQ22680-30-005 58795 S109900-2007
SSQ22680-30-006 58795 S109900-3007 Smiths Connectors
(formerly Sabritec)
SSQ22680-30-007 58795 S109900-2008 1550 Scenic Avenue,
Suite 150
SSQ22680-30-008 58795 S109900-3008 Costa Mesa, CA 92626
SSQ22680-30-011 58795 S083300-2001 (714) 371-1100
SSQ22680-30-012 58795 S083300-3001
SSQ22680-30-013 58795 S083300-2002
SSQ22680-30-014 58795 S083300-3002
SSQ22680-30-015 58795 S109900-3005
SSQ22680-30-016 58795 S109900-3006
SSQ22680-30-017 58795 S109900-2009
SSQ22680-30-018 58795 S109900-2010
SSQ22680-30-009 06324 600-084 Glenair, Inc.
1211 Air Way,
Glendale, CA 91201
(818)247-6000
Notes:
1. Configurations are obsolete for new procurement.
III-5
Figure 30-1 Protective Cover, Size 1, Plug (P/N SSQ 22680-30-001) Non-ESD Cover
III-6
Figure 30-2 Protective Cover, Size 1, Receptacle (P/N SSQ22680-30-002)
III-7
Figure 30-3 Protective Cover, Size 2, Plug (P/N SSQ22680-30-003) Non-ESD Cover
III-8
Figure 30-4 Protective Cover, Size 1, Receptacle (P/N SSQ22680-30-004)
III-9
Figure 30-5 Blind Mate, Dummy Connector, Size 1, Plug, (P/N SSQ22680-30-005)
III-10
Figure 30-6 Blind Mate, Dummy Connector, Size 1 Receptacle

(P/N SSQ22680-30-006)
III-11
Figure 30-7 Blind Mate, Dummy Connector, Size 2, Plug,

(P/N SSQ22680-30-007)
III-12
Figure 30-8 Blind Mate, Dummy Connector, Size 1, Receptacle

(P/N SSQ22680-30-008)
III-13
Figure 30-9 EMI Band (P/N SSQ22680-30-008)
III-14
Notes
1. Protective cover P/N SSQ22680-30-012 may damage EMI spring and
therefore shall not be used.
Figure 30-10 ESD Protective Cover, Receptacle
III-15
Figure 30-11 ESD Protective Cover, Plug
III-16
Figure 30-12 EVA Friendly, Dummy Connector, Size 1, Receptacle

(P/N SSQ22680-30-015)
III-17
Figure 30-13 EVA Friendly, Dummy Connector Size 2 Receptacle

(P/N SSQ22680-30-016)
III-18
Figure 30-14 EVA FRIENDLY, DUMMY CONNECTOR, SIZE 1, PLUG

(P/N SSQ22680-30-017)
III-19
Figure 30-15 EVA Friendly, Dummy Connector Size 2 Plug

(P/N SSQ22680-30-018)
III-20
IV. APPENDIX IV
TOOLS, INSERTION AND REMOVAL, CRIMP CONTACTS
IV-1
40.0 Appendix IV
40.1 Scope
This appendix covers insertion and removal tools used in electrical connections
conforming to SCD SSQ22680.
40.1.1 Contact insertion and removal tool part numbers
Contact insertion and removal tools shall be in accordance with Table 40-1, and shall be
ordered by their part numbers only. The part numbers shall have the following form:
SSQ22680-40-XXXX
SSQ22680 Is the SSQ specification identifier for ORU connector
family and related accessories.
-40 Is the insertion and removal tool identifier.
-XX (First 2 characters) Is the contact size accommodated by the tool.
(Single digit used
for contact size 8 and larger.)
X (Third character) Is the material Identifier:
M - Metal
P - Plastic
X (Forth character) Is the type of the tool:
N - Insertion tool
E - Extraction tool
C - Combination insertion and extraction tool
The following documents of the exact issue shown form a part of this SCD to the extent
specified herein. The effective issue of those documents not specifically identified by
change letter or date shall be the latest issue in effect on the date of contract. In the event
of conflict between the documents referenced herein and contents of this document, this
document shall take precedence.
SPECIFICATION
MIL-I-81969 Installing and Removal Tools, Connector, Electrical Contact, General
Specification for
SSQ22680 Connectors, Rectangular, (ORU), Space Quality, General Specification for
40.3 Requirements
Unless otherwise specified, all applicable provisions and requirements of MIL-I-81969
and SSQ22680 pertaining to contact insertion and removal tools specified herein shall
apply to tools specified in this Appendix.
IV-2
40.3.1 Durability
The installation and removal tools shall perform their respective service function in
accordance with MIL-I-81969.
40.3.2 Insertion and Removal of Contacts Using Metal Tools
Insertion tools are not required for size 8 and larger contacts when attached to electrical
cable. However, removal tools are required for size 8 and larger in all instances. Size 12,
16 and 20 contacts must be inserted and removed with the appropriate tool. The tool size
22 contact is a multi-purpose insert/removal tool.
40.3.3 Quality Assurance Provisions
Unless otherwise specified, all requirements of MIL-I-81969, Paragraph 4 apply to this

Appendix.
Unless otherwise specified, all requirements of SSQ22680, Paragraph 5 apply to this
Appendix.
40.4.1 Tool Quantity
Metal tools, indicated with a SSQ22680-40-XXMX shall be ordered separately, as

needed by the end user.
Only the item described on this drawing when procured from the vendor(s) is approved
by the NASA Space Station Program Office for use in the application(s) specified. A
substitute item shall not be used without prior approval by the NASA Space Station
Program Office. Identification of the approved source(s) of supply is not to be construed
as a guarantee of present or continued availability as a source of supply for the item
described on the drawing.
IV-3
Table 40-1 CONTACT INSERTION AND REMOVAL TOOL APPROVED

SOURCE(S) OF SUPPLY
APPROVED SOURCE(S) OF SUPPLY3

SSQ22680 Manufacturer Cooper Industries Astro Tool
Part Number Cage Code (formerly G&H Corporation 2
Technology)
Manufacturer Part
Number 1
SSQ22680-40-0PE Notes 1, 2 1089-327-001
SSQ22680-40-0ME 1089-351-002 ATRD6586
SSQ22680-40-4PE Notes 1, 2 1089-327-002
SSQ22680-40-4ME 1089-352-002 ATRD6393
SSQ22680-40-8PE Notes 1, 2 1089-327-007
SSQ22680-40-8ME 1089-356-002 ATRD6289
SSQ22680-40-12PC Notes 1, 2 1089-327-003
SSQ22680-40-12ME 1089-353-001 ATRD6153
SSQ22680-40-12MN 1089-353-002 ATRD5153
SSQ22680-40-16PC Notes 1, 2 1089-327-004
SSQ22680-40-16ME 1089-354-001 ATRD6105
SSQ22680-40-16MN 1089-354-002 ATRD5105
SSQ22680-40-20PC Notes 1, 2 1089-327-005
SSQ22680-40-20ME 1089-355-001 ATRD6072
SSQ22680-40-20MN 1089-355-002 ATRD5072
SSQ22680-40-22MC Notes 1,2 1089-260-001 ATRD6050
Notes:
1. Cooper Industries Inc. (formerly G&H Technology) 750 W. Ventura Blvd., Camarillo, CA 93010 CAGE
Code: 99447
2. Astro Tool Corp., 21615 S.W. T-V Hwy., Beaverton, OR 97003, CAGE Code: 58164 (503) 642-9853
3. Approved source of supply part numbers are given for reference only.
IV-4
Table 40-2 CONTACT INSERTION AND REMOVAL TOOL

UTILIZATION CROSS REFERENCE
Tool Part Number SSQ22680 Contact Part Number

SSQ22680-40-0PE SSQ22680-20-0-0P
SSQ22680-40-0ME SSQ22680-20-0-0S
SSQ22680-20-0-4P
SSQ22680-20-0-4S
SSQ22680-40-4PE SSQ22680-20-4-4P
SSQ22680-40-4ME SSQ22680-20-4-4S
SSQ22680-40-8PE SSQ22680-20-CTP
SSQ22680-40-8ME SSQ22680-20-CTS
SSQ22680-20-CTS-1
SSQ22680-20-CTS-2
SSQ22680-40-12PE SSQ22680-20-12-12P
SSQ22680-40-12MN SSQ22680-20-12-12S
SSQ22680-40-12ME SSQ22680-20-12-12S-1
SSQ22680-20-12-16P
SSQ22680-20-12-16S
SSQ22680-20-12-16S-1
SSQ22680-40-16PC SSQ22680-20-16-16P
SSQ22680-40-16MN SSQ22680-20-16-16S
SSQ22680-40-16ME SSQ22680-20-16-16S-1
SSQ22680-40-20PC SSQ22680-20-20-20P
SSQ22680-40-20MN SSQ22680-20-20-20S
SSQ22680-40-20-ME SSQ22680-20-20-20S-1
SSQ22680-40-22MC SSQ22680-20-22-22P
SSQ22680-20-22-22S
SSQ22680-20-22-22S-1
IV-5
Figure 40-1 Insertion, Removal Tool, Plastic, Sizes 8 Twinax through 0
IV-6
Figure 40-2 Insertion, Removal Tool, Plastic, Size 20 through 12
IV-7
Figure 40-3 Insertion, Removal Tool, Metal, Size 22
IV-8
9.5 +/- 1.0

.020 MAX GAP
AT CLOSED
POSITION
COLOR BANDS
F .003 R
1.875 MIN
E
A B
3.025 MIN G 9319-91
Tool Size A Dia B Dia C Dia D Dia E Dia F Min G Dia Color
0 0.588 0.628 0.583 0.629 0.75 0.785 0.572 Blue

0.584 0.624 0.582 0.628 0.570 0.585 MIN
4 0.395 0.421 0.390 0.423 0.550 0.585 0.369 Yellow

0.391 0.417 0.389 0.422 0.447 0.365
TWX 0.291 0.320 0.286 0.322 0.427 0.269 Red

0.287 0.316 0.285 0.321 0.265
Notes:
1. Handle design optional.
2. With handles fully open, gap between tips must easily accept max diameter wire.
Figure IV.2a Extraction Tool, Metal, Sizes 8 through 0
Figure 40-4 Extraction Tool, Metal, Sizes 8 through 0
IV-9
Figure 40-5 Insertion Tool, Metal, Sizes 20-12
IV-10
V. APPENDIX V
GROMMET SEALING PLUGS
V-1
50.0 Appendix V
50.1 Scope
This Appendix covers contact replacing grommet sealing plugs conforming to SCD SSQ 22680.
50.1.1 Grommet Sealing Plug Part Numbers
Grommet Sealing Plugs shall be of the part numbers in accordance with Table 50-1, and shall be
ordered by these part numbers only. Part numbers shall be of the following form:
SSQ22680-050-XX, where
SSQ22680 Is SSQ SCD identifier for ORU connector family and related accessories.
-050 Is the SSQ 22680 identifier for grommet sealing plugs.
-XX Is grommet sealing plug size, (the same as contact size it replaces).
specified herein. The effective issue of those documents not specifically identified by change
letter or date shall be the latest issue in effect on the date of contract. In the event of conflict
between the documents referenced herein and contents of this document, this document shall
take precedence.
SPECIFICATION
SSQ 22680 Connector, Rectangular, (ORU) Space Quality
50.3 Requirements
Unless otherwise specified, all applicable provisions and requirements of SSQ 22680 pertaining
to grommet sealing plugs specified herein shall apply to this Appendix.
Unless otherwise specified, all requirements of SSQ 22680, Paragraph 4 apply to this Appendix.
Unless otherwise specified, all applicable requirements of SSQ 22680, Paragraph 5 apply to this
Appendix.
50.5.1 Grommet Sealing Plug Quantity
The quantity of the grommet sealing plugs to be supplied with each connector unit package shall
be in accordance with Table 50-2, unless otherwise specified by the applicable contractual
documents.
Only the item described on this drawing when procured from the vendor(s) is approved by The
NASA Space Station Program Office for use in the application(s) specified. A substitute item
shall not be used without prior approval by The NASA Space Station Program Office.
Identification of the approved source(s) of supply is not to be construed as a guarantee of present
or continued availability as a source of supply for the item described on the drawing.
V-2
Table 50-1 GROMMET SEALING PLUGS APPROVED SOURCE(S) OF SUPPLY
SSQ Part Number Manufacturer Part Manufacturer Manufacturer Part

Number 1 Part Number 2 Number 3
SSQ22680-050-0 1089-1151-001 7206-001-0000 S130-0009-001
SSQ22680-050-4 1089-1151-002 7206-001-0400 S130-0009-002
SSQ22680-050-8 1089-1151-003 7206-001-0800 S130-0009-003
SSQ22680-050-8P S130-0009-00-008
SSQ22680-050-12 1089-1152-001 7206-001-1200 S130-0009-004
SSQ22680-050-16 1089-1152-002 7206-001-1600 S130-0009-005
SSQ22680-050-20 1089-1152-003 7206-001-2000 S130-0009-006
SSQ22680-050-22 1089-1152-004 7206-001-2200 S130-0009-007
NOTES:
1. Cooper Industries Inc. (formerly G&H Technology), 750 W. Ventura Blvd., Camarillo, CA 93010, (805)
484-0543, Cage Code 99447
2. Aero Electric Connector, Inc., 16207 Carmenita Rd., Cerritos, CA 90703, (310) 404-8005, Cage Code 59976.
3. Smiths Connectors (formerly Sabritec), 1550 Scenic Ave, Suite 150 Costa Mesa, CA 92626 714-371-1100,
Cage Code 58795.
Table 50-2 GROMMET SEALING PLUGS UTILIZATION CROSS REFERENCE
SSQ Part Number Quantity Per Connector

SSQ22680-050-0 Full complement
SSQ22680-050-8P Full complement, less two
V-3
INSTALL IN
CONNECTOR
DASH SIZE A B C D E L N COLOR CONTACT
DIA DIA DIA DIA CAVITY
(GROMMET
CAVITY
SIZE)
-0 1/0 .358 .615 .564 .450 .048 .678 .160 YELLOW 1/0
.354 .611 .550 .400 .044 .668
-4 4 .226 .417 .376 .300 .048 .678 .160 BLUE 4
.224 .414 .363 .250 .044 .668
-8 TWX .219 .316 .276 .200 .032 .520 .250 RED TWX
.214 .313 .263 .150 .029 .500
-8P 8 .143 .306 .276 .200 .048 .520 .250 BROWN 8
.141 .303 .272 .150 .044 .500
Figure 50-1 Grommet Sealing Plugs, Sizes 0, 4, 8
V-4
INSTALL IN
DASH CONNECTOR CONTACT
SIZE A B C D E F K L COLOR CAVITY (GROMMET
NO
CAVITY SIZE)
-12 12 .095 .182 .151 .110 .048 .250 .284 YELLOW 12
.093 .179 .143 .090 .044 .274
-16 16 .063 .132 .103 .080 .048 .250 .284 BLUE 16
.061 .129 .096 .060 .044 .274
-20 20 .041 .066 .102 .070 .065 .048 .250 .284 RED 20
.039 .063 .100 .063 .055 .044 .274
-22 22 .030 .045 .065 .032 .250 BLACK 22
.024 .043 .055 .029
Figure 50-2 Grommet Seal Plugs, Sizes 12, 16, 20, 22
V-5
VI. APPENDIX VI
SSQ REPAIR PROCEDURES, REQUIREMENTS FOR
VI-1
60.0 Appendix VI
60.1 Scope
This procedure outlines the chemicals and methods required for minor defect repair of electroless
nickel plating on none functioning surfaces of nickel plated ORU connector components
conforming to SCD SSQ 22680. The minor defects are defined as surfaces where exposed
aluminum substrate does not exceed one sixteenth inch (1/16 inch) in any direction. The
maximum treated surface area shall not exceed .02 in2. The maximum amount of treated areas
shall not exceed 10. No rework permitted on mating surfaces as defined in Figure 60-1.
take precedence.
60.2.1 Specification
MIL-C-5541 Chemical Conversion Coatings On Aluminum and Aluminum Alloys

MIL-C-81309 Corrosion Preventive Compounds, Water Displacing,
Ultra-Thin Film
60.2.2 Materials
Equivalent materials can be used as determined by materials and processes engineering.

El Dorado Chemical, AC-102 Cleaner, Deoxidizer
San Antonio, TX
Witco, Des Plaines, IL Iridite 14-2 Chromate Conversion Coating per
MIL-C-5541, Class 3
Steven Industries Bayonne, N. J. 22028CM-3 Bulk, Corrosion Preventive Compound
per MIL-C-81309, Type III, Class 1
60.2.3 Application of Chemical Conversion Coating
60.2.3.1 Surface Preparation

a. Remove any loose plating on damaged area by abrading with ink eraser
head.
Note: Wear plastic gloves for the following operations
b. Apply AC-102 to damaged areas with cotton swabs. Keep area wet by
applying continuously for a minimum of three (3) minutes.
c. Rinse off AC-102 using kimwipes moistened in water. Clean well and dry
with dry kimwipes.
VI-2
60.2.3.2 Application of Conversion Coating

a. Using cotton swabs, apply Iridite 14-2 per MIL-C-5541 Class 3 to damaged
areas. Two applications to be made, approximately one (1) minute apart. Air-
dry three (3) minutes minimum.
b. Using kimwipes moistened with water, wipe away excess Iridite. Dry with dry
kimwipes.
60.2.3.3 Application of Corrosion Coating
a. Using cotton swabs, apply MIL-C-81309 material to damaged areas,
overlapping onto nickel plating. Air-dry one (1) hour.
60.3 EMI Spring Repair Procedure for Connector Receptacles
60.3.1 Scope
This procedure defines the process for the removal and replacement of the EMI ground spring on
Cooper Industries (formerly G&H Technology) manufactured ORU receptacle connectors built
per specification number SSQ 22680.
60.3.1.1 Note
All repair procedures shall be approved by an authorized Material Review Board in accordance
with SSP 41173, prior to the repair being performed.
60.3.2 References
SSQ 22680 Connectors, Rectangular (ORU), Space Quality, General Specifications For
60.3.3 Materials List
The materials list is as follows:

60.3.3.1 Repair Kits
EMI Spring Kit, Size 1, Quantity one per connector (Smiths Connectors (formerly Sabritec) P/N
S109900-9006)
EMI Spring Kit, Size 2, Quantity one per connector (Smiths Connectors (formerly Sabritec) P/N
S109900-9007)
60.3.3.2 Tools
EMI Spring Repair Tool Kit, Quantity 1 (Smiths Connectors (formerly Sabritec) P/N S109900-
7000):
Dummy Test Plug (No Polarization Key Installed), ORU Shell Size 1 (Smiths Connectors
(formerly Sabritec) P/N S100-1826-10X)*
Dummy Test Plug (No Polarization Key Installed), ORU Shell Size 2 (Smiths Connectors
(formerly Sabritec) P/N S100-1828-10X)*
(The * denotes the polarization of the shell, which is not required for this application).
Epoxy Removal Tool, Quantity 1 (Smiths Connectors (formerly Sabritec) P/N F-0337):
a. Epoxy Removal Tool Handle, Quantity 1 (Smiths Connectors (formerly Sabritec)
P/N F-0337-01)
b. Guide Block, Quantity 1 (Smiths Connectors (formerly Sabritec) P/N F-0337-02)
VI-3
c. Epoxy Removal Tool Blade, Quantity (Smiths Connectors (formerly Sabritec) P/N
F-0337-03)
d. Screw, Quantity 3 (Smiths Connectors (formerly Sabritec) P/N F-0337-04)
e. Debris Catch Box, Size 1 (Smiths Connectors (formerly Sabritec) P/N F-0338-01)
f. Debris Catch Box, Size 2 (Smiths Connectors (formerly Sabritec) P/N F-0338-02)
g. Dental Pick (Smiths Connectors (formerly Sabritec) P/N T-1096)
h. Angled Mirror (Smiths Connectors (formerly Sabritec) P/N T-1097)
60.3.3.3 Equipment
Vacuum System (present on site)
Pliers (present on site)
Flashlight or other light source (present on site)
60.3.3.4 Recommended Consumables
Cotton swabs (present on site)
Clean cloth (present on site)
Toothbrush (present on site)
Isopropyl Alcohol (present on site)
Note: If a Smiths Connectors (formerly Sabritec) part number is referenced, Smiths Connectors
(formerly Sabritec) supplies this part or kit.
60.3.4 Procedure
The following procedure is based on the removal and installation of the EMI spring with clear
access to the top (interface surface) of the connector to be repaired. The following steps may be
modified if access is obstructed. The accompanying data sheet should be filled out as required
during the removal and installation operation.
a. Place the Debris Catch Box (Size 1 or 2) over the connector. The catch box must be
installed past the EMI spring. There shall be no gaps between the rubber seal and the
connector body.
b. Use the Dental Pick and pliers to remove the EMI spring. The dental pick is used to
pry the EMI spring tangs out of the groove.
c. Use the Epoxy Removal Tool to remove epoxy and spring fragments from the groove
in the connector shell. The Guide Block rests against the top (interface) of the
connector to guide the tool around the connector shell. Remove and replace dull
Epoxy Removal Tool Blades as required. The Dental Pick may also be used for
cleanup of the spring groove.
d. Vacuum debris that has deposited in the Catch Box and on the connector. All debris
should be cleaned up prior to removal of the Catch Box.
e. Clean the connector with isopropyl alcohol using cotton swabs, and a toothbrush.
Wipe off any excess alcohol with a clean cloth.
f. Check spring groove and Catch Box for any leftover particles of the spring or epoxy
using the Angled Mirror and a light source. If particles are still present, repeat steps 3
through 5 until clean.
VI-4
g. Remove the Catch Box from the assembly. If the box is difficult to remove, use the
chain handles to lift the box off of the connector. After removal, check the rubber
gasket for rips and tears.
h. Install a new EMI spring from the appropriate EMI Spring Kit (Size 1 or 2). Install
the new spring as specified below. Make sure that the steel spring clip is along the
surface of one of the longer sides of the connector shell and not on a corner.
1) EMI Spring Installation: Install the spring assembly over the shell by slightly
expanding the spring. When the spring is in place, start pressing the locking fingers
into the groove by pressing on the curved part of the spring. Pressing on the curve
flattens the spring and allows the tines to slip into the groove at the four corners first.
Then seat the spring at the center of the flat sides. Seat the spring at points equally
distant between previously seated spots until the spring is completely seated.
i. Check the spring for defects and proper installation in accordance with Appendix X
herein. If the spring does not install properly carefully remove the spring and check
the cleanliness of the groove. Also check that the EMI Spring Kit has not been
damaged. A damaged spring must be discarded and replaced with a new kit.
j. Using the appropriate ORU Dummy Test plug shell (Size 1 or 2) mate and remove the
shell five (5) cycles. Make sure the spring is undamaged.
k. Perform the shell to shell conductivity test per paragraph 3.2.1.4 and in accordance
with paragraph 4.8.4b herein.
l. Verify data sheet has been filled out properly with all required data.
60.3.5 Data Sheet
Acceptance Data Sheet

SSQ 22680 Repair Procedure For EMI Springs
Date:_____________
SSQ Part Number:______________
Supplier Part Number_________________
Connector Serial Number:_________________
Connector Date Code:___________
Smiths Connectors (formerly Sabritec) EMI Spring Kit P/N:_____________
EMI Spring Kit Date Code/Lot Number:_____________
Test and Operation Step Number Result (Pass Stamp and

or Fail) Signature
Successful repair of ground Visual Inspection of EMI Spring
spring with Smiths (Paragraph 60.2.4, Step i.)
Connectors (formerly
VI-5
Sabritec) EMI Spring Kit

Five (5) mating cycles Visual Inspection of EMI Spring
(Paragraph 60.2.4, Step j).
Shell to shell conductivity (Paragraph 60.2.4, Step k).
Figure 60-1 Definition of Non Repairable Connector Surfaces
VI-6
VII. APPENDIX VII

STRIPPING OF ELECTRICAL WIRE AND CABLE INSULATION
VII-1
70.0 Appendix VII
70.1 Scope
This Appendix covers the procedural requirements for the preparation and stripping of insulation
from cable and wire prior to crimping, hereinafter referred to as wire preparation, for electrical
connectors conforming to SCD SSQ22680. The requirements specified herein meet or exceed
requirements set forth in NHB 5300.4(3G) applicable to insulation stripping of wire and cable.
take precedence.
SPECIFICATIONS:
O-E-760D Ethyl Alcohol (Ethanol), Denatured Alcohol, Proprietary Amendment 2
Solvent and Special Industrial Solvents
TT-I-735A Isopropyl Alcohol Notice 1
NHB 5300.4(3A-1) Requirements for Soldered Electrical Connections
December 1976
SSQ22680 Connectors, Rectangular, (ORU), Space Quality
MIL-STD-45662 Calibration System Requirements
70.3 Requirements
Care shall be exercised during the performance of this process. Good workmanship practices are
essential to the safety of personnel using the finished product and to the safety of the equipment
in which the connector contact assembly is an integral part.
70.3.1 Equipment
The equipment required for wire preparation is identified below. Where an integral piece of
equipment or tool is not specified, the tool used shall be calibrated and certified in accordance
with MIL-STD-45662. All vital information, (manufacturer, description, calibration
information, part number, etc.) shall be recorded or logged into the applicable documents and
shall be made available for review at all times.
VII-2
Nomenclature Part Number Manufacturer Usage

Wire Cutter, Manual 45-123 Ideal Wire Stripping
No. 100 Miller Greenlee
Wire Cutter, Automatic Various Kingsley Eubanks Wire Stripping
Wire Stripper, Mechanical 45-1610/1611 Ideal Wire Stripping
Wire Stripper, Thermal Various Astro Pico Wire Stripping
Wire Stripper, Automatic Various Teledyne Wire Stripping
Stripall
Blade or knife Various Kingsley Eubanks Wire Stripping
Note: Tools equivalent to those listed above may be used only when evidence or proof of
calibration and certification have been performed, reviewed and/or approved in
accordance with MIL-STD-45662
70.3.2 Materials
The following materials or their acceptable equivalent shall be required for use with this
specification. Where other materials are not listed, a record shall be kept of actual materials used.
The information, as a minimum, shall include: name of substance, part number, manufacturer, lot
date code, shelf life and storage information. The materials listed are usage items as defined in
Section 70.6.2.3
Nomenclature Part Number and Manufacturer Usage
Specification
Ethyl Alcohol ACS grade, 99.5% or 95% by Various Cleaning
volume (O-E-760)
Isopropyl Alcohol Best commercial grade, 99% Various Cleaning
pure (TT-I-735)
Kay Dry Tissues N/A Kimberly Clark Corp Cleaning
(Kimwipes) Neenah, WI
70.3.3 Required Procedures and Operations
70.3.4 Records
Records shall be kept to provide correlation between the finished product, the operator, and the
tools used. Comprehensive records shall be kept of the certification of the personnel and tooling
required herein in accordance with specification Section 70.4.4.
70.3.5 Wire Preparation and Handling
The following steps shall be performed prior to stripping for all sizes and types of wire and cable
unless otherwise noted:
VII-3
a. Check wire insulation visually for cuts, breaks, abrasions, or other defects
that may result in insulation failure.
b. Except where automatic cutting and stripping machines are used, cut wire or
cable to length specified in controlling documents. Ensure all cuts are clean
and square.
70.3.5.1 Stripping Procedure
70.3.5.1.1 Strip Dimensions
Using the appropriate method defined in 70.3.3.3.2, conductors shall be stripped to the
dimensions specified in the authorizing or controlling documents. Use the diagram shown in
Figure 70-1for guidelines when dimensions are specified. Dimensions shall be determined as
follows:
a. Shields shall have no more than 5 percent broken strands and no more than 5
percent additional damage in nicked or shaved strands after jacket removal,
cutting and pigtailing of conductor shield.
b. Unless otherwise specified, strip length of wire is the depth of solder cup or
contact barrel plus 1/32 inch, with a tolerance of +1/32, -0 inch.
c. Shielded conductor shall be stripped as follows:
1) Shield jacket shall be stripped to the length of dimension A.
2) When documents specify a shield pigtail length, dimension D shall
apply.
3) Strip length of primary conductors shall be dimension C.
4) Unused shields shall be trimmed to dimension B.
70.3.5.1.2 Stripping Method
70.3.5.1.2.1 Shielded Conductor

The shielded conductor may be stripped by using thermal strippers or a blade or knife. These
methods are defined in the following paragraphs.
70.3.5.1.2.1.1 Thermal Strippers
Removal of the outer jacket of dimension(s) as specified in Figure 70-1 with thermal wire
strippers shall be as follows:
a. Verify stripper setting as follows:
1) Set the wire stop on the stripper for the predetermined length.
2) Place a scrap piece of cable into the jaws to verify set length.
3) Close the jaw down on the cable and heat the blades. As the blades are
heating, rotate the stripper 180 degrees around the jacket, making sure
the insulation is penetrated but not the shield.
4) Release the jaws, remove the cable and pull the cut insulation from the
shield.
VII-4
5) If cut insulation cannot be pulled from the shield, use a blade and cut a
slit in the lengthwise direction of the insulation (see Figure 70-2). Use
caution in applying pressure to control the depth of the blade when
cutting.
6) Visually inspect the shield for damage, and verify the strip length.
7) If the stripper must be reset, repeat steps a and b, above before stripping
production wires and cable.
b. Strip production wire/cable in accordance with step a, substeps 1 through 6.
70.3.5.1.2.1.2 Blade or Knife Method
Removal of the outer jacket of dimension(s) as specified in Figure 70-2 with a blade or knife
shall be as follows:
CAUTION
To avoid damaging wires/cables, use extreme care to control the depth of the cut
when using a blade or knife for stripping.
a. Measure the dimension of insulation to be removed and make a light scratch
marking the measurement using a blade.
b. Make a light cut around the circumference of the wire at the mark. Use
caution in applying pressure with the blade around the circumference.
c. Use even pressure on the blade and slit the jacket lengthwise from the light
cut at the circumference to the tip of the cable (see Figure 70-2).
d. Peel the jacket off from the shield at the tip of the cable and gently tear back
to the circumference. Tear it off around the circumference of the cable.
e. Inspect the shield for nicks, cuts, or any damage to the strands.
70.3.5.1.2.2 Conductor Extraction
70.3.5.1.2.2.1 Shield Pigtails
When shield pigtails, or pigtail length are specified, the conductors shall be extracted as follows:
a. Using an awl, remove conductors from the shield without disturbing the
shield stranding.
b. Push the shield braid gently backwards towards the circumference of the
cable expanding the shield slightly and freeing the conductors (see
Figure 70-3, detail A). If the cable has multi-conductor wires, untwist
the conductors slightly.
c. Insert an awl at approximately 1/8 inch from the conductor shield and
cable circumference to open a hole in the shield (refer to Figure 70-3,
detail B for more details). Caution should be used not to damage the
shield strands or the wires within.
d. Rotate the awl in a clockwise direction to expand the hole.
VII-5
e. Slip the point of the awl under the conductor and bend the wire towards
the point of the opening and pull the conductor out (see Figure 70-3,
detail C).
f. For multi-conductors, remove each wire separately.
70.3.5.1.2.2.2 360 Shield
When 360 shield is required, the conductors shall be extracted as follows:
a. When conductors cannot be extracted from the shield, separate the shield
by un-stranding with an awl.
b. Separate the weave working from the cable tip towards the wire jacket
circumference (see Figure 70-3 detail D).
c. Separate by parting the braid lay, but by keeping the strand group
together. Caution should be used not to damage the shield strands or the
conductor insulation.
d. Work the braid separation spirally around the shield until the jacket is
reached.
70.3.5.1.2.3 Conductor Stripping
The conductor may be stripped by using hand strippers, thermal strippers, knife, or cutting
machine. These methods are defined in the following paragraphs.
70.3.5.1.2.3.1 Hand Strippers
Hand held strippers shall be used for stripping insulation of stranded wire of sizes 16 American
Wire Gage (AWG) through 22 AWG, when practical. Hand strippers may be used on other
types of wire of size 22 AWG through 12 AWG. Wires shall be stripped with the use of hand
strippers as follows:
a. Select the applicable hand stripper for the gage wire to be stripped.
Verify that the strips on the jaws are not worn and will grip the
conductor firmly.
b. Place wire into the proper gage slot on the jaws of the stripper. Verify
the correct dimension as specified in the controlling documents.
c. Close the handles so that the blades grip the conductor evenly and
firmly without jerking or pulling.
d. Remove the insulation from the wire with care not to damage the wire
strands.
NOTE: The hand strippers are latch controlled. Make sure the stripper head
travels to the fully extended position before releasing the handles. When the
head travels part way, and when the latch has not yet fully engaged, the wire
may be bent, splayed, or scraped.
70.3.5.1.2.3.2 Thermal Strippers
When the hand strippers cannot remove insulation effectively, thermal strippers shall be used as
follows:
VII-6
a. Set the wire stop on the stripper for the predetermined length (refer to
70.3.3.3.2.1.1),
b. Heat the blades and close the jaws.
c. If hot tweezers are being used, set the wire in to the proper gage notch and
close the blades.
d. Rotate the stripping blades 180 degrees around the wire making sure the
insulation has been penetrated, but the wire strands are not damaged.
e. Release the jaws and pull the insulation off.
f. Verify the strip length. If necessary, reset the wire stop and repeat steps b
through e.
g. Inspect the strands of wire for damage.
NOTE: The insulation may have a slight bulge at the end, and exhibit slight
discoloration. This is normal for thermally stripped wire.
70.3.5.1.2.3.3 Knife
The use of a knife or blade may be used to strip larger gage wires as follows:
CAUTION
To avoid damaging wires, use extreme care to control the depth of the cut
when using a blade or knife for stripping. Cutting too deep can nick or mark
the wire strands beneath.
a. Determine the point where the insulation is to be cut using a scale or ruler.
b. Mark and cut around the circumference of the wire very lightly.
c. Increase the pressure of the blade gradually while cutting around the
circumference. Continue until the insulation can be parted with slight
finger pressure.
d. Larger wire may require a lengthwise slit from the circumference to the tip
of the wire and the peeling away of the insulation (see Figure 70-2)
70.3.5.1.2.3.4 Cutting Machines
The conductor may be stripped using a cutting machine as follows:
a. Set up the cutting machine in accordance with the manufacturers
operating procedures and instructions. Install the proper cutting fixtures
and dies for the applicable wires.
b. Verification of the cutting machine set-up and certification of operating
procedures shall be approved by the qualifying activity prior to any
cutting process, and also during the interim process for accommodating
different wire sizes. In addition, a minimum of three certification
samples shall be submitted for approval by the qualifying activity prior
to each new configuration.
VII-7
c. When set-up has been approved, cut wires in accordance with the
instructions accompanying the cutting machine. When there is a conflict
regarding dimensions, dimensions shall be as specified in the controlling
documents.
d. At the close of the shift, a minimum of three samples of the days work
shall be examined. All results shall be recorded into the log records.
70.3.5.2 Post-Strip Inspection
Stripped wire and cable shall be visually examined for damaged wire insulation, nicked or
scraped wire, broken conductors, etc. See Figure 70-4 for wire stripping examples. Inspections
shall be made visually or under magnification, when required, for conformance with the criteria
as specified in the following paragraphs.
70.3.5.3 Stripped Wire Strands
Stripped wire shall not be nicked, cut, broken, shaved, or contain contaminated strands; primary
and secondary wires shall not be frayed or scraped. Plated conductor strands of stripped wire
shall be free of nicks, cuts, or scrapes that penetrate the plating.
70.3.5.3.1 Stripped Wire Conductors
When the strand or member lay is disturbed, the strand or member shall be restored to its original
lay. The conductor cross section shall not be altered or reduced as a result of stripping.
70.3.5.3.2 Unstripped Insulation
The unstripped insulation of stripped wire or cable shall display no evidence of burning, scrapes,
cuts which penetrate the topcoat, deformation, or other damage. Slight discoloration, charring or
melting of the insulation is permissible at the strip point. Removal of insulation topcoat within
1/32 inch of the strip point is acceptable.
70.3.5.3.3 Insulation Flash
Insulation edge flash shall not exceed approximately twice the insulation wall thickness.
Insulation streamers shall be removed.
70.3.5.3.4 Shields
Shields of stripped cable shall have no broken strands or other visible evidence of damage.
70.3.5.3.5 Cleanliness
Stripped wire and cable shall be free of oil, dirt, grease, chips and other debris and foreign
materials. Clean the wires and cables with the applicable solvent(s) or any mixture of the
solvents listed in 70.3.2, using a wetted lint-free cloth or by wiping with approved assembly
wipes.
70.4.1 Responsibility for Inspection
Unless otherwise specified in the contract or order, the user of this specification is responsible
for the performance of all inspection requirements as specified herein.
VII-8
70.4.2 Monitoring Procedures for Equipment Used in Process
All applicable tools requiring calibration and certification must be done prior to production use.
Tools and equipment shall be calibrated and maintained at prescribed time intervals. All
documentation shall be kept within the processing area and shall be made available for
inspection and review at all times. Calibration data shall include, as a minimum, the last date of
calibration, the next due date for calibration, the stamp or mark of calibration and approval. All
equipment failing to meet calibration or showing a pass due date shall not be used and shall be
marked as such. These items shall be removed to another area until calibration has been
performed.
70.4.3 Monitoring Procedures for Materials
Certification supported by verifying data that the materials listed herein used in fabricating
assemblies are in accordance with the applicable referenced specifications, inspections, and
requirements, shall be required and be made available for review at all times.
70.4.4 Certification
70.4.4.1 Maintenance of Certification Logs

Maintenance of logs for the certification of all personnel involved in production under the
provisions of this specification shall be implemented. All documentation shall be kept current
and shall be presented for inspection and review upon request.
70.4.4.2 Personnel Certification
All personnel shall have on file certification documentation showing date of issuance, type of
training received, dates of training, etc. The documentation shall be kept current and shall be
presented for inspection and review upon request. As a minimum, the personnel must
demonstrate the ability for proficient workmanship in a manufacturing environment.
Re-certification shall be granted only when skills and techniques have been demonstrated and
retraining has been completed.
70.4.5 Test Methods
70.4.5.1 Inspection Methods

All stripped wire and cable shall be visually inspected with and without the aid of magnification.
Inspection with magnification shall be between 3 power and 10 power magnification, depending
on wire size, for compliance and conformance with requirements and specifications as specified
herein. Additional magnification shall be used as necessary to resolve suspected anomalies or
defects.
70.4.5.1.1 Acceptance Criteria
An acceptable wire stripping process will be characterized by, but not limited to the following:
a. No visible damage to wire strands.
b. Minor burnishing and indentation.
c. Minimal edge flash not exceeding wire insulation diameter.
VII-9
70.4.5.1.2 Rejection Criteria
An unacceptable wire stripping process will be characterized by:

a. Damaged, crushed, charred, cracked, or melted insulation.
b. Separation of wire strands.
c. Cut, nicked, stretched, or scraped leads or wires.
d. Gouged, scraped, exposed base metal.
e. Original lay of stranding distorted and straightened.
This section is not applicable to this specification.
70.6 Notes
70.6.1 Intended Use
The wire and cable preparation and stripping procedures contained in this specification are
intended for use on ORU rectangular electrical connectors prior to tinning, crimping or
soldering.
70.6.2 Definitions
70.6.2.1 Circumference
The circular scribed mark along the girth of the wire or cable where insulation is to be
removed to as measured from the tip of the cut wire.
70.6.2.2 Flash, Insulation
Remnants of wire or cable insulating material that is left due to an improper stripping
process.
70.6.2.3 Usage Items
Usage items are materials, which are consumed or used in uncontrolled amounts during
assembly procedures not necessarily, called out on engineering control documents.
VII-10
FOR SHIELDED CABLE WHERE

THE SHIELD IS NOT TERMINATED,
THE FOLLOWING SHALL APPLY:
-THE OUTER JACKET STRIP LENGTH

IS DIMENSION A
- THE SHIELD IS TRIMMED TO
DIMENSION B
- THE EXPOSED CONDUCTOR LENGTH
SHALL BE DIMENSIONED C
FOR SHIELDING CABLE

TERMINATIONS
THE FOLLOWING SHALL APPLY:
- THE OUTER JACKET AND SHIELD

STRIP LENGTH IS DIMENSION A
- THE EXPOSED CONDUCTOR
LENGTH
IS DIMENSION C
C Dimension
Contact Size Wire Barrel Size Tolerance Applicable Document
Minimum Maximum
0 0 .610 .630
0 4 .515 .535 SSQ 22680
4 4 .515 .535
8 8 .515 .535
12 12 .260 .300
12 16 .260 .300
16 16 .260 .300
20 20 .180 .193
22 22 .145 .190
TWX In accordance with Appendix VIII, Figure 80-15.
Note: 1. All dimensions are in inches.
Figure 70-1 Wire Dimension References
VII-11
Figure 70-2 Insulation Removal
VII-12
Figure 70-3 Conductor Extraction from Shield
VII-13
Figure 70-4 Examples of Wire Stripping
VII-14
VIII. APPENDIX VIII

CRIMPING OF ELECTRICAL CONNECTIONS
VIII-1
80.0 Appendix VIII
80.1 Scope
This Appendix establishes the procedural requirements for the crimped connections of ORU
connector contacts on wire and cables, hereinafter referred to as crimping, used on space vehicles,
space vehicle mission-essential support equipment, and electrical systems for the Space Station.
The requirements specified herein meet or exceed requirements set forth in NHB 5300.4(3H);
applicable to crimping.
80.2 Classification
The specifications and requirements for the preparation and crimping of cable and wire shall be of
the following types specified:
a. Type I - Termination of insulated conductor wires with standard crimp contacts.
b. Type II - Termination of insulated conductor wires with reduced crimp barrel
contacts.
c. Type III - Termination of shielded cable.
documents referenced herein and the contents of this document, the contents of this document shall
take precedence.
SPECIFICATIONS:
TT-I-735A Isopropyl Alcohol, Notice 1
MIL-C-22520 Crimping Tools, Terminal, Hand or Power Actuated, Wire Termination,
and Tool Kits General Specification for
MIL-C-22520/1 Crimping Tools, Terminal, Hand, Wire Termination; For Wire Barrel Sizes
12 through 20
MIL-C-22520/2 Crimping Tools, Terminal, Hand, Wire Termination; For Wire Barrel Sizes
20 through 28
MIL-C-22520/3 Crimping Tools, Terminal, Hand, Wire Termination; In-Service Inspection
Gages
MIL-C-22520/5 Crimping Tools, Terminal, Hand, Wire Termination, Large For Coaxial,
Shielded Contacts and Ferrules, Terminal Lugs, Splices,
and End Caps
MIL-C-22520/23 Crimping Tools, Terminal, Hand or Power Actuated, Wire Termination;
Pneumatic Tool for Wire Barrel Sizes 0000 through 8
MIL-STD-45662 Calibration System Requirements
SSQ 21655 Cable, Electrical, MIL-STD-1553 Data Bus, Space Quality, General
Specification for
VIII-2
NHB 5300.4(3H) Requirements for Crimping and Wire Wrap, 01 May 1984
RM2589 Cable, Electrical, Two Conductor, Shielded
SSQ 22680 Connectors, Rectangular, (ORU) Space Quality
80.3.1 Requirements
essential to the safety of personnel using the finished product and to the safety of the equipment in
which the connector contact assembly is an integral part.
80.3.2 Equipment
The equipment required for wire crimping is identified below. Where an integral piece of
equipment or tool is not specified the tool or equipment used shall be calibrated and certified in
accordance with MIL-STD-45662. All vital information, (manufacturer, description, serial
number, calibration information, part number, etc.) shall be recorded or logged into the applicable
assembly documents.
Nomenclature Model Number Manufacturer Usage
Trimming Tool 62006 Hunter Shield dressing
Heat Gun HG501A Master Shrink Sleeving
Gage M22520/3 Checking Crimp Tools
Crimp Tools M22520/xx Crimping
(refer to 80.3.1.1) Pico (Refer to 89.3.1.1)
500 D Crimping
Note: Tools not listed in the table, or tools equivalent to those listed above may be used
only when applicable calibration has been performed in accordance with MIL-STD-
45662.
80.3.2.1 Crimp Tools
Appropriate crimp tools shall be determined in accordance with Table 80-1 through Table 80-4
and shall be in accordance with the following specifications:
MIL-C-22520
MIL-C-22520/1
MIL-C-22520/2
MIL-C-22520/3
MIL-C-22520/5
MIL-C-22520/23
80.3.2.2 Ratcheting
Unless otherwise specified, hand crimp tools shall employ an integral mechanism, which controls
the crimping operation to the extent that once a crimping operation has started the tool cannot be
opened until the crimp operation has been completed.
VIII-3
80.3.2.3 Indenters
Unless otherwise specified, each crimp tool shall have a minimum of four indenter blades.
80.3.2.4 Tool Identification
Each tool shall be identified and marked, including the following as a minimum:
a. Serial number
b. Calibration date.
c. Expiration date of calibration.
The materials required for wire crimping are identified below:
Nomenclature Part Number Specification Manufacturer Usage
Isopropyl Alcohol Best commercial grade, 99% pure (TT-I-735) Commercial Cleaning
Tubing, Heat Refer to 80.3.2.2
Shrink
Assembly Wipes Clean Room Approved Commercial Cleaning
80.3.2.5 Solvents
Only the solvents listed are acceptable when used for cleaning. Solvents shall be properly labeled
and shall be maintained in a clean and uncontaminated condition. Solvents shall be nonconductive
and non-corrosive: shall not dissolve or degrade the quality of parts or materials. Any solvent
showing evidence of contamination or decomposition shall not be used. The solvent materials
listed are usage items as defined in 70.3.2.
80.3.2.6 Heat Shrink Tubing Material
Heat shrink tubing shall be in accordance with Table 80-5. In the event of a conflict between the
materials specified herein and the materials of the controlling documents or drawings, the
materials of the controlling documents/drawings shall take precedence.
80.3.3.1 General
80.3.3.1.1 Records
tools used. Comprehensive records shall be kept of the certification of the personnel and the
calibration of tooling required herein.
80.3.3.1.2 Hardware
The hardware shall be as specified in the controlling documents. Wire, crimp hardware and
contacts shall be kept free of dirt and contaminants.
80.3.3.1.3 Wire
Stranded wire shall be used for all crimps. Crimping of solid conductor wire is prohibited.
VIII-4
80.3.3.1.4 Crimp Tool Calibration
Calibration of all crimp tools shall be in accordance with applicable engineering documents or
MIL-STD-45662. The use of un-calibrated or out-of-calibration crimp tools shall be prohibited.
80.3.3.1.5 Facility Cleanliness
Assembly and fabrication areas shall be maintained in a clean and orderly condition.
80.3.3.1.6 Environmental Conditions
80.3.3.1.7 Controlled Temperature and Humidity
Temperature and humidity requirements shall be continuously maintained in the range specified in
Figure 80-7.
80.3.3.1.7.1 Critical Environments
When the parts or equipment being processed require more critical environmental conditions, such
requirements shall take precedence.
80.3.3.1.7.2 Lighting
Light intensity shall be a minimum of 100 foot-candles (1076.4 lumens/m2) on the surface of all
crimping operations.
80.3.3.2 Cleaning
Clean the wires and contact components with the applicable solvent(s) listed in 80.3.2, using a
wetted lint-free cloth or by wiping with approved assembly wipes.
80.3.3.3 Crimp Assembly Requirements
80.3.3.3.1 Heat Shrink Sleeving
When required to build up the outside diameter of the finished wire to the appropriate diameter in
accordance with paragraph 80.3.3.3.2, heat shrinkable sleeving (refer to Table 80-5) shall be used.
It shall be installed before the crimping of connector contacts to wires. Refer to the controlling
documents for additional details.
80.3.3.3.1.1 General Requirements
Heat shrinkable parts shall have the following requirements:
a. They shall be shrunk uniformly to ensure a tight fit.
b. The sleeving shall firmly grip the wire over which it has been installed.
c. The sleeving shall be free from cracks, punctures, blisters, and burned
areas.
80.3.3.3.1.2 Application of Heat Shrinkable Sleeving
Heat shrinkable sleeving shall be applied to shield braids as follows:
a. Strip the outer jacket in accordance with Appendix VII.
b. Trim braid stranding (if any) to the dimensions shown in the controlling documents.
Use the top diagram in Figure 80-8 as reference. Care should be used to avoid
disturbing the shield weave, or nicking or cutting the inner jacket insulation.
VIII-5
c. Cut a piece of heat shrinkable sleeving 7/8 to 1 1/8 inch long and slip it
over the wire.
d. Position the sleeving as shown in Figure 80-8 or 80-9 , and heat shrink as follows:
NOTE: The gripping section of the sleeving shall be shrunk first.
1) Protect parts that may be damaged from heat sources.
2) Shrink the sleeving with a heat gun. Locate the sleeve near the center
of the deflector while applying heat. The deflector will ensure the
application of uniform heat. If the deflector is not used the heat gun or
sleeving must be manipulated to assure that the heat is applied
uniformly around the sleeve.
3) Apply no more heat than necessary to produce shrinking.
e. Allow the sleeving to cool and strip conductor wire in accordance with Appendix
VII.
f. If the wire requires subsequent sleeving, repeat steps c and d (see Figures 80-8 and
80-9). Verify that the overall diameter of the sleeved wire does not exceed the
required dimensions shown in the controlling documents.
80.3.3.3.2 Contact-Conductor Combinations
The allowable combinations for contact sizes and finished wire/cable, unless otherwise specified,
shall be as shown below:
Contact Size Wire Size Outer Diameter
(AWG) Finished Wire (in.)
22 22 0.048 to 0.060
24
20 20 0.048 to 0.070
22
16 16 0.056 to 0.087
20
12 12 0.074 to 0.124
16
8 8 0.124 to 0.260
4 4 0.233 to 0.360
0 0 0.389 to 0.555
0 4 0.389 to 0.555
(Note 1)
Note: 1. Requires the usage of heat shrinkable sleeving.
80.3.3.3.3 Insulation Clearance
The maximum insulation clearance or gap between wire insulation and crimped contacts shall be
as outlined below and shown in Figure 80-10.
VIII-6
Clearance
Contact Sizes Minimum Maximum
Sizes 22 and smaller 0.010 inch 0.030 inch
Sizes 12 and larger 0.010 inch 0.050 inch
80.3.3.3.4 Contact Crimping
80.3.3.3.4.1 Crimping Type I - Standard Contacts

Type I crimping shall be performed as follows:
a. Inspect wire for nicks and wear in the insulation, and strip insulation in accordance
with Appendix VII.
NOTE: If heat shrink tubing is specified by the controlling documents, apply in accordance
with paragraph 80.3.3.3.1.2.
b. Verify that there is no disturbance of the wire lay. If disturbed, re-twist the wire to
its original lay.
c. Insert the conductor fully into the crimp barrel (see Figure 80-4), ensure that all
strands are included.
d. Verify that the conductor is visible in the inspection window of the contact barrel.
e. Verify that the clearance between the insulation and the end of the crimp barrel is as
shown in Figure 80-4 and as specified in 80.3.3.3.3 (reference Note 1).
f. Verify that the correct tool and die attachment is being used for the specified
contact and cable size (refer to Table 80-1 or Table 80-2).
g. Verify that the tool is in the open position. For hand tools, set the crimp tool to the
open position by closing the handles together to their maximum position and
releasing them.
h. Insert contact in crimp die of crimping tool. Fold shield pigtail (if any) out of the
way of the crimp tool mechanism.
i. Verify that the contact is inserted to the full depth in the crimp tool die. Close the
handles of manual tool fully, or actuate the trip mechanism of the power-actuated
tool. The tool will not release unless the crimp indenters have been fully actuated.
j. Release the handle of the manual tool, or wait until the indenters of the power
actuated tool returns to the open position and remove the contact from the crimp
tool for inspection and/or test.
80.3.3.3.4.2 Crimping Type II - Reduced Crimp Barrel Contacts
Type II crimping shall be performed as follows:
a. Inspect wire for nicks and wear in the insulation, and strip insulation in accordance
with Appendix VII.
b. Verify that there is no disturbance of the wire lay. If disturbed, re-twist the wire to
its original lay.
VIII-7
NOTE: If heat shrink tubing is specified by the controlling documents, apply in accordance
with paragraph 80.3.3.3.1.2.
c. Insert the conductor fully into the crimp barrel (see Figure 80-4), ensure that all
strands are included.
d. Verify that the conductor is visible in the inspection window of the contact barrel.
e. Verify that the clearance between the insulation and the end of the crimp barrel is as
shown in Figure 80-4 and as specified in 80.3.3.3.3 (reference Note 1).
f. Verify that the correct tool and die attachment specified in Table 80-2 is being used
for the contact-wire combinations specified.
g. Verify that the tool is in the open position. For hand tools, set the crimp tool to the
open position by closing the handles together to their maximum position and
releasing them.
h. Insert contact in crimp die of crimping tool. Fold shield pigtail (if any) out of the
way of the crimp tool mechanism.
i. Verify that the contact is inserted to the full depth in the crimp tool die. Close the
handles of the manual tool fully, or actuate the trip mechanism of the power-
actuated tool. The tool will not release unless the crimp indenters have been fully
actuated.
j. Release the handle of the manual tool, or wait until the indenters of the power
actuated tool returns to the open position and remove the contact from the crimp
tool for inspection and/or test.
80.3.3.3.4.3 Crimping type III - shielded cables
Type III crimping for twin-axial cables shall be as follows:
a. Step 1 (see Figure 80-5).
1) Remove the contact from container. Verify all the parts are present.
2) Perform the center socket contact separating force test in accordance with
paragraph 80.4.4.3.4
NOTE: Dual entry pin dielectric (white) is not interchangeable with the dual entry socket
dielectric (colored).
b. Step 2 (see Figure 80-6).
1) Strip the outer jacket in accordance with Appendix VII to the dimension specified.
2) Care should be taken to avoid nicking or cutting the braid strands when cutting
the outer jacket.
3) Gently flare the shield braiding open and fold it back over the outer jacket to
expose the twin conductors within.
4) Remove filler flush with braid. Do not cut the shield braid strands.
c. Step 3 (see Figure 80-7).
1) Fold the braid shield back over the twin conductor wires again.
VIII-8
2) Insert the twin wires and the shield in through the outer ferrule.
3) Push the outer ferrule back until the outer jacket insulation of the cable bottoms
on the ferrule.
4) Fold the shield braid over the outer ferrule and trim excess shield material at the
shoulder of the ferrule.
5) Measure and cut the twin conductor to the specified length.
6) Score the insulation of the conductor wires and remove the insulation from the
twin wires protruding through the crimp bushing.
d. Step 4 (see Figure 80-7).
1) Bend the wire designated the I wire slightly outward, and position the wire
designated the C wire to the center of the cable.
2) Insert the C wire into the center pin / socket dielectric assembly.
3) Push back the dual entry dielectric prior to crimping.
4) Make sure the wire designated C is inserted into the center contact.
5) Verify that the C wire can be seen in the inspection hole of the contact before
crimping.
6) Place the pin / socket contact into the appropriate crimping tool as specified in
Table 80-4. Apply pressure against the contact to the crimp tool, and crimp
completely.
7) Fully seat the dual entry dielectric. Verify the overall length of the complete pin /
socket dielectric assembly is as specified in Appendix II, Figures 20-12 and 20-
13.
e. Step 5 (see Figure 80-7).
1) Place the intermediate contact over pin / socket dielectric assembly.
2) Put the I wire into the small hole at the rear of the intermediate contact. Make
sure the wire designated I is positioned through the side slot provided.
3) Press against the assembly slightly until the intermediate contact bottoms against
the shoulder of the center pin / socket dielectric assembly.
4) Verify that the I wire is visible in the inspection hole of the intermediate contact
before crimping.
5) Install intermediate contact assembly into an appropriate crimp tool (see Table
80-4) and hold assembly firmly in place. Verify the slot in the intermediate
contact is aligned with the tool locator (key) in the crimp tool. Crimp in place.
f. Step 6 (see Figure 80-8).
1) Push this assembly into the outer contact housing until it bottoms out. Make
sure the braid is distributed evenly over the ferrule surface.
VIII-9
NOTE: Alignment sprocket should secure the outer contact insertion into the crimp
tool from the same side as the intermediate contact. Alignment sprocket
shall be attached at the end of the hex side of the crimp die.
2) With the contact assembly held in place, apply the final crimp to the contact
(see Table 80-4).
3) Remove the contact assembly and set aside for test / inspection.
g. Step 7 (see Figure 80-8).
1) Inspect the complete TWX contact assembly in accordance with paragraph
80.4.4.3.2.2.2.
80.3.4 Recommended Procedures and Operations
This paragraph is not applicable to this specification.

Certification of personnel shall be in accordance with the applicable Quality Assurance

documents. Certification documentation shall meet or exceed the requirements specified, shall be
the latest issue in effect, and shall be approved by the appropriate quality or product assurance
activity for use. In the event of conflict between certification documents and the contents of this
Appendix, the contents of this Appendix shall be the superseding requirement.
80.3.5.1 Personnel Certification
Personnel shall be certified in accordance with appropriate control document approved by quality
or product assurance activity for use, unless otherwise specified.
80.3.5.1.1 Special Skills Requirements
Personnel that terminate concentric Twinax contacts shall successfully complete Boeing Special
Skills Course No 3263SS.
80.3.5.2 Certification Records
Maintenance of logs for the certification of all personnel and tooling involved in production
crimping operations under the provisions of this specification shall be implemented. The log shall
include the dates of the most recent certification/re-certification testing and personnel
identification. All certified personnel shall have records kept on file of all certification
documentation showing date of issuance, type of training received, dates of training, etc. The
documentation shall be kept current and shall be presented for review upon request.
Unless otherwise specified in the contract or order, the supplier is responsible for the performance
of all inspection requirements as specified herein. The Buyer reserves the right to perform any of
the inspections set forth in the specification where such inspections are deemed necessary to assure
supplies and services conform to prescribed requirements.
VIII-10
80.4.2.1 Certification and Calibration

Crimping tools, manual and power actuated shall be certified and calibrated prior to production
crimping of contacts to wire. Certification documentation shall meet or exceed the requirements
specified herein, shall be the latest issue in effect, and shall be approved by the appropriate quality
or product assurance activity for use. In the event of conflict between certification documents and
the contents of this Appendix, the contents of this Appendix shall be the superseding requirement.
All applicable documentation shall be kept on file and shall be made available for inspection and
review at all times. Calibration data for tools shall include as a minimum, the last date of
calibration, the next due date for calibration, the tool serial number, the stamp or mark of
calibration and approval. All equipment failing to meet calibration, exhibiting a broken seal, or
showing a pass due calibration date, shall not be used and shall be marked as such. These items
shall be removed from the work area until calibration has been performed.
80.4.2.2 Sealing
Calibrated tools and equipment shall be marked and sealed to ensure against unauthorized
alterations or adjustments. Seals shall be placed on all external adjustment points on the tools.
80.4.2.3 Calibration Interval
The crimp tools, power crimping dies and contact-conductor combinations to be used in the
production run shall be calibrated every 6 months in accordance with MIL-STD-45662. Test
results shall be recorded and maintained for each crimp tool and contact-conductor combination.
80.4.3 Monitoring Procedures for Materials
Monitoring procedures shall consist of certification supported by verifying data that the materials
listed herein used in fabricating assemblies are in accordance with the applicable referenced
specifications and the quality assurance provisions. All data shall be maintained and be made
available for review at all times as specified herein.
80.4.4 Test Methods
80.4.4.1 Number of Samples

A total of six crimped samples shall be prepared and tested for each tool and contact-conductor
combination, including Twinax contacts: three at the start, and three at the end of each work shift
or production run, whichever is shorter. The specimens shall also be prepared and tested whenever
there is a change in the tooling, wire size, or contact size. All samples shall be prepared and
tensile tested as specified herein. If the specimens fail to meet tensile requirements, all production
crimps produced by the operator and the tool subsequent to the last acceptable sampling shall be
rejected. Testing results shall be recorded and maintained for each tool and contact-conductor
combination.
80.4.4.2 Visual and Mechanical Inspection
All crimped contacts including test samples shall be visually inspected for conformance with
requirements of SSQ22680, this Appendix and Appendix X. The dimensions as specified in Figure
80-4, Figure 80-6, and Figure 80-7 shall be measured and recorded. Twinax pin contacts shall be
visually inspected for proper center pin alignment. When pin contacts fail visual inspection they
shall be subjected to contact alignment procedure in accordance with paragraph 80.4.4.3.5.
VIII-11
Magnification between 4 power to 10 power, depending on contact style and wire size
combination, shall be used. Additional magnification shall be used as necessary to resolve
suspected anomalies or defects.
80.4.4.2.1 Crimp Acceptance Criteria
The acceptance criteria for crimped contacts shall be, but not limited to, the following:
a. Contact deformed only by tool indentation.
b. Crimp indents located in proper area of barrel.
c. Conductor visible through inspection hole of barrel.
d. Wire insulation and jacket free of punctures, cuts, nicks, and deformation.
e. Metal ferrules tightly and symmetrically crimped.
f. Clearance between end of wire insulation and the crimp barrel conforms are in
accordance with paragraph 80.3.3.3.3.
g. Shield termination free of loose conductors or projecting conductors.
h. Insulation sleeving uniformly shrunk, providing proper covering and securing wire
in to place.
i. Conductors not broken, nicked, or cut; burnishing is permissible provided base
material is not exposed.
j. Conductor insulation not nicked, cut, crushed, or charred; slight discoloration is
acceptable.
k. Shield conductors clean, with nicks not exceeding 10 percent of total number of
conductors.
80.4.4.2.2 Crimp Rejection Criteria
The rejection criteria for crimped contacts shall be as follows:

a. Over-crimping: broken conductor or strands.
b. Under-crimping: loose or pulled out conductors.
c. Wire insulation crushed, cut, or punctured.
d. Insulation clearance insufficient or excessive.
e. Insulation whiskers (as defined in paragraph 80.6.2.2) extending into crimp barrel.
f. Contact plating peeling or flaking.
g. Cracks in crimp barrel.
h. Contact damaged, bent, or otherwise deformed.
i. Crimp indents not centrally located on crimp barrel.
j. Conductor not visible in inspection hole.
k. Conductor birdcaged (as defined in paragraph 80.6.2.3) or otherwise damaged.
l. Metal ferrules crimped with improper alignment.
VIII-12
m. Cracked, charred, or split insulation sleeving.

n. Excessive number of nicked braid conductors.
o. Improper sleeving coverage.
p. Damaged insulation in excess of slight discoloration from thermal stripping
operation.
q. Damaged conductors.
r. Reduction of the conductor cross-sectional area.
s. Tarnished, corroded, or contaminated crimp contacts.
80.4.4.3 Crimp Tensile Strength
80.4.4.3.1 Test Sample Requirements
Test samples by the designated crimp tool shall have the minimum axial load required to separate
the wire from the contacts either by pulling the wire out of the wire barrel or wire barrel bushing,
or breaking the wire. The minimum tensile strength of the crimped test sample connections shall
be as specified in Table 80-6.
80.4.4.3.2 Tensile Strength Testing
80.4.4.3.2.1 Test Samples

The tensile test shall be conducted on each individual test sample of initially crimped contacts
specified in paragraph 80.4.4.3.1. Samples shall be crimped to minimum lengths of appropriate
size wire as listed in Table 80-6.
80.4.4.3.2.2 Testing Procedures
80.4.4.3.2.2.1 Power Contact Testing Procedure
The contact under test shall be secured in the test fixture in such a manner that no external pressure
is applied to the contact crimp barrel. The un-terminated ends of the test samples shall be stripped
to facilitate gripping in the serrated jaws of the tensile testing machine. The stripped end of the
wire shall be gripped in the serrated jaws of the tester. Application of an axial force to the test
specimen shall be at a speed of 1.00 0.25 inch per minute to separate the contact and wire.
Crimped contacts shall conform to the values specified in Table 80-6.
80.4.4.3.2.2.2 Concentric Twinax Contact Testing Procedure
The contact under test shall be secured in the test fixture in such a manner that no external pressure
is applied to the contact crimp barrel. The un-terminated ends of the test samples shall be stripped
and twisted together (Figure 80-9) to facilitate gripping in the serrated jaws of the tensile testing
machine. The stripped end of the twisted cable components shall be gripped in the serrated jaws of
the tester. Application of an axial force to the test specimen shall be at a speed of 1.00 0.25 inch
per minute to separate the contact and wire. Crimped contacts shall conform to the values specified
in Table 80-6.
VIII-13
80.4.4.3.3 Twinax Contacts Electrical Continuity
a. Concentric Twinax contacts shall be tested with a calibrated volt-ohm-meter

between the test points specified below. No electrical continuity shall exist nor be
detected between the points specified within the terminated cables inserted into the
connector assemblies. If permitted, attachment of the test probes shall be at the un-
terminated ends of the cables.
Center conductor to intermediate conductor
Center conductor to outer shield
Intermediate conductor to outer shield
b. Concentric Twinax contacts shall be tested for electrical continuity with a calibrated
volt-ohm-meter from the exposed end of the cable conductor to the applicable
component of Twinax contact.
80.4.4.3.4 Twinax Socket Contact Separation Force
The purpose of this test is to demonstrate the force required separating the test pin from the
Twinax center contact socket. The following details shall apply:
a. Test Equipment
1) Drop weight assembled in accordance with Figure 80-10.
2) Solution for cleaning the test pin.
b. Test Samples
The samples shall consist of the socket dielectric assembly as shown in Figure 80-5
and / or Twinax socket contacts, part number SSQ22680-20-CTS-2, as shown in
Figure 80-6.
c. Test Procedure
1) The test pin shall be cleaned periodically to remove any foreign surface film,
which may affect the separation force recorded.
2) During the test each Twinax socket shall be aligned with the test pin of the drop
weight.
3) Condition the socket contact by inserting and removing the test pin one at a
time.
4) Position the contact under test in a vertical position, with the socket tines in the
upright position.
5) Insert the drop weight into the socket contact to a specified length, (ref. Figure
80-10). Slowly turn the contact to the vertical downward position. If the drop
weight is retained, the socket is acceptable.
6) Record the pass/fail results by contact lot number, and / or connector part
number and serial number along with any observations.
VIII-14
80.4.4.3.5 Twinax Center Pin Alignment Procedure
The purpose of this procedure is to ensure proper axial position of the center pin contact.
a. Test Equipment
1) Alignment tool FA22680-1.
2) Solution for cleaning test pins.
b. Test Procedure
1) The aligning tool shall be cleaned periodically to remove any foreign surface
film, which may contaminate contact surface.
2) During the procedure the aligning tool shall be aligned with the pin contact.
3) The aligning tool shall be inserted into the pin contact assembly until it hits the
bottoms. Axial force shall be applied gradually.
4) The aligning tool shall be slowly rotated 360 at a uniform rate so that the force
is applied uniformly to the outside diameter of the center pin. Complete 2 to 3
rotations.
5) Remove the aligning tool and visually inspect contact for axial alignment.
80.4.4.3.6 Socket Contact Separation Force
This test shall be performed prior to crimping on 100% of socket contacts, sizes 22, 20, 16 and 12.
The purpose of this test is to demonstrate that the socket contacts meet minimum socket separation
force requirement in accordance with SSQ22680, section 6, Table IV. The following details shall
apply:
a. Test Equipment
1) Drop weight assembled in accordance with Figure 90-39
2) Solution for cleaning the test pin
b. Test Procedure
1) The test pin shall be cleaned periodically to remove any foreign surface film, which
may affect the separation force recorded.
2) During the test each socket shall be aligned with the test pin of the drop weight.
3) Condition the socket contact by inserting and removing the test pin one time.
4) Position the drop weight test pin in a vertical position.
5) Install the socket contact into the drop weight to an approximate length L1, (ref.
Figure 90-39). Slowly lift up contact with the weight pin. If the drop weight is
retained, the socket is acceptable.
6) Record the pass/fail results by contact lot number. When the contact is a part of the
connector kit, record connector part number, serial number and contact lot number
along with any observations.
VIII-15
80.4.4.3.7 Data Recording
The data sheets and records shall include, as a minimum, the following details:
a. Title of test, date, and name of operator.
b. The identification number of the crimping tool and the applicable controls and
instructions.
c. Equipment used and calibration data.
d. Individual measurement and observation of performed tests.
e. The test log entries shall also indicate the following modes of separation when
applicable:
1) Break at crimp.
2) Break outside of crimp.
3) Fray Break: wire strands break in crimp and some strands broke
outside of crimp.
4) Pull out.
5) Other: define in detail.
80.6 Notes
80.6.1 Intended Use
The procedural requirements established herein are for production crimping of ORU connector
contacts of various sizes and styles to be used on space vehicles, mission-essential support
equipment, and electrical systems for the International Space Station. The requirements specified
herein shall meet or exceed requirements set forth in NHB 5300.4(3H), applicable to crimping of
connector contacts.
80.6.2 Definitions
80.6.3 Usage items
Usage items are materials, which are consumed or used, in uncontrolled amounts during assembly
procedures, not necessarily called out on engineering control documents.
80.6.3.1 Insulation Whiskers
Acceptable minimum remnants of wire or cable insulation due to the use of thermal strippers.
80.6.3.2 Birdcaging
The radial expansion of individual strands in a stranded conductor (bowing outward) that can
occur in the exposed portion of the conductor between the insulation strip and termination point.
Table 80-1 CRIMP TOOLS FOR SIZE 4 AND LARGER CONTACTS
VIII-16
Description Contact Tool Part Number Equivalent Tool

Size (Note 1) (Notes 1, 2)
Basic Tool 0 M22520/23-01 500-D
Die Set M22520/23-05 514DA-0N
Locator M22520/23-13 5440
Basic Tool 4 M22520/23-01 500-D

Die Set M22520/23-04 514DA-4N
Locator M22520/23-11 5420
Basic Tool 8 M22520/23-01 500-D

Die Set M22520/23-04 514DA-8N
Locator M22520/23-11 5400
Notes:
1. Tools not listed in the table or tool equivalent tools may be used only when applicable calibration
has been performed in accordance with MIL-STD-45662.
2. Pico Crimping Tools part numbers are specified
Table 80-2 CRIMP TOOLS FOR SIZE 12 AND SMALLER CONTACTS

Description Contact Contact Wire Tool Part Recommended
Size Barrel Size Number (Note Selector
1) Setting
Basic Tool M22520/1-01
Positioner (yellow) 12 12 12 M22520/1-04 8
Positioner (blue) 16 16 16 M22520/1-04 6
Positioner (blue) 16 16 20 M22520/1-04 4
Positioner (red) 20 20 20 M22520/1-02 4
Positioner 22 22 22 M22520/2-07 4
24 M22520/2-07 3
Note:
1. Tools not listed in the table, or tools equivalent to those listed above may be used only
when applicable calibration has been performed in accordance with MIL-STD-45662.
Table 80-3 TOOLS for REDUCED BARREL CONTACTS

Description Contact Wire Wire Part
Size Barrel Size Number(1)
Basic Tool 12 16 16 M22520/1-01
Positioner (blue) M22520/1-02
(Pin & Socket)
Selector Setting 6
VIII-17
Basic Tool 0 4 4 500-D 2

Die Set 514DA-0/4N-185 2
Locator 5440 2
Notes:
1. Tools not listed in the Table or tools equivalent tools may be used only when
applicable calibration has been performed in accordance with MIL-STD-45662.
2. Pico Crimping Tools part numbers are specified.
Table 80-4 TOOLS for TWINAX CONTACTS

Description Wire Recommended Tool Part Number
Size Selector Setting
Center Contact 22 7 K7091
Positioner 24 5
Intermediate Contact Die N/A N/A Y631 Die Closure B 1
Outer Crimp Sleeve (Die) N/A N/A Y631 Die Closure A 1
Twinax Pin Pressure Aid N/A N/A FA22680-9 3
Twinax Pin Pressure Aid N/A N/A FA22680-9 4
1. Notes: Daniels Manufacturing Corporation part number is specified.
2. N/A - Not Applicable.
3. Spring to be calibrated to 5.5 0.5 pounds when compressed to 0.790 inches.
4. Spring to be calibrated to 6.5 0.5 pounds when compressed to 0.730 inches.
Table 80-5 HEAT SHRINK TUBING MATERIAL

Cable Application Ordering Size ID M230553/13
(minimum) 1 Part Number 2
4 AWG 0.625 M23053/13-05-0
Notes:
1. All dimensions are in inches.
2. Or equivalent with the same properties and characteristics.
VIII-18
Table 80-6 CRIMP TENSILE STRENGTH

Wire Barrel Conductor Conductor Test Wire Tensile
Size Size (AWG) Material/Type Length Strength (lbs)
22 22 High Strength-Nickel 4 inch 8
Plated Copper Alloy
20 20 Copper 4 inch 20.6
8 8 Copper 6 inch 288
Twinax size 8 RM 2589-xxx Shielded Cable 6 inch
-001 Single Shield 25
-002 Dual Shield 25
-003 Single Shield 25
Twinax size 8 NDBC-TFE-22- Shielded Cable 6 inch 25
2SJ-75
VIII-19
100
COMFORT ZONE
90
O
( F)
80
TEMPERATURE
70
60
10 30 50 70 90
RELATIVE HUMIDITY ( % )
9319-6
Figure VIII.1 Contact to Wire Insulation Clearance
Figure 80-1 Contact to Wire Insulation Clearance
VIII-20
HEAT SHRINK SLEEVING

FOR UNUSED SHIELDED CABLES
SLEEVING
1.125 MIN
.200 MIN
.300 MAX
SUBSEQUENT SLEEVING (IF REQUIRED)
.200 MIN
.300 MAX
Notes:
1. All dimensions are in inches.
9319-7
Figure VIII.2 Shrink Sleeving Application (Braids)
Figure 80-2 Shrink Sleeving Application (Braids)
VIII-21
Figure 80-3 Shrink Sleeving Application (Conductors)
VIII-22
Figure 80-4 Contact to Wire Insulation Clearance
VIII-23
Figure 80-5 ORU Twinax Contact Components
VIII-24
Step 2
a. Strip the outer jacket in accordance with Appendix VII to the dimension specified.
b. Care should be taken to avoid nicking or cutting the braid strands when cutting the
outer jacket.
.75 0
c. Gently flair the shield braiding open and fold it back over the outer jacket to expose
the twin conductors within.
d. Do not cut the shield braid strands.
.
040
-
.
06
F
I
LL
ER
e. Measure and cut two conductor wires by .040 - .060 in.
ROD
Step 3
a. Fold the braid shield back over the twin conductor wires again.
b. Insert the twin wires and the shield in through the outer ferrule.
c. Push the outer ferrule back until the outer jacket insulation of the cable bottoms on
the ferrule.
d. Fold the shield braid over the outer ferrule and trim excess shield material at the
shoulder of the ferrule.
VIII-25
e. Measure and cut the twin conductor wires to the specified length. The measurement
shall be taken from the shield.
Note: shield shall be held firmly against the ferrule during

measurement.
"I " W
IRE .3
55-.3
70
"C "W E .3
IR 40-.3
55
f. Score the insulation of the conductor wires and remove the insulation from the C
wire protruding through the crimp bushing.
" C" WIRE

.1
50-.1
60
Step 4 .1
50-.1
60
" -I" WIRE
a. Bend the wire designated I slightly
INoutward,
SU LATIO and
NS position
COR IN Gthe wire designated C
to the center of the cable.
"I " W IRE
b. Insert the C wires into the"

center
C " Wpin/socket
IR E dielectric assembly until the wire
insulation bottoms against the center contact.
c. Push back the dual entry dielectric prior to crimping.
d. Make sure the wire designated C is inserted into the center contact.
VIII-26
INSPECTIONHOL
E
e. Verify that the C wire can be seen in the inspection hole of the contact before
crimping.
f. Place the pin/socket contact into the appropriate crimping tool specified in Table
80-4 and while applying pressure against the contact and the crimp tool, complete
the crimp.
g. Fully seat the dual entry dielectric. Verify the overall length of the complete
Pin/Socket dielectric assembly is as specified in Figure 80-6.
Figure 80-6 Cable, Wire and Braid Preparation(steps 2 through 4)
Step 5
a. Remove the insulation from the I wire.

b. Insert the center pin/socket dielectric assembly into intermediate contact until it
bottoms.
c. Insert the I wire into the small hole at the rear of the intermediate contact. Make
sure the wire designated I is positioned through the side slot in dual entry
insulator.
" I " WIRE
" I " WIRE
CENTERCONTACT
ENDVIEW OF
d. Verify that the I wire is visible in the inspection hole
INTERMEDIATE of the intermediate contact
before crimping. CONTACT
e. Install the intermediate contact assembly into an appropriate crimp tool (see Table
80-4), and hold the assembly firmly in place. Verify that the slot in the intermediate
contact is aligned with the tool locator (key) in the crimp tool. The crimp marks on
the intermediate contact should resemble those shown in the diagram.
VIII-27
DUA
"I"
A INT
ERMEDIAT
E
CONTACT
T
OO LL
O CAT
ORING ROOVE
OFINT
E RMEDIAT
ECONTACT
V
IEWA-A
Figure 80-7 Intermediate Contact Crimping (step 5)
VIII-28
Step 6
a. Taper braid over intermediate contact assembly and slide the outer ferrule forward
until the braid is trapped between the outer ferrule and dual entry insulator of the
center pin/socket assembly. Fold braid back over the ferrule. Make sure the braid is
distributed evenly over the ferrule surface.
b. Push intermediate contact assembly into the outer contact housing until it bottoms
out as shown.
c. Install TWX Contact assembly into the jaws of the specified crimp tool (see Table
80-4). Close dies approximately half way to make sure it retains the rear end of the
TWX contact assembly.
NOTE: Alignment sprocket should secure the outer contact insertion into crimp tool from the
same side as intermediate contact. Alignment sprocket shall be attached at the end of the hex
side of the crimp die.
d. Install Pin Pressure Aid (Part Number FA22680-9) over the TWX Pin Contact or
Socket Pressure Aid (Part Number FA22680-10) over the TWX Socket Contact as
applicable and push it forward until it bottoms on the front surface of the TWX Outer
Body.
e. With the aid of the pressure tool apply pressure to contact assembly in the direction
shown while applying the final crimp to the contact.
f. Remove the contact assembly and set aside for test/inspection.
Step 7
a. Inspect complete TWX contact assembly in accordance with 80.4.4.3.2.2.2.
VIII-29
PIN CONTACT
CABLE
1.233 +.012 / -.008
CRIMP INDENTS
(NOTE 2)
(INTERMEDIATE TO OUTER)
.016 +/-.015
(CENTER TO OUTER)
SOCKET CONTACT
CABLE (INTERMEDIATE TO OUTER)
FULLY ASSEMBLED CONTACTS

SHALL HAVE HEX CRIMP INDENTS
AND DIMENSIONS AS SPECIFIED
1.209 +.012/-.008
CRIMP INDENTS
(NOTE 2)
NOTE:
1. ALL DIMENSIONS ARE IN INCHES.
2. NOT TO EXCEED .257 DIA AFTER HEX CRIMP.
Figure 80-8 Outer Contact Crimping (steps 6 and 7)
VIII-30
Figure 80-9 Wire Preparation for Crimp Tensile Test
VIII-31
TEST ARTICLE LENGTH OF ENGAGEMENT L +

0.03
CENTER SOCKET CONTACT ASSEMBLY 0.10
COMPLETE SSQ22680-20-CTS-1 TWINAX 0.17
CONTACT
Figure 80-10 1 oz Drop Weight
VIII-32
Figure 80-11 Aligning Tool FA22680-1 for SSQ22680-20-CTP-TWINAX
VIII-33
IX. APPENDIX IX
ASSEMBLY PROCEDURES FOR CONNECTORS,
RECTANGULAR (ORU), SPACE QUALITY
IX-1
90.0 Appendix IX
90.1 Scope
This specification establishes the procedural requirements for the assembly and wiring of
connectors, rectangular, (ORU), space quality, hereinafter referred to as connector assembly,
used on space vehicles, space vehicle mission-essential ground support equipment, and electrical
systems for the Space Station.
90.2 Classification
The specifications and requirements for the preparation and assembly of the connectors shall be
of the types specified as follows:
a. Type I Connector Plug with Pin type contacts.
b. Type II Connector Receptacle with Socket type contacts.
90.2.1 Applicable Documents
90.2.1.1 Government Documents

The following documents of the exact issue shown form a part of this specification to the extent
between the documents referenced herein and the contents of this specification, the contents of
this specification shall take precedence.
SPECIFICATIONS
MS217488 Plug, End Seal, Electrical Connector, Specifications for
MIL-I-23053/13 Insulation Sleeving, Electrical, Heat Shrinkable, Fluoroelastomer, Flexible
TT-I-735 Isopropyl Alcohol.
NHB 5300.4(3G) Requirements for Interconnecting Cables, Harnesses, and Wiring.
SSQ 22680 Connectors, Rectangular, (ORU), Space Quality.
90.3 Requirements
essential to the safety of personnel using the finished product and to the safety of the equipment
in which the connector assembly is an integral part.
90.3.1 Equipment
A partial list of equipment required for connector assembly is identified below. Where an
integral piece of equipment or tool is not specified, the tool or equipment used shall be calibrated
and certified in accordance with the latest issue(s) of applicable calibration document(s) in effect,
approved for use by the appropriate quality or product assurance activity. All vital information,
(manufacturer, description, serial number, calibration information, part number, etc.) shall be
recorded or logged into the applicable ledger or record book.
IX-2
Nomenclature Part Number (1) Manufacturer Usage

Trimming Tool 62006 Hunter Shield Dressing
Heat Gun HG501A Master Shrink Sleeving
Contact Insertion Tool Refer to 3.3.4.2.4 Cooper Inserting of Contacts
Industries,
(formerly G&H
Technology)
Contact Removal Tool Refer to 3.3.4.2.4 Cooper Extraction of Contacts
Industries,
(formerly G&H
Technology)
Crimp Tools See Note 2 Crimping
Push Tool (TBD) (TBD)
Shielding Clamping Tool 600-058 Glenair Shielded Termination
EMI Banding Clamps 600-052 (.240 wide) Glenair Shielded Termination
Notes:
1. Tools not listed in the Table, or tools equivalent to those listed above may be used only
when all applicable calibration and certification have been performed.
2. Unless otherwise specified in the controlling documents, crimp tools shall be as specified
in Appendix VII of SSQ22680.
90.3.1.1 Hand Tools
Cleaning, calibration, and maintenance of tools on a periodic basis shall be performed to assure
proper function, control, and safety.
90.3.1.1.1 Tool Calibration and Identification
All calibrated tools shall be identified and marked, including the following as a minimum:
a. The manufacturers part number as applicable.
b. The manufacturers cage code number as applicable.
c. Tool nomenclature.
d. Calibration date.
e. Expiration date of calibration.
90.3.2 Materials
The materials required for connector assembly preparation are identified below:
IX-3
Nomenclature Part Number or Manufacturer Usage

Specification1
Isopropyl Alcohol Best Commercial Grade, Commercial Various
99% Pure (TT-I-735)
Tubing, Heat Shrink Refer to 3.2.2
Assembly Wipes Approved Clean Room Commercial Cleaning
Assembly Wipes
Notes:
1. Materials not listed in the table, or materials equivalent to those listed above may
be used only when prior approval is granted by the product assurance activity.
90.3.2.1 Solvents
Only the solvents listed are acceptable when used for the assembly process. Solvents shall be
properly labeled and shall be maintained in a clean and uncontaminated condition. Solvents shall
be nonconductive and non-corrosive: shall not dissolve or degrade the quality of parts or
materials. Any solvent showing evidence of contamination or decomposition shall not be used.
The solvent material listed is the usage items as defined in 70.3.2.
90.3.2.2 Heat Shrink Tubing Material
When required, heat shrink sleeving shall be applied as specified in section 90.3.3.3.1. Heat
shrink sleeving, unless otherwise specified, shall be in accordance with MIL-I-22053/13. In the
event of conflict between the materials referenced herein and the materials specified in the
controlling engineering documents or drawings, the contents of the controlling engineering
documents shall take precedence.
90.3.3.1 General
90.3.3.1.1 Records
calibrated tools and equipment used. Comprehensive records shall be kept of the certification of
the personnel and the calibration of tooling and equipment required as specified.
90.3.3.1.2 Hardware
The hardware shall be as specified in the controlling documents or drawings. Wire, connectors,
connector use accessories, and contacts shall be kept free of dirt and contaminants.
90.3.3.1.3 Uncalibrated Tools
The use of uncalibrated or out-of-calibration tools shall be prohibited.

90.3.3.1.4 Assembly Facilities
Environmental conditions, and the cleanliness of assembly and fabrication areas, shall be
maintained in accordance with requirements specified in NHB 5300.4(3G).
IX-4
90.3.3.1.5 Cleaning
General cleaning of wires and connector components shall be performed using a lint-free cloth or
approved assembly wipe wetted with the applicable solvent(s) listed in 90.3.2.
90.3.3.1.6 Storage and Handling
Appropriate containers compatible with the materials stored shall be used for assemblies to
control conditions that could degrade the reliability of the parts and deliverable items. In
particular, containers shall be used to prevent damage or contamination during handling and
storage.
90.3.3.2 Part Assembly Requirements
90.3.3.2.1 Heat Shrink Sleeving
Heat shrink sleeving specified shall be larger than the maximum diameter of the wire or cable
being covered, (refer to manufacturer specifications for recommended heat shrink sleeving
dimensions), and after shrinking shall provide a tight fit over the wire or cable in the area of
maximum diameter.
90.3.3.2.2 Shrink Sleeving: Conductor Application
Heat shrink sleeving shall be applied as required or when specified prior to crimping of the
connector contacts in accordance with SSQ22680, Appendix VII.
90.3.3.2.3 Shrink Sleeving: General Application
Heat shrink sleeving shall be applied as required, or when specified, in accordance with the
specifications below:
a. When two or more pieces of sleeving are required, the minimum length of
overlap shall be 1/2 inch.
b. A deflector shall be attached to the heat source to ensure uniform heating.
c. Heat shields or heat sinks shall be used where there is danger of damage to
adjacent parts or insulation.
d. Pre-set thermostat settings shall not be changed.
e. Heat one end of the sleeving to anchor the tubing in place first. Then move
gun slowly along sleeving to distribute heat evenly.
f. Do not leave heat gun in one position, but move it within a small area to
prevent blistering due to overheating.
g. Allow sleeving to cool to room temperature before subsequent application.
IX-5
90.3.3.2.4 Contact Crimping
All crimping shall be performed as specified in section 90.3.4.3.2.

90.3.3.2.5 Threaded Fasteners
Threaded fasteners not requiring specific torque values shall be tightened with the appropriate
hand tools.
90.3.3.3 ORU Connector Configurations
The ORU connectors consist of a main connector housing or body with removable crimp
contacts of various sizes dictated by the insert option letter. The specific type of connector shall
be as specified in the controlling documents or drawings. The different insert options and
associated contact sizes for the ORU connectors are indicated below.
Contact Total Number of Contact Size(s)

Arrangement1 Contacts
A 8 #1/0, #4
B 11 #4
C 56 #4, #12, #16
D 86 #16, #20
E 86 #20, #22, TWX
F 58 #16, #20, #22, TWX
G 76 #12, #22
J 234 #8, FO, #22
K 88 #8, #12, #20
Notes:
1. See applicable figures in the SSQ 22680 document for the insert arrangement
diagrams.
2. TWX - concentric Twinax cable connector contacts.
90.3.3.3.1 Connector Preparation
Connectors and their related components shall be free of dirt, grease, dust, and contaminants.
Connectors shall be cleaned as specified in section 90.3.3.2. All contacts for the connectors
specified herein shall be crimped and assembled outside of the connector housing, and shall be
subsequently installed into the connector insert.
90.3.3.3.2 Connector Parts and Accessories
Verify all parts are supplied as specified in the controlling engineering documents or
specifications. To prevent damage of parts and contamination by dust, dirt, or grease and oil, do
not open individually packaged part items unless they are ready for assembly. Verify that the
connector identification (see Figures 90-2 or 90-4) is as specified in applicable engineering
document or drawing.
IX-6
NOTE: Extreme care shall be exercised when handling the connectors due to the
fragile EMI shielding gaskets and EMI spring encircling the connector body.
When handling the connectors, hold the connectors at the front end by the
protective covers or by the connector mounting ears. The protective covers do
not have to be removed. Care must be taken to avoid breaking the EMI
springs or damaging the gaskets.
90.3.3.3.2.1 Contacts
Verify that all the specified sizes and types of contact are correct for the particular insert option
of the connector. Refer to the controlling engineering documents or drawings for the specified
connector configuration and options.
90.3.3.3.2.2 Grommet Sealing Plugs
Unless otherwise specified, unused cavities of connector inserts shall be filled with the grommet
sealing plugs. The military grommet sealing plugs shall be an allowable alternate to the SSQ
grommet sealing plugs. The part numbers of the grommet sealing plugs and their corresponding
cavity sizes will be as follows:
90.3.3.3.2.3 Backshells
SSQ22680 Part Number Grommet Cavity Connector backshells are

Size specified in the applicable
controlling engineering
SSQ22680-050-22 22 drawings or documents. When
SSQ22680-050-20 20 supplied, visually inspect the
connector backshells for dirt,
SSQ22680-050-16 16 dust, contaminants, damage, or
SSQ22680-050-12 12 anomalies of any kind. Clean
the connector backshells using
SSQ22680-050-8 TWX the approved solvent specified
SSQ22680-050-8P 8 in 90.3.2 and dry with approved
assembly wipes. Store in
SSQ22680-050-4 4
storage container until ready
SSQ22680-050-0 0 for assembly.
90.3.3.3.2.4 Insertion/Extraction Tools
Connector contacts and sealing plugs shall be inserted and removed using approved tooling as
specified in the table below, (refer to SSQ22680, Appendix IV for physical configurations and
dimensions). In the event of conflict between the tools specified herein and the tools specified in
the controlling engineering documents, the contents of this document shall take precedence.
NOTE: For contacts larger than size 4, and for concentric twin axial (TWX)
contacts, the use of an insertion tool will not be required.
IX-7
90.3.3.4 Assembly Processes

90.3.3.4.1 Crimping
Remove the contacts from the package and visually inspect for dirt, dust, contaminants, damage,
or anomalies of any kind. Clean the connector contacts using the approved solvent specified in
90.3.2 and dry with approved assembly wipes. Crimp all contacts to wires as specified in
SSQ22680, Appendix VII.
90.3.3.4.2 Contact Insertion
To install the crimped contacts into the connector insert cavities, the insertion tool or the
inserting end of the combination tool shall be used as specified in 90.3.3.4.2.4. For Twinax
contacts and contact size 4 or larger, insertion tools will not be necessary. Use Figures 90-8 and
90-9 for reference.
NOTE: Any damaged plastic installation or removal tool must be discarded immediately
and replaced with a new tool. Should part of the tip of the plastic tool break off, all pieces
of the tip must be accounted for. The responsible engineer shall be notified immediately.
a. Visually inspect the insert cavities for dirt, dust, contaminants, damage, or
anomalies of any kind. When required, clean the connector cavities using
the approved solvent specified in 90.3.2, and air-dry it with pressurized air
when available.
b. When using an insertion tool, carefully snap the tool around the wire
insulation with the tip of the tool butting up against the rear shoulder of
the contact.
c. Dip contact (and the tip of the tool if it is used) into an approved alcohol
solution for lubrication.
d. Axially align the contact with the insert cavity and gently push the contact
forward until it bottoms. A slight click sound may be heard when
inserted correctly.
e. If the tool was used, carefully remove the insertion tool; do not pull on the
wire while taking the tool out.
f. Grip the wire firmly between the thumb and forefinger and pull the wire
gently in a perpendicular direction to the plane of the connector rear face.
g. Verify that the contact is held in place. The amount of pull applied shall
be the normal force applied using the thumb and forefinger only.
NOTE: Care shall be taken not to damage the wire grommet seal or the wire
insulation during installation or testing of the wire. Any damage to the
grommet seal must be reported for disposition and proper corrective actions.
It is recommended that the centermost contacts be inserted first, progressively working
outwards.
IX-8
90.3.3.4.2.1 Conditioning Of SSQ 22680-20-4-4s Socket Contact

Condition SSQ 22680-20-4-4S socket contact with the purpose to reduce risk of possible damage
due to interference between pin and socket contacts in process of connector mate. This procedure
shall be used on size 4 socket contacts installed into connector.
90.3.3.4.2.2 Tools
Engagement Aid, Part Number FA22680-4-10 in accordance with the following figure herein.
Note: Only certified tools shall be used for contact conditioning.
Conditioning Procedure:
a. Remove the connector front cover as required.
b. Perform visual inspection under 7 10X power for equal circumferential and radial
tine positions with regard to the center post and take photographs of the connector.
c. Align the Engagement Aid tool with the socket contact centerline. The Engagement
Aid tool shall be cleaned periodically to remove any foreign surface film, which may
contaminate contact or connector.
d. Carefully insert Engagement Aid tool into the socket. Push until it bottoms, hold for
approximately 3 to 5 seconds, and then remove. Perform visual inspection under 7
10X Power for equal circumferential and radial tine positions with regard to the
center post.
Notes:
No discontinuity at blend of 0.10 radius & .196-.198

2. Material: Stainless Steel
Figure 90-1 Engagement Aid, Part Number FA220-4-10
IX-9
90.3.3.4.3 Contact Removal
To remove a contact, the appropriate extraction tool or the extracting end of the appropriate
combination tool shall be used. Refer to the table in section 90.3.3.4.2.4 for the tool specified.
Use Figures 90-8 and 90-10 as reference.
NOTE: Always apply a small amount of alcohol solvent to the tip of the tool before
inserting into the insert cavity. This will provide lubrication and prevent damage to
the connector insert grommet.
a. Wet the tip of the tool with alcohol and carefully snap the tool around the wire
insulation. Push forward into the cavity of the connector insert until it bottoms
against the shoulder of the contact.
b. Press and hold the wire down between the thumb and the serrated portion of
the tool. Gently pull away at an axial direction from the connector and extract
the contact/wire assembly.
90.3.3.4.4 Grommet Sealing Plug Insertion
90.3.3.4.4.1 SSQ Grommet Sealing Plug Insertion

When specified, all unused cavities shall be filled with grommet sealing plugs as follows:
a. Carefully insert the narrow end of the grommet sealing plug into the tip of the
insertion tool (see Figure 90-11), with the tip of the tool butting up against the
rear shoulder of the plug.
b. Dip the tool and sealing plug into an approved alcohol solution for lubrication.
c. With the grommet sealing plug and tool axially aligned with the connector
insert cavity, insert and push the plug forward into the connector cavity until it
bottoms.
d. Carefully remove the insertion tool from the connector insert.
90.3.3.4.4.2 Military grommet sealing plug insertion
DELETED
90.3.3.4.4.2.1 Regular contacts
DELETED
90.3.3.4.4.2.2 Twinax Contacts
DELETED
IX-10
90.3.3.4.5 Power Connectors - No Shield Braids
The backshells for these connector types have rectangular exit holes for the wire and are
available in three types of configurations: straight, 45-degrees, or 90-degrees, (refer to
SSQ22680, Appendix I for physical characteristics and dimensions). These backshells are single
piece construction with strain relief saddle attachments that can be removed and tightened by two
screws. Connector backshells are connected directly to connector housings with the use of four
screws. Refer to Figures 90-12 through 90-15 for reference, and assemble the connector as
follows:
a. Terminate the wires by installing and crimping the contacts as specified in
90.3.4.3.1.
b. Insert crimped, terminated wire bundle through the narrow end of the backshell
and move the backshell along the wire bundle, out of the way.
c. Cut a piece of heat shrinkable tubing about 1.5 inches long, or as required, and
slip it over the wire bundle. Move the shrink tubing along the wire bundle, out of
the way.
d. Remove the clear plastic cover from the connector. Do not remove the front
protective covers on the connectors. Use extreme care and avoid touching or
disturbing the EMI shielding gaskets. When handling the connectors, hold the
connectors by their mounting ears or by their protective front covers (refer to
Figures 90-2 or 90-3).
e. Install crimped contacts into connector as specified in 90.3.4.3.2. Verify proper
seating of the contacts by performing the test specified in 90.4.5.2.
f. Slide the backshell forward and butt the backshell against the connector housing.
Mark the approximate location of the saddle clamps with respect to the wire
bundle using a piece of adhesive tape.
g. Move the backshell out of the way and position the heat shrink tubing
accordingly.
h. Remove the tape marker and re-position the heat shrink tubing. Heat shrink into
place as specified in 90.3.3.3.1.
i. Slide the backshell forward and insert the four screws. Tighten, and then torque
the screws down with a calibrated tool to a value of 8 to 10 inch-pounds.
j. Attach the strain relief saddle attachments and tighten securely onto the heat
shrunk section on the wire bundle. If possible, allow a little slack on the wires
within the backshell to prevent undue stress on the wire grommet seals.
k. Torque saddle clamp screws to the specified value of 12 to 14 inch-pounds.
l. After completion of the assembly with the backshell, make sure that each contact
can reasonably float in a radial direction and move a few thousandths of an inch
in an axial direction IAW paragraph 90.4.5.4.
m. Perform Twinax socket contact retention force test in accordance with paragraph
90.4.5.5 when SSQ22680-010-1 and SSQ22680-012-1 ORU connectors are
harnessed.
IX-11
n. Inspect Twinax pin contacts for proper alignment in accordance with 90.4.5.6 when
connector SSQ22680-009 and SSQ22680-011 ORU connectors are harnessed.
90.3.3.4.6 EMI Type Backshells
These backshells have removable strain relief clamps that are threaded onto the main body of the
backshell (part numbers SSQ22680-10-003,-004,-005,-006,-008,-009) or attached by four screws
(part numbers SSQ22680-10-014). Figure 90-16 and 90-17 shows a typical circular type
backshell and strain relief clamp. Connector backshells are connected directly to connectors
with the use of four screws. Termination of the wire shield braids will vary for various wire
bundle types. Always refer to the applicable figures for reference.
90.3.3.4.6.1 Overall Shield Braid Only
The process outlined below is for the termination of a wire bundle comprised of various sized
wires with an overall shield braid. The applicable figures to use as reference are Figures 9-20,
90-21, and 90-22.
a. For wire bundles with an outer jacket: trim the jacket back as required, but no
more than 4 inches, in accordance with SSQ22680, Appendix VII.
b. Trim the outer shield braid back as required, but no more than 2 inches maximum,
from the end of the wire bundle.
c. Crimp the connector contacts onto the wires as specified in 90.3.4.3.1.
d. Insert the wire bundle through the strain relief cable clamp first (observe proper
orientation of the strain relief clamp). Then, insert wire bundle through the
circular end of the backshell, and move the backshell and clamp along the wire
bundle and out of the way.
e. Insert a piece of heat shrink tubing about 2 inches long, and move it along the
wire bundle and out of the way.
f. Remove the clear plastic cover from the connector. Do not remove the front
Figures 90-2 or 90-3).
g. Install crimped contacts into connector as specified in 90.3.4.3.2. Verify proper
h. Slide the backshell forward towards the connector and butt the backshell against
the connector housing. Insert the four screws through the backshell and into the
threaded holes of the connector housing. Tighten the screws and torque down to
the specified value of 8 to 10 inch-pounds.
NOTE: For wire bundle with an outer jacket material: if the jacket is still in excess,
preventing the EMI clamping process, trim away the excess jacket as required
IAW SSQ22680, Appendix VII. The end of the jacket should be about 1 inch
away from the shield retention area of the backshell, but no more than 1.25
inches.
i. Prepare the shield braid as follows:
IX-12
1) Flare the shield braid open. If necessary, trim the shield braid if there is an
excess amount.
2) Roll the edges of the shield braid approximately 1/4-inch inwards. The
overlap should be as shown in Figure 90-22.
3) Place overlapped portion of wire braid over the termination area of the
backshell for EMI band clamping.
4) Prepare a shield braid EMI clamping band by rolling the tail indicator mark on
the EMI band around the wire bundle and through its buckle slot twice around
(see Figure 90-23).
5) Slip the EMI clamping band over the termination area of the backshell.
6) Milk the shield braid as required to remove the slack around the backshell
7) Insert the tail end of the EMI clamping band into the clamping tool. The tool
to use in terminating this band and the process sequence is as shown in
Figures 90-25 through 90-28.
8) Squeeze the handle of the tool to compress the band and take up the excess
clamp band.
NOTE: Verify that the shield braid is positioned correctly at all times
throughout all steps of the band clamping process.
9) Compress the band until the handle locks indicating the calibrated tension is
reached.
10) Cut the excess EMI band off by squeezing the cut-off handle.
j. Slide the heat shrink tubing forward and position the tubing under the strain relief
saddle attachment, and to overlap the outer bundle jacket. Use Figure IX.6 as
reference.
k. Shrink tubing into place as specified in 90.3.3.3.1.
l. Attach strain relief as follows:
1) When assembling backshells, part numbers SSQ 22680-10-003,-004,-005,-
006,-008,-009 (ref. Figure 90-16) slide the strain relief clamp forward and
thread the clamp retaining nut onto the backshell. Torque to the specified
value of 120 inch-pounds.
2) When assembling backshell, part number SSQ 22680-10-104 (ref. Figure 90-
17) slide the strain relief clamp forward and butt against the backshell
housing. Insert the four screws through the strain relief and into the threaded
holes of the backshell housing. Tighten the screws and torque down to the
specified value of 8 to 10 inch pounds.
IX-13
m. Attach the strain relief saddle attachments and tighten saddle attachment screws
securely onto the heat shrunk section of the shielded wire harness. Allow a little
slack on the wires within the backshell before the strain relief attachments are
tighten securely onto the heat shrunk section on the wire bundle to prevent undue
stress on the contacts. Tighten and torque screws to the specified value of 10 to
12 inch-pounds. When assembling backshell, part number SSQ 22680-10-014
(ref. Figure 90-17), place the screw protectors over the exposed threads on the
saddle clamp screws and torque them to the values specified in the controlling
engineering documents (4-6 inch-pounds)
n. After completion of the assembly with the backshell, make sure that each contact
o. Perform Twinax socket contact retention force test in accordance with paragraph
harnessed.
p. Inspect Twinax pin contacts for proper alignment in accordance with 90.4.5.6
when connector SSQ22680-009 and SSQ22680-011 ORU connectors are
harnessed.
90.3.3.4.6.2 Individual Shielded Wire Braids Only
The process outlined below is for the termination of a wire bundle comprised of various cables
with individual shield braids.
more than 4 inches, as specified in accordance with SSQ22680, Appendix IX.
b. On each individual shielded wire/cable, remove the jacket and extract the wire
conductor(s) from the shield braid as specified in SSQ22680, Appendix IX.
Remove no more than the specified amount of jacket or shield as shown for the
type of backshell listed below (see also Figures 90-20 and 90-31 for reference):
Backshell Part Backshell Type Maximum Jacket /
Number Shield Length
SSQ22680-10-003 90, EMI 4.0 inches
SSQ22680-10-004 Straight, EMI 3.0 inches
SSQ22680-10-005 90, EMI 4.0 inches
SSQ22680-10-006 Straight, EMI 3.0 inches
SSQ22680-10-008 30, EMI 4.0 inches
SSQ22680-10-009 30, EMI 4.0 inches
c. Install and crimp the connector contacts as specified in 90.3.4.3.1.
IX-14
d. Insert the wire bundle through the strain relief cable clamp first (observe proper
e. Cut a piece of heat shrinkable tubing about 1.5 inches long and slip it over the
wire bundle. Move the shrink tubing along the wire bundle, out of the way.
f. Remove the clear plastic cover from the connector. Do not remove the front
Figures 90-2 and 90-3).
g. Install crimped contacts into connector as specified in 90.3.4.3.2. Verify proper
h. Slide the heat shrink tubing forward and position the tubing as shown in the
Figure.
i. With the tubing aligned, heat shrink into place as specified in 90.3.3.3.1.2.
j. Fold the individual shield braids backwards and slide the backshell forward
towards the connector. Make sure all the shield braids are inserted through the
circular opening of the backshell (use Figure 90-32 as reference).
k. Butt the backshell against the connector and insert the four screws through the
backshell into the threaded holes of the connector housing.
l. Tighten and then torque down the screws to the specified value of 8 to 10 inch-
pounds.
NOTE: For wire bundle with an outer jacket material: if the jacket is still in
excess, preventing the EMI clamping process, trim away the excess
jacket as required in IAW SSQ22680, Appendix VII. The trimmed end
of the jacket should be at about 1 inch away from the shield retention area
of the backshell, but no more than 1.25 inches.
m. Prepare the shield braids as follows:
1) Fold the shield braids forward over the termination area of the backshell. Use
adhesive tape to temporarily hold down the shields.
2) Prepare a band clamp for the backshell for clamping (see Figure 90-23).
3) Prepare a EMI clamping band by rolling the tail indicator mark on the band
around the wire bundle and through its buckle slot twice around.
NOTE: Verify that the shield braids are positioned correctly at all times
throughout all steps of the band clamping process. Use Figures 90-25 to
90-29 as references for the banding process.
4) Slip the EMI clamping band over the termination area of the backshell and
over the shields (see Figure 90-33).
IX-15
5) Insert the EMI clamping band into the clamping tool. Clamping will be
performed with a tool shown in Figure 90-25.
clamp band.
reached.
8) Cut the excess tie band off by squeezing the cut-off handle.
n. Remove the adhesive tape and trim excess shield braid material from the
assembly.
o. Slide the strain relief nut clamp forward and thread the clamp onto the backshell.
Torque to the specified value of 120 inch-pounds.
p. Attach the strain relief saddle attachments and tighten saddle attachment screws
securely onto the heat shrunk tubing area of the wire harness. Allow a little slack
on the wires within the backshell before the strain relief attachments are tighten
securely onto the heat shrunk section on the wire bundle to prevent undue stress
on the contacts. Tighten and torque screws to the specified value of 12 to 14
inch-pounds.
q. After completion of the assembly with the backshell, make sure that each contact
r. Perform Twinax socket contact retention force test in accordance with paragraph
harnessed.
s. Inspect Twinax pin contacts for proper alignment in accordance with 90.4.5.6
harnessed.
90.3.3.4.6.3 Shielded Wires And Outer Shield Braid
The process outlined below is for the termination of a wire bundle comprised of an overall
outer shield braid with various shielded wires within the wire bundle.
more than 4 inches, as specified in accordance with SSQ22680, Appendix VII.
b. Trim the outer shield braid back, but no more than 2 inches maximum, from the
end of the wire bundle (see Figure 90-20).
c. On each wire/cable, remove and extract the wire conductor(s) from the shield
braid as specified in SSQ22680, Appendix VII. Remove no more than the
specified amount of jacket and shield as specified in paragraph 90.3.4.3.6.2b.
d. Install and crimp the connector contacts as specified in 90.3.4.3.1.
IX-16
e. Insert the wire bundle through the strain relief cable clamp first (observe proper
f. Cut two pieces of heat shrinkable tubing each about 1.5 inches long and slip them
over the wire bundle. Move the shrink tubing along the wire bundle, out of the
way.
g. Remove the clear plastic cover from the connector. Do not remove the front
disturbing the EMI shielding gaskets. When handling the connectors, hold them
by the mounting ears or by the protective front covers (refer to Figures 90-2 or
90-3).
h. Install crimped contacts into connector as specified in 90.3.4.3.2. Verify proper
i. Slide the first piece of heat shrink tubing forward and position the tubing as
shown in Figure 90-13.
j. Align and heat shrink tubing into place as specified in 90.3.3.3.1.2.
k. Fold the individual shield braids backwards and slide the backshell forward
towards the connector. Make sure all the shield braids are inserted through the
circular opening of the backshell.
l. Butt the backshell against the connector and insert the four screws through the
backshell into the threaded holes of the connector housing.
m. Tighten and then torque down the screws to the specified value of 8 to 10 inch-
pounds.
NOTE: For wire bundle with an outer jacket material: if the jacket is still in
excess, preventing the EMI clamping process, trim away the excess
jacket as required in accordance with SSQ22680, Appendix VII. The
end of the jacket should be about 1 inch away from the shield retention
area of the backshell, but no more than 1.25 inches.
n. Prepare the outer shield braid and individual shields as follows:
1) Flair the shield braid open. If necessary, trim the shield braid if there is still
an excess amount.
2) Roll the edges of the shield braid approximately 1/4-inch inwards. The
overlap should be as shown in Figure 90-22.
3) Align the individual shield braids along the band retention area. Use adhesive
tape to temporarily hold the individual shields in place (see Figure 90-34).
4) Place overlapped portion of the outer shield braid over the termination area of
the backshell for band clamping.
IX-17
5) Prepare a shield braid EMI clamping band by rolling the tail indicator mark on
the band around the wire bundle and through its buckle slot twice around (see
Figure 90-23).
NOTE: Verify that the shield braids are positioned correctly at all times
throughout all steps of the band clamping process. Use Figures 90-25 to
90-29 as reference for the banding process.
6) Slip the EMI clamping band over the termination area of the backshell (use
Figure 90-35 as reference).
7) Milk the shield braid as required to remove the slack around the backshell
8) Insert the EMI clamping band into the clamping tool. An example of the tool
to use in terminating this band is shown in Figures 90-25 to 90-29.
clamp band.
reached.
11) Cut the excess tie band off by squeezing the cut-off handle.
o. Remove the adhesive tape and trim excess shield braid material after clamping.
p. Slide the strain relief nut clamp forward and thread the clamp onto the backshell.
Torque to the specified value of 120 inch-pounds.
q. Slide the heat shrink tubing forward and position the tubing to overlap the outer
bundle jacket just under the strain relief saddle attachment.
r. Shrink tubing into place as specified in 90.3.3.3.1.2.
s. Attach the strain relief saddle attachments and tighten saddle attachment screws
securely onto the heat shrunk section of the wire harness. Allow a little slack on
the wires within the backshell before the strain relief attachments are tighten
securely onto the heat shrunk section on the wire bundle to prevent undue stress
on the contacts. Tighten and torque screws to the specified value of 12 to 14
inch-pounds.
t. After completion of the assembly with the backshell, make sure that each contact
u. Perform Twinax socket contact retention force test in accordance with paragraph
harnessed.
v. Inspect Twinax pin contacts for proper alignment in accordance with 90.4.5.6
harnessed.
IX-18
Personnel and process techniques shall be certified as specified in 80.3.5.

90.3.4.1 Test Methods
90.3.4.1.1 Visual Inspection
All connector assemblies shall be visually inspected for conformance with requirements and
specifications herein. Inspections shall be made at appropriate points during assembly, and at the
completion of assembly. Magnification between 4 power to 10 power shall be used as necessary
to resolve suspected anomalies or defects.
90.3.4.1.2 Contact Retention Test
All contacts shall be verified 100% for proper retention and seating.
90.3.4.1.3 Contact Sizes 16 And Larger
Verification of the power contacts sizes 16 and larger shall be performed as specified:
a. Remove the front protective cover from the connector.

b. Visually inspect front face of the connector in accordance with applicable requirements
of SSQ 22680, Appendix X.
c. Apply a light pulling force to the wire and consequently to the contact to verify that the
contact is held in place. Pulling force shall be applied from the rear end of the connector.
Contacts not properly seated and retained will begin to back out. Verify the contacts do
not back out of the connector cavity.
d. If any contacts are displaced, the contacts shall be inspected for damages under
magnification as specified in 90.5.4.1. If there is no damage, the contact shall be re-
inserted and re-checked.
e. Should the contact be displaced a second time, the connector shall not be used. The
appropriate quality or product assurance activity or the engineer in charge shall
disposition accordingly.
IX-19
90.3.4.2 Contact Size 20 and Smaller and Concentric Twinax Contacts

All contacts shall be verified for proper seating and retention as specified in the procedures
below. When tested using appropriate seating tools, power contacts, sizes 20 and smaller and
concentric Twinax contacts shall meet the retention forces as shown in the following table:
Tool Part Number Contact Type Test Force (pounds)
ATC 3074-02 Size 22, pin 46
ATC-3075-00 Size 20, pin 57
ATC 3076MOD TWX, pin 46
ATC 3076-00 TWX, socket 46
ATC 3112-00 Size 22, socket 2.5 3.5
ATC-3113-00 Size 20, socket 2.5 3.5
a. Determine the contact size and type (male or female contacts) and use the
appropriate tool as specified in the above table. Use flat shaped probe for female
contacts and cup shaped probe for male contacts (see Figure 90-2 herein for a
drawing example of a retention test tool).
b. Remove the front protective cover from the connector.
c. Clean tools during the test periodically to remove any surface film, which may
contaminate contact surface.
d. Pin Contact
1) Nest the probe against the front of the inserted contact.
2) Establish the reference or zero displacement position of the contact. Verify
the proper tool positioning over the contact by applying light pressure to
the contact prior to applying full load.
3) Press down until the probe is flush with the probe guide, or when the full
compression of the spring is achieved. Make sure that direction of the
applied force lines up with the contact axis, while applying pressure to the
tip of the pin contact.
e. Socket Contact:
Align probe of the seating tool with the centerline of the socket contact being tested.
1) Carefully insert probe of the tool into the connector cavity and nest the
probe against the front of the inserted contact. The flat front surface of the
probe shall be positioned on the front surface of the stainless sleeve of the
contact.
2) Establish the reference or zero displacement position of the contact.
Verify the proper tool positioning over the contact by applying light
pressure to the contact prior to applying full load.
IX-20
tip of the pin contact.
f. TWX Contact Socket
1) Align probe of the seating tool with the centerline of the TWX socket
contact being tested.
2) Carefully insert probe of the tool into the connector cavity and nest the
probe against the front surface of intermediate pin contact.
3) Nest the Part. Number 23025760 probe of ATC3076-00 tool against the
front of the inserted intermediate pin contact.
4) Establish reference or zero displacement position of the contact. Verify
the contact prior to applying full load.
tip of the intermediate pin contact.
g. TWX Contact Pin
1) Carefully insert the ATC 3076MOD retention tool into TWX Pin. Nest the
2302C760MOD probe of the tool against intermediate socket contact
shoulder.
2) Establish reference or zero displacement position of the contact. Verify
the contact prior to applying full load
compression of the spring is achieved. Make sure that direction of the applied
force lines up with the contact axis, while applying pressure to the pin contact.
CAUTION
Sudden loads shall not be applied.
h. Contacts not properly seated and retained will begin to back out. Verify the contacts
do not back out of the connector cavity.
i. If any contacts are displaced, the contacts shall be inspected for damages under
magnification as specified in 90.4.5.1. If there is no damage, the contact shall be re-
inserted and re-checked.
j. Should the contact be displaced a second time, the connector shall not be
used. The appropriate Quality or Product Assurance activity or the
Engineer in charge shall disposition accordingly.
IX-21
32
D L
Size Diameter D (inches) L (inches) Astro Tool Astro Tool Spring Force
Probe Part Seating Tool (pounds)
Number Part Number
22 0.042 0.041 0.200 minimum 2302C112 ATC-3112 2.5 3.5
20 0.052 0.051 0.400 0.420 2302C113 ATC-3113 2.5 3.5
Figure 90-2 Seating Test, Tool Probe for Socket Contacts
IX-22
90.3.4.3 Certification Records

Maintenance of logs for the certification of all personnel and tooling involved in production
assembly operations under the provisions of this specification shall be implemented. The log
shall include dates of most recent certification/recertification, testing, and personnel
identification. Tooling logs shall also include usage data.
All certified personnel shall have records kept on file of all certification documentation as
specified in NHB 5300.4(3G), showing date of issuance, type of training received, dates of
training, etc. The documentation shall be kept current and shall be presented for inspection upon
request.
Unless otherwise specified in the contract or order, the supplier is responsible for the
performance of all inspection requirements as specified herein. The Buyer reserves the right to
perform any of the inspections set forth in the specification where such inspections are deemed
necessary to ensure supplies and services conform to prescribed requirements.
90.4.2.1 Certification and Calibration

All applicable assembly production tools, manual and power actuated, shall be certified and
calibrated prior to production use. Certification of the tools shall be in accordance with the
applicable documents when specified. In the event of conflict between certification documents
and the contents of this specification, the contents of this specification shall take precedence. All
applicable documentation shall be kept on file and shall be made available for inspection at all
times. Calibration data for tools shall include as a minimum, the last date of calibration, the next
due date for calibration, the tool serial number, the stamp or mark of calibration and approval.
All equipment failing to meet calibration, exhibiting a broken seal, or showing a pass due
calibration date, shall not be used and shall be marked as such. These items shall be removed to
another area until calibration has been performed.
90.4.3 Monitoring Procedures For Materials
Monitoring procedures shall consist of certification supported by verifying data that materials
listed herein used in the assemblies are in accordance with the applicable referenced
specifications and the quality assurance provisions. All data shall be maintained and be made
available for inspection at all times as specified herein.
90.4.3.1 Connector Contact Separation Force (sizes 22, 20, 16, 12 and TWX)
The purpose of this test is to demonstrate the minimum force required to separate the test pin
from the contact socket. The following details shall apply:
90.4.3.1.1 Test Procedure, Connector
90.4.3.1.1.1 Test Equipment

a. Drop weight assembled in accordance with attached Figures 90-39 and 90-40.
b. Solution for cleaning test pin.
IX-23
90.4.3.1.1.2 Test Procedure

a. Remove the front cover from the connector.
b. The test pin shall be cleaned periodically to remove any foreign surface film, which
may affect the separation force recorded.
c. During the test, test pin of the drop weight shall be aligned with each socket contact
undergoing the test.
d. Position the connector under test in a vertical position, with the socket tines in an
upright position.
e. Insert the drop weight test pin into the socket contact to a specified length (see Figures
90-39 for insertion depth in TWX socket and 80-10, dimension L Ins for power
contacts). Slowly turn the connector to the vertical downward position. If the drop
f. When the connector is installed in the vertical downward position, carefully insert the
drop weight test pin into the socket contact to a specified length (see Figures 90-39 for
insertion depth in TWX socket and 80-10, dimension L Ins for power contacts) and
release the test pin. If the drop weight is retained, the socket is acceptable.
g. If an inverted position is not attainable, the socket may be tested in a vertical upright
position. Insert the drop weight test pin into the socket contact to a specified length
then release test pin. If the socket holds the weight in an upright position, it is
acceptable.
h. If neither vertical position is attainable for the TWX socket contact, the alternate
method described below must be used.
i. Record pass/fail results by contact lot number, or connector part number, serial number,
and contact cavity number along with any observations.
90.4.3.1.2 Alternate Method (TWX Socket Contact only)
a. Test Equipment
1) Force gage, Chatillon digital force gage, DGGS.
IX-24
Table 90-1 Part Number
FA22680-40 Description Weight Pin Diameter A Test Pin Insertion Length L Maximu
Part Number (ounces) Length L (inches) m Flat B
Minimum Contact Connector
L1 L2
(inches) (inches)
-22 Size 22 0.70 0.72 0.0295 0.0296 0.50 0.200 0.270 0.007
Drop
Weight
-20 Size 20 0.70 0.72 0.0390 0.0391 0.50 0.200 0.270 0.007
Drop
Weight
-16 Size 16 2.0 2.1 0.0615 0.0616 0.72 0.400 0.470 0.015
Drop
Weight
-12 Size 12 3.0 3.1 0.0930 0.0931 0.72 0.400 0.470 0.015
Drop
Weight
Notes: Unless Otherwise Specified

1.Test Pins in accordance with MS3197
2.Gages shall be engraved or stamped with applicable dash number only from Table 6-1.
Complete part numbers are not required. Drop weights shall requires initial calibration
only
IX-25
1 L min
L2 Ins
Test Pin
B
ref
1 .50
Full R
A
4
Radii shall be smoothly

Drop Weight
blended into pin diameter
Figure 90-3 FA22680-40, Drop Weight Gage Socket Contact

Sizes 22, 20, 16 and 12
Notes: Unless otherwise specified

1 Overall length & diameter as required to attain the required weight
2 Dimensions are in inches
3 Dimensions A & B are found in Figure 90-3.
4 Visual Indicator of proper insertion length
90.4.4 Torque Verification
All fasteners on connectors, backshells, strain reliefs, etc., requiring torque shall be verified for
compliance with torque values as specified.
90.4.4.1 Contact Strain Relief Test
The purpose of this test is to demonstrate that each contact cab reasonably float in a radial
direction and move a few thousandths of an inch in an axial direction
NOTE: This test is not required for contact sizes 20 and 22.
90.4.4.1.1 Test Equipment:
a. Mating contacts used as seating tools / strain relief inspection tools for all power
contacts.
b. Strain Relief Inspection tool FA22680-2P for the Twinax pin contact (ref. Figure
90-38).
c. Strain Relief Inspection tool FA22680-2S for the Twinax socket contact (ref.
Figure 90-37).
90.4.4.1.2 Test Procedure:
a. Remove the front cover from the connector.
IX-26
b. Carefully insert the appropriate mating contact, which is used as a strain relief
tool, until it bottoms out.
c. When Twinax contacts are inspected, insert the appropriate strain relief tool until
it bottoms out.
d. While applying gentile side pressure to the strain tool, verify that the contact can
reasonable float in a radial direction and move a few thousandths of an inch in an
axial direction.
e. Should the inspected contact be completely stiff, the connector shall not be used.
The appropriate personnel in charge shall disposition it accordingly.
90.4.4.2 Twinax Socket Contact Separation Force
The purpose of this test is to demonstrate the force required to separate the test pin from
the Twinax contact socket. The following details shall apply:
a. Preferred Method
1) Test Equipment
a) Drop weight assembled in accordance with attached Figure 90-39.
b) Solution for cleaning test pin.
2) Test Procedure
a) Remove the front cover from the connector.
b) The test pin shall be cleaned periodically to remove any foreign surface
film, which may affect the separation force recorded.
c) During the test, each Twinax socket shall be aligned with the test pin of
the drop weight.
d) Position the contact under test in a vertical position, with the socket tines
in an upright position.
e) Insert the drop weight test pin into the socket contact to a specified length.
Slowly turn the connector to the vertical downward position. If the drop
f) If an inverted position is not attainable, the socket may be tested in a
vertical upright position. Insert the drop weight test pin into the socket
contact to a specified length then release it. If the socket holds the weight
in an upright position, it is acceptable.
g) If neither vertical position is attainable, the alternate method described
below must be used.
h) Record pass/fail results by contact lot number, or connector part number,
serial number, and contact cavity number along with any observations.
3) Alternate Method
4) Test Equipment
IX-27
a) Force gage, Chatillon digital force gage, DGGS is recommended.

b) A pin test adapter assembled in accordance with attached Figure 90-40.
c) Solution for cleaning test pin.
5) Test Procedure
a) Remove the front cover from the connector.
b) During the test, each Twinax socket shall be aligned with the test pin of
the test adapter.
c) Axial force shall be applied gradually. The depth of engagement shall be
as specified in attached Figure 90-40.
d) Insert a test pin to specified depth. As the test pin is withdrawn, measure
the separation force. The separation force shall be 1.00 ounce minimum.
e) Record actual value, connector part number, serial number, and contact
cavity number along with any observations.
90.4.4.3 Twinax Center Pin Alignment Procedure
The purpose of this procedure is to ensure proper axial position of the center pin contact.
90.4.4.3.1 Test Equipment:
a. Align tool FA22680-1 (ref. Figure 80-11).

b. Solution for cleaning test pins.
90.4.4.3.2 Test Procedure:
a. The aligning tool shall be cleaned periodically to remove any foreign surface film,
which may contaminate contact surface.
b. During the procedure the aligning tool shall be aligned with the pin contact.
c. The aligning tool shall be inserted into the pin contact assembly until it bottoms
out. Axial force shall be applied gradually.
d. The aligning tool shall be slowly rotated 360 at a uniform rate so that the force is
applied uniformly to the outside diameter of the center pin. Complete two to three
rotations.
e. Remove the aligning tool and visually inspect contact for axial alignment.
90.4.5 Rework
Rework shall be permissible unless excluded by other provisions of the contract. All rework shall
meet the requirements of this specification. Rework is not repair. Repair shall be made only in
compliance with applicable contractual requirements.
90.4.5.1 Plating Defects
Unless otherwise specified, defect repair of electroless nickel plating on non-functional surfaces
of nickel-plated connector components shall be in accordance with procedures outlined in
SSQ22S80, Appendix V.
IX-28
90.4.5.2 Data Recording

The data sheets and records shall include, as a minimum, the following details:
a. Title of tests, dates, and names of operators.
b. The identification numbers of the crimping tools and the applicable controls and
instructions.
c. Equipment used and equipment calibration data.
d. Individual measurements and observations when required or specified.
e. Discrepancy reports and disposition of actions taken.
90.6 Notes
90.6.1 Intended Use
The procedural requirements established herein are for the assembly and wiring of ORU
connectors from Cooper Industries, (formerly G&H Technology), Inc to be used on space
vehicles, mission-essential ground support equipment, and electrical systems for the Space
Station program.
90.6.2 Definitions
90.6.2.1 Usage Items

Usage items are materials, which are consumed or used in uncontrolled amounts during assembly
procedures not necessarily, called out on engineering control documents.
IX-29
Figure 90-4 Physical Envelope-Typical Connector
IX-30
Connector Shell Size 2
NOTE: For reference purposes, only the larger size contacts are shown here. See the applicable controlling
Engineering documents(s) for more details.
Figure 90-5 Typical Connector, Shell Size 2
IX-31
Figure 90-6 Pressure Plate and Retaining Screws
Figure 90-7 Typical Contact Insertion
IX-32
Figure 90-8 Contact-Insertion Tool Alignment
IX-33
PRESS THE WIRE BETWEEN THE THUMB

AND THE SERRATED PART OF THE TOOL
AND PULL THE WIRE AND TOOL TOGETHER
9319-21
Figure 90-9 Contact Extraction
IX-34
MAKE SURE THAT THE TIP IS BUTTING AGAINST

THE REAR SHOULDER OF THE END SEAL PLUG
9319-22
Figure 90-10 SSQ22680 End Seal Plug Insertion
IX-35
9319-23
Figure 90-11 Typical Rectangular Backshell
IX-36
RECTANGULAR TYPE BACKSHELL
INSERT WIRE
INSERT SHRINK TUBING
9319-24
Figure 90-12 Backshell and Shrink Tubing Insertion
IX-37
VIEW SHOWING ALIGNMENT

OF RECTANGULAR TYPE
BACKSHELL FOR SHELL
SIZE 1 CONNECTOR
WIRE END VIEW

SHOWING ALIGNMENT OF
RECTANGULAR CONNECTOR
BACKSHELL
9319-25
Figure 90-13 Alignment of Rectangular Backshell

IX-38
APPROXIMATE LOCATION OF
HEAT SHRINK TUBING
1/2 INCH MIN
LOCATION OF HEAT
SHRINK TUBING (SIDE VIEW)
9319-26
Figure 90-14 Alignment of Shrink Sleeving
IX-39
9319-27
Figure 90-15 Backshell with Circular Opening
IX-40
REAR END (WIRE END)

90 TURNED
Figure 90-16 Typical Backshell FRAM with Circular Opening
IX-41
INSERT THE STRAIN

RELIEF CLAMP FIRST
TERMINATED
WIRE BUNDLE
BRAIDED SHIELD INSERT WIRE
INSERT BACKSHELL AND MOVE

BACKSHELL AND CLAMP ALONG
WIRE BUNDLE OUT OF THE WAY
FOR JACKET AND BRAIDED SHIELD
PREPARATION.
INSERT HEAT SHRINK

TUBING - 2 INCHES LONG
9319-28
Figure 90-17 Circular Backshell Insertion
IX-42
Figure 90-18 Circular Backshell, FRAM
IX-43
IF WIRE BUNDLE HAS OUTER JACKET, INITIALLY

TRIM JACKET BACK AS INDICATED IN THE
APPLICABLE SECTIONS OF THE ASSEMBLY
PROCEDURES
TRIM OVERALL BRAIDED SHIELD BACK AS SHOWN. REFER TO THE

APPLICABLE SECTIONS IN THE ASSEMBLY PROCEDURES FOR
CORRECT DIMENSIONS.
TRIM INDIVIDUAL BRAIDED SHIELDS BACK AS SHOWN. REFER TO THE

APPLICABLE SECTIONS OF THE ASSEMBLY PROCEDURES
FOR CORRECT DIMENSIONS.
9319-29
Figure 90-19 Insulation Strip Lengths
IX-44
CONNECTOR
BACKSHELL
WIRE BUNDLE
FOLLOWING INSERTION OF CRIMPED CONTACTS AND

THE ATTACHMENT OF THE BACKSHELL, THE BRAIDED
SHIELD AND OUTER JACKET IS TRIMMED AS REQUIRED
FOR EMI BAND CLAMPING
TRIM JACKET BACK NO MORE

THAN THE SPECIFIED LENGTH
IN THE APPLICABLE SECTIONS
OF THE ASSEMBLY PROCEDURES. 9319-30
Figure 90-20 Braided Shield Trimming

IX-45
FLAIR BRAIDED SHIELD OPEN, WIDE ENOUGH TO

DIAGRAM SHOWS CUT-AWAY VIEW OF
SLIP OVER BANDING AREA OF BACKSHELL.
FLAIRED SHIELD.
ROLL EDGES OF BRAIDED SHIELD INWARDS

TO APPROXIMATELY 1/4 INCH OF OVERLAP.
1/4 INCH OVERLAP

9319-31
Figure 90-21 Braid Preparation
IX-46
TAIL LENGTH INDICATOR MARK
BUCKLE SLOT
ROLL TAIL LENGTH INDICATOR MARK

THROUGH THE BUCKLE SLOT TWICE
FIRST LOOP
SECOND LOOP 9319-32
Figure 90-22 EMI Clamping Band Preparation
IX-47
APPROX 1/4 INCH

OVERLAP
MILK THE BRAIDED SHIELD AS REQUIRED

TO RELIEVE THE SLACK AND INSURE
A TIGHT FIT.
ALIGN THE EMI BANDING CLAMP AND

COMPRESS WITH THE SPECIFIED TOOL.
RETENTION LIP
GAP MUST NOT BE

GREATER THAN 1/8 INCH 9319-33
Figure 90-23 Alignment of Shield and Backshell
IX-48
CUT-OFF HANDLE
CUTTING
BLADE
TOOL BODY
PULL-UP HANDLE
RELEASE LEVER
9319-34
Figure 90-24 Typical Band Clamping Tool
IX-49
CUTTING
PULL-UP HANDLES BLADE
SQUEEZE HANDLES
TO INSERT BAND
GRIPPER RELEASE LEVER
9319-35
Figure 90-25 Orientation of EMI Clamping Band and Tool
IX-50
SQUEEZE HANDLES
TO COMPRESS BAND
EXCESS BAND
SQUEEZE HANDLES UNTIL CALIBRATED TENSION IS

REACHED (WHEN THE PULL-UP HANDLE LOCKS INTO
PLACE)
9319-36
Figure 90-26 Compression of EMI Clamping Band
IX-51
SQUEEZE HANDLES
TO CUT EXCESS BAND
BLADE
EXCESS BAND
9319-37
Figure 90-27 Cutting Excess EMI Clamping Band
IX-52
CLAMPED BAND WITH

BRAIDED SHIELD IN PLACE
POSITION HEAT SHRINK TUBING

AS SHOWN AND SHRINK INTO PLACE
GAP NOT TO EXCEED 1/8 INCH
TIGHTEN STRAIN RELIEF CLAMP

SCREWS AND TORQUE DOWN
AS SPECIFIED.
9319-38
Figure 90-28 Shrink Sleeving and Clamp Positioning

IX-53
DIAGRAM SHOWING COMPLETED

ASSEMBLY OF CIRCULAR, RIGHT
ANGLE TYPE BACKSHELL FOR
SHELL SIZE 1 CONNECTOR
9319-39
Figure 90-29 Completed Backshell Circular Type
IX-54
STRIP WIRE INSULATION OF WIRE PAIR TO THE CORRECT

LENGTH AS SPECIFIED IN THE PROCEDURES.
EXTRACT WIRE PAIRS FROM INDIVIDUAL SHIELDED

CABLES AND CRIMP CONNECTOR CONTACTS AS SPECIFIED
APPLY THE HEAT SHRINK TUBING AT THE

SHIELD AND CABLE INSULATION JUNCTION
WITH THE CONTACTS INSERTED INTO THE CONNECTOR,

POSITION SHIELDS AS SHOWN SO THAT BACKSHELL
CAN SLIDE FORWARD OVER THE WIRE SHIELDS
9319-40
Figure 90-30 Individual Shield Preparation
IX-55
SLIDE BACKSHELL FORWARD; MAKE SURE ALL THE

SHIELDS ARE INSERTED THROUGH THE OPENING
ONLY THE THREADED PORTION AND

THE BAND RETENTION AREA OF THE
BACKSHELL IS SHOWN FOR CLARITY
USE ADHESIVE TAPE TO

SECURE INDIVIDUAL SHIELDS
HEAT SHRINK TUBING
DRAPE SHIELDS ALONG BACKSHELL

9319-41
SHIELD RETENTION AREA AS SHOWN
Figure 90-31 Alignment of Individual Wire Shield
IX-56
INSERT AN EMI CLAMPING BAND AND CLAMP
INTO PLACE AS SPECIFIED IN THE PROCEDURES.
ONLY THE THREADED PORTION AND
THE BAND RETENTION AREA OF THE
BACKSHELL IS SHOWN FOR CLARITY
TRIM EXCESS BRAIDED SHIELDS
AFTER CLAMPING IN PLACE 9319-42
Figure 90-32 Clamping Individual Shields
IX-57
CUTAWAY VIEW OF OUTER BRAIDED SHIELD
SHOWING INDIVIDUAL SHIELD POSITIONING
ROLL OUTER BRAID AND ALIGN THE
BRAIDS AS SHOWN BELOW.
1/4 INCH
OVERLAP
9319-43
Figure 90-33 Overall Braid and Individual Shield
IX-58
POSITION THE EMI CLAMPING BAND AS SHOWN
AND CLAMP DOWN AS SPECIFIED. TRIM EXCESS
BRAIDED SHIELD BEFORE INSTALLING SHRINK
SLEEVING (IF REQUIRED), STRAIN RELIEF
CLAMP, AND SADDLE ATTACHMENTS.
9319-44
Figure 90-34 Clamping Overall Braid and Shields
IX-59
RETENTION TEST TOOL
(PIN PROBE SHOWN)
ALTERNATE TEST PROBE

(SOCKET PROBE)
HANDLE PLUG
NOSE NUT
PROBE GUIDE
TO INSTALL PROBE, UNSCREW NOSE NUT AND
REMOVE PROBE GUIDE. INSERT PROBE INTO
PROBE GUIDE AND RE-INSTALL PROBE GUIDE
AND NOSE NUT. 9319-45
Figure 90-35 Seating Test Tool
IX-60
Figure 90-36 Strain Relief Inspection Tool, Part Number FA22680-2S For
SSQ22680-20-CTS-1, TWX Contact Socket
IX-61
Figure 90-37 Strain Relief Inspection Tool, Part Number FA22680-2P for SSQ22680-20-CTS-TWX
Contact Pin
IX-62
0.03
Figure 90-38 0.50 oz Drop Weight, FA22680-4
IX-63
Figure 90-39 Contact Separation Force Test Adapter
IX-64
X. APPENDIX X
SSQ22680 CONNECTOR INSPECTION PROCEDURES
X-1
100.0 Appendix X
100.1 In-process Contact Inspection

The in-process harness assembly inspection for workmanship shall be as specified in paragraph
3.3.4 Workmanship, of this document. Defect criteria shall be as specified in paragraph 3.3.4.1
Defect Criteria, and paragraph 3.3.4.2 Wire Sealing Members (Rear Grommet) Defect Criteria,
of this document.
100.1.1 Inspection at Assembly
100.1.1.1 Prior to Crimping

Prior to crimping visually inspect
a. Contacts for cleanliness.
b. Each contact for damages such as nicks that caused exposed metal, scuffs, out-of-
roundness conditions, and bent pin as specified in Figure 100-2.
c. Each contact socket for symmetrically formed tangs with regard to the socket
centerline as specified in Figure 100-3.
d. Each contact socket for uniformity or the tang thickness as specified in Figure
100-3.
e. Each contact for condition of gold plating (flaking, discoloration).
f. Scrap contacts of size 12 and smaller that failed visual inspection (paragraphs b
through e) and submit findings to EEE Engineering for evaluation.
g. Contacts of sizes 4, 0 and Twinax that failed visual inspection shall be submitted
to EEE Engineering for evaluation and final disposition.
100.1.1.2 After Crimping
After crimping, inspect each contact as specified in Appendix VIII, herein and as follows:
a. Contacts for cleanliness.
b. Each contact for damages such as nicks that caused exposed metal, scuffs, out-of-
roundness conditions, and bent pin as specified in Figure 100-2.
c. Each contact socket for symmetrically formed tangs with regard to the socket
d. Each contact socket for uniformity or the tang thickness as specified in Figure
100-3.
e. Each Twinax contact for damages in handling such as nicks that cause exposed
metal, scuffs, out-of-roundness conditions, and bent pin as specified in Figure
100-4.
f. Each Twinax contact for compliance with Figure 80-7 herein. Intermediate
socket and center pin position with respect to outer body shall be verified by
testing in accordance with paragraph 3.3.1 herein.
X-2
g. Scrap contacts of size 12 and smaller that failed visual inspection (paragraphs b
through f) and submit findings to EEE Engineering for evaluation.
h. Contacts of sizes 4, 0 and Twinax that failed visual inspection shall be submitted
to EEE Engineering for evaluation and final disposition.
100.1.2 Prior to Connector Assembly
Prior to connector assembly, inspect each connector as specified Appendix IX, herein and as
follows:
a. Connector for workmanship defects in accordance with paragraph 3.3.4.1, herein.
b. Connector internal, mating surfaces for cleanliness.
c. Connector receptacle for EMI spring damage in accordance with paragraph 2.5 herein.
d. Rear end of the connector for EMI gasket damage prior to backshell installation. If the
gasket is damaged, remove and discard it.
e. Rear end of the connector for grommet seal damage in accordance with paragraph 3.3.4.2
herein.
f. Connectors that fail visual inspection shall be submitted to EEE Engineering for
evaluation and final disposition.
100.1.3 After Connector Assembly
After the connector assembly is completed, visually inspect each connector as specified in
Appendix IX, herein and as follows:
a. Connector internal, mating surfaces for cleanliness.
b. Connector receptacle for EMI spring damage in accordance with paragraph 2.5
herein.
c. Accessible surfaces of each contact for damages such as nicks that cause exposed
metal, scuffs, out-of-roundness conditions, and bent pins as specified in Figure
100-2.
d. Each contact socket for symmetrically formed tangs with regard to the socket
e. Each contact socket for uniformity of the tang thickness as specified in Figure
100-3.
f. The distance from the front face of the connector receptacle to each tang of any
contact socket shall be the same as specified in Figure 100-5.
g. Twinax contacts for compliance with Figure 80-14, accessible surfaces only.
Twinax pin contacts shall also be tested for recessed or extended condition in
accordance with paragraph 100.2.2.5.1 herein.
h. Take and examine pictures of each connector. These pictures shall become part
of the as-built record.
X-3
100.1.4 EMI Spring
100.1.4.1 Visual Inspection

All SSQ22680 connector receptacles shall be visually inspected for EMI spring damage.
Magnification between 4 X power and 10 X power can be used as necessary to resolve suspected
anomalies or defects. The following criteria, with the specified acceptable irregularities, shall be
used:
a. One slightly lifted finger which does not have exposed burrs or sharp edges and would
not get caught in the mating process. Only one lifted finger along any single side of the
connector shell, but no more than a total of two over the whole EMI spring.
b. One broken off finger which does not have exposed burrs or sharp edges and would not
get caught in the mating process. Only one broken finger along any single side of the
connector shell, but no more than a total of two over the whole EMI spring length is
acceptable.
c. Surface deformation, such as finger flatness, stretching between fingers, nicks, dings, is
acceptable providing that no more than two adjacent fingers along each single side of the
connector are affected.
d. Surface blemishes or wear marks that can be attributed to the mating process and do not
expose base metal are acceptable.
NOTE: Single connector side is defined as one side of the connector shell with two adjacent
radii on each end.
100.1.4.2 EMI Spring Replacement
EMI springs that do not meet the criteria of paragraph 100.1.4.1 herein shall be replaced in
accordance with paragraph 60.2 of Appendix VI herein.
100.1.5 Visual Aids
The connector internal, mating surfaces and contacts shall be examined using 4X and 10X
magnifications. Additional magnification shall be used as necessary to resolve suspected
anomalies or defects.
100.2 Testing
When contacts failed any of the visual inspection as specified in paragraph 2.3, the following
testing is recommended to aid final disposition.
100.2.1 Pin Contact Alignment
The purpose of this procedure is to ensure proper axial position of the pin contact.
X-4
100.2.2 Test Equipment
100.2.2.1 Solutions for Test Toll Cleaning

Acceptable cleaning materials for test tools are:
a. Ethyl alcohol, 0-E-760, Types III, IV, V
b. Isopropyl alcohol, TT-I-735
c. Assembly wipes
100.2.2.2 Aligning Tools
The following table defines contact sockets that can be used as the aligning tools, except for
Concentric Twinax Center pin.
X-5
Table 100-1 CONTACT PIN ACCEPTABLE FOR ALIGNING TOOLS

Contact Pin Part Contact Pin Tool Part Number Tool Nomenclature
Number Nomenclature
SSQ22680-20-12-12P Size 12 Crimp Pin Contact SSQ22680-20-12-12S Size 12 Crimp Socket
Size 12 Crimp Pin Contact SSQ22680-20-12-12S-1 Contact
SSQ22680-20-12-16P with 16 crimp barrel SSQ22680-20-12-16S
SSQ22680-20-12-16S-1
SSQ22680-20-16-16S-1 Contact

SSQ22680-20-20-20S-1 Contact

SSQ22680-20-22-22S-1 Contact
SSQ22680-20-CTP Size 8 Crimp Concentric FA22680-1 Aligning Tool for the

(center pin contact) Twinax Pin Contact Center Pin Contact
100.2.2.3 Test Procedure

a. The alignment tool shall be cleaned periodically to remove any foreign surface
b. Aligning tool shall be aligned with the pin contact during the procedure.
c. The aligning tool shall be gently inserted into the pin until it reaches the bottom.
For all power contacts:
1) Gently adjust the pin by slowly applying side pressure to the mating socket
used as aligning tool towards the centerline of the leaning pin.
2) Carefully remove mating socket and repeat, as required, until pin is aligned
with adjacent pins, but no more than four times. Rotate mating socket
approximately 90 after each engagement.
3) Install fully populated mating test connector using normal technique.
4) Remove mating test connector and visually inspect both connectors in
accordance with paragraph 2.4 herein.
5) Record findings.
d. For concentric Twinax pin contact follow paragraph 80.4.4.3.5, Twinax Center
Aligning Procedure of this document.
100.2.2.4 Socket Contact Proper Engagement Test Procedure
The purpose of this procedure is to ensure proper configuration of socket contact tangs.
X-6
100.2.2.4.1 Test Equipment
100.2.2.4.1.1 Solutions for Test Tool Cleaning

Solution for test tool cleaning as defined in paragraph 100.2.2.1.
100.2.2.4.2 Aligning Tools
The following table defines contact sockets that can be used as the aligning tools, except for
Concentric Twinax Center pin.
Table 100-2 SOCKET CONTACT ENGAGEMENT TOOLS

Contact Socket Part Contact Socket Test Pin Part Test Pin
Number Nomenclature Number Nomenclature
SSQ22680-20-0-0S Size 1/0 Crimp Socket Contact SSQ22680-20-0-0P Size 1/0 Crimp
SSQ22680-20-0-4S Size 1/0 Crimp Socket Contact SSQ22680-20-0-4P Pin Contact
with 4 crimp barrel
SSQ22680-20-4-4S Size 4 Crimp Socket Contact SSQ22680-20-4-4P Size 4 Crimp Pin
Contact
SSQ22680-20-12-12S Size 12 Crimp Socket Contact SSQ22680-20-12-12P Size 12 Crimp
SSQ22680-20-12-12S-1 Size 12 Crimp Socket Contact Pin Contact
SSQ22680-20-12-16S with 16 crimp barrel SSQ22680-20-12-16P
SSQ22680-20-12-16S-1
SSQ22680-20-16-16S-1 Pin Contact
SSQ22680-20-20-20S Size 20 Crimp Socket Contact SSQ22680-20-20-20P Size 20Crimp Pin

(center pin contact) Contact
SSQ22680-20-22-22S-1 Pin Contact
a. The mating contacts shall be cleaned periodically to remove any foreign surface
b. Pin contact shall be aligned with the socket contact being inspected.
c. Mating pin shall be gently inserted into the suspect socket until it bottoms. The
engagement process shall be even with reasonably low engagement force.
d. Second mating pin of the same size shall be gently inserted into adjacent or
closest socket contact of the same size until it bottoms. Relative position of the
pin contacts with regard to each other shall be within 0.020 Inch.
e. Make sure that both contacts are set against contact retainer inside of the
connector.
f. Carefully remove mating pin contacts and inspect them for any new scratches,
nicks, scuffs, and out-of-roundness condition.
X-7
g. If no anomalies are found, install fully populated mating test connector using
normal technique.
h. Remove mating test connector and visually inspect both connectors in accordance
with paragraph 2.4 herein.
i. Record findings.
100.2.2.5 Twinax Contact Testing
Twinax contacts shall be tested in accordance with the requirements herein.
100.2.2.5.1 Inspection Procedure for Concentric Twinax Pin Contacts
SSQ22680-20-CTP concentric Twinax pin contact components could be recessed or extended as

a result of incorrect assembly. The cause for recess is a gap between the internal insulator and the
ferrule. The internal gap would allow for excessive center contact axial movement resulting in a
center pin to center socket open circuit. The second anomaly, which would manifest itself in the
same failure mode, would be the center pin contact pushed back through the center insulator /
retainer. The cause for the extended condition is excessive force applied to the intermediate
contact assembly resulting in damage to the shield insulator. Any Twinax pin contacts that are
found to have recessed or extended condition shall be replaced. The purpose of this test is to
verify that the Twinax pin contact wire harness fabricated within acceptable tolerance range.
a. Visually inspect each Twinax contact for damages due to handling such as nicks that
cause exposed metal, scuffs, out-of-roundness condition of intermediate/outer contacts
and bent center pin. Use magnification between 4 X power minimal visual magnification
to resolve suspected anomalies or defects. If needed, take pictures of the suspected
anomalies or defects and submit findings to EEE Engineering for evaluation.
b. Tools
The following table defines the tools to be used during the test:
Table 100-3 TWINAX CONTACT TEST TOOLS
Tool Part Tool Nomenclature Tool Purpose Tool

Number Marking
ATC Contact Retention test Places intermediate contact in the
3076MOD Tool (calibrated to most-recessed position in relation to
4.5 5.0 lbs) the outer body
2302C760 Probe, Socket Probe for use with ATC3076MOD
MOD tool
RTCRT- Contact retention Test Places center contact in the most-
95PIN Tool (calibrated to 12 recessed position in relation to the
20oz) intermediate contact and the outer
body
FA22860-5 Center Pin Position Verifies proper position of the center RED color
Gage pin in relation to the outer body band
FA22860-8 Twinax Pin Protrusion Verifies proper position of the Yellow
X-8
Gage Intermediate socket in relation to the color band

outer body
c. Twinax Pin Contact Test Steps.

1) During the test all tools should be periodically cleaned to remove any surface
film, which may contaminate the contact surface.
2) Carefully insert the ATC 3076MOD retention tool into the concentric Twinax
pin. Nest the 2302C760 MOD probe of the tool against the intermediate
socket contact shoulder.
3) Apply an even pressure to the tool until the probe is flush with the probe
guide, or when the full compression of the spring is achieved.
4) Remove the test tool and carefully insert the RTCRT-95PIN tool, nesting the
probe of the tool fully onto the center PIN contact. This is a one (1) pound
pressure tool. If any resistance is detected that may exceed one (1) pound, the
flight hardware could be damaged, and this test should be stopped
immediately.
5) Apply an even pressure to the tool until a clicking action occurs, indicating
attainment of the required pressure. The tool will not exceed its calibrated
value, and is designed to stop against the connector shell, if the operator
applies additional pressure, after the click stop has been reached.
6) Remove the retention test tool and inspect contact to verify the correct
position of intermediate contact assembly with regard to the front face of the
outer contact using FA22680-5, and FA22680-8 gages as follows:
a) Install FA22680-5 center pin position gage (tool with RED color band)
over the outer contact to verify the center pin to outer body position.
Gently depress the center shaft until it bottoms.
b) Observe the position of the red color band on the center pin gage. The red
color band on the center pin gage should be at least partially visible
outside of the tool outer housing. If the color band is not at least partially
visible, the contact is recessed and shall be replaced. Remove the gage.
X-9
c) Install FA22680-8 Twinax pin protrusion gage (tool with the yellow color
band) over the outer contact to verify that intermediate contact position is
within acceptable tolerance range. Gently depress the center shaft until it
bottoms.
d) Observe the position of the yellow color band on the positional gage. The
yellow color band on the positional gage shall not be visible outside of the
tool outer housing. When finished, remove the gage.
100.2.2.5.2.1 Inspection Procedure for Concentric Twinax Socket Contacts
SSQ22680-20-CTS-2 Concentric Twinax Socket contact components could be recessed as a
result of incorrect assembly. The cause for recess is a gap between internal insulator and the
ferrule. That internal gap would allow for excessive center contact axial movement resulting in
center pin to center socket open circuit. The purpose of this test is to verify that the Twinax
socket contact wire harness fabricated within acceptable tolerance range.
100.2.2.5.2.1.1 Test Procedure
a. Visually inspect each Twinax contact for damages due to handling such as nicks
that cause exposed metal, scuffs, out-of-roundness condition of intermediate/outer
contacts. Use magnification between 4 to 10 powers as necessary to resolve
suspected anomalies or defects. If needed, take pictures of suspected anomalies
or defects and submit findings to EEE Engineering for evaluation.
b. Tools
Use FA22680-7 TWX Socket Intermediate / Outer Position gage (Green Color
Band)
c. Install FA22680-7 TWX Socket Intermediate / Outer Position Gage (tool with the
GREEN color band) into the outer socket contact until it bottoms to verify
Intermediate to Outer contact position.
d. Observe the position of the green color band on the socket gage positioner. The
green color band on the socket gage positioner should be at least partially visible
outside of the tool outer housing. If the color band is not is not at least partially
visible, the contact is recessed and shall be replaced. Remove the gage.
X-10
Figure 100-1 EMI SRING
X-11
STRAIGHT
BENT PIN LEANING PIN
PIN
Pin Size Nominal Pin Not to exceed A Notes

Diameter dimension
12 .094 .070 Approximately of Pin diameter
16 .063 .050 Approximately of Pin diameter
20 .040 .045 Approximately one Pin diameter
22 .030 .035 Approximately one Pin diameter
Figure 100-2 POWER PIN CONTACT VISUAL AID
X-12
Distance
between tangs
not constant
Symmetrically formed Non-symmetrically

tangs formed tangs
Large Size Contacts Shown
Symmetrically Formed Non-Symmetrically Formed

Tangs Tangs
Note: Tangs can be seen by tilting contact
Small Size Contacts Shown (Sizes 16, 20 22)
Figure 100-3 POWER SOCKET CONTACT VISUAL AID
X-13
Correctly Protruding
Assembled TWX Intermediate Recessed
Pin Contact and Center Center Pin
Contacts
Intermediate Contact
Bent Tang
Correctly Bent Center Pin

Assembled TWX
Pin Contact
Figure 100-4 TWINAX CONTACT VISUAL AID
X-14
Figure 100-5 TYPICAL POSITION OF SOCKET CONTACT IN CONNECTOR

RECEPTACLE CAVITY
X-15
XI. APPENDIX XI
APPLICABLE FORMS
XI-1
110.0 Material Usage Agreement

MATERIAL USAGE AGREEMENT
Material Usage Agreement Usage Agreement No. Rev.
Page of
Project: System: Subsystem: Originator: Organization/Contractor
Part Number(s): Using Assembly(s): Item Description: Issue:
Material Designation: Manufacturer: Specification: Proposed Effectivity:
Material Code: Location: Environment:
Thickness: Weight: Exposed Area: Habitable Pressure PSIA
XI-2
MATERIAL USAGE AGREEMENT
Block Requirement
1. Contractor Contractor responsible for component.
2. Drawing No. Drawing that shows component in assembled form, which nominally would
include an inclusive parts list.
3. Rev. Letter Revision level of drawing/detail drawing.
4. Next Assembly Drawing number and name of assembly in which this component is to be
included.
5. Part Name Name of component.
6. System (Sub)System of WP-04 Electric Power System
7. Pressure System pressure if component is hermetically sealed/fluid system, or vacuum
(Low Earth Orbit) if external.
8. Media Fluid or gas present, if applicable.
9. Temp. Range Temperature range component will see in actual use.
10. Detail Drawing Drawing/dash number of parts that make up component; for
Standard/Commercial parts used in final assembly drawing (Block 2) and dash
number if no detail drawing exists.
11. Nomenclature List part name, material, manufacturers designation, material form, and/or
Standard/Commercial part number.
12. Material Code Five-digit code number, as assigned by NASA/MSFC, in MAPTIS or MSFC-
HDBK-527/JSC 09604.
13. Material Spec. Military, Federal, Commercial or contractor specification to which part or
material is manufactured.
14. Manufacturer Source of part of material.
15. Process Spec. Specifications for applicable surface treatment, passivation, heat treatment,
painting/coating, etc.
16. Environment Identify applicable column; STD refers to standard environment for NSTS
payload bay and Low Earth Orbit operation Other indicates material is
internal to a hermetically sealed container/fluid system.
17. Nonmetallics For flammability and TVS evaluation; list material weight, thickness and
exposed surface area.
18. Evaluation Enter applicable material ratings from MAPTIS or MSFC-HDBK-527/JSC
09604.
19. MUA/Test Report Identify specific MUA document which justifies use of the non A-rated
material.
20. Remarks Identify FMEA criticality code, fracture critical designation, cure code/data
for nonmetallics, or any other appropriate information; for parts with separate
MI\UL, list manufacturer and MI/UL number.
21. Prepared By Contractor materials person responsible for generation/acceptance of the
MI/UL.
22. Procuring Activity Contractor/NASA materials person signature indicating approval by the
procuring Approval activity.
XI-3
MATERIAL IDENTIFICATION/USAGE LIST

Contractor Rocketdyne Part Name __________________________________
Dwg. No. ________________Rev_______ System __________________________________
Next Assembly __________________________ Pressure ____________Media________Temp_____
Detail Rev Nomen- Matl- MAT MFR Proc. ENV WT THK AREA FLM TVS TOX COR SCC AGE MUA OR REMARKS
Dwg # clature Code SPEC Spec LB IN SQIN. TEST
REPORT
Prepared By___________________________ Procuring Act. Approval________________________________
XI-4

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Connectors, Rectangular, (ORU), Space Quality, General

INTERNATIONAL SPACE STATION PROGRAM

SSQ 22680, Revision L

EXPORT CONTROLLED - The technology or software is subject to the Export

National Aeronautics and Space Administration

REVISION HISTORY PAGE

ERU: /s/ Sheree Phillips 12-07-15

SPACE STATION PROGRAM OFFICE

2.0 APPLICABLE DOCUMENTS ..........................................................2-1

3.0 REQUIREMENTS ........................................................................3-1

3.2.5.2.3 Pressure ............................................................................................................................................... 3-6

3.3.19 EMI Spring ................................................................................................................................... 3-16

4.0 QUALITY ASSURANCE PROVISIONS ............................................4-1

4.8.12 Contact Insertion and Removal Force ........................................................................................... 4-8

4.11.5.1 Scope....................................................................................................................................................... 4-26

5.0 PREPARATION FOR DELIVERY ....................................................5-1

6.0 NOTES .......................................................................................6-1

10.0 APPENDIX I .......................................................................... I-2

20.0 APPENDIX II ........................................................................ II-2

20.3 REQUIREMENTS........................................................................................................................................... II-2

30.0 APPENDIX III ...................................................................... III-3

40.0 APPENDIX IV ...................................................................... IV-2

50.0 APPENDIX V ........................................................................ V-2

60.0 APPENDIX VI ...................................................................... VI-2

60.2.3 Application of Chemical Conversion Coating................................................................................ VI-2

70.0 APPENDIX VII .................................................................... VII-2

80.0 APPENDIX VIII .................................................................. VIII-2

80.4.4.3.4 Twinax Socket Contact Separation Force........................................................................................ VIII-14

90.0 APPENDIX IX ...................................................................... IX-2

90.3.3.4.6.3 Shielded Wires And Outer Shield Braid .................................................................................... IX-16

100.0 APPENDIX X ........................................................................ X-2

100.2.2.4.3 Test Procedure ................................................................................................................................... X-7

110.0 MATERIAL USAGE AGREEMENT ...............................................2

Figure 90-5 Typical Connector, Shell Size 2 ...................................................................................................... IX-31

APPENDIX I BACKSHELLS I-1

2.0 Applicable documents

MIL-STD-970 Standards and Specifications, Order of Preference

3.1 Item Definition

a. Connector shall be identified in accordance with paragraph 3.3.3 herein. Nomenclature

3.1.3 Standard Tolerances

Unless otherwise specified, tolerances on:

3.2.1.1 Contact Resistance

3.2.1.4 Shell to Shell Conductivity

3.2.3.1 Mean Time Between Failure (MTBF)

3.2.3.4.2 Contact Twinax Accelerated Aging

a. Operating - From 25% to 70%

a. Operating - From 85.5 to 104.1 kPa (12.4 psi to 15.1 psi).

Non-operating - The connector shall show no evidence of cracking, breaking, loosening of

3.2.5.2.1.1 Temperature for ORU Connector(s) (Table 6-2)

Operating - relative humidity of 25% to 75%, at a temperature of +16C to +32C,

a. The connector shall operate in three pressure environments:

3.2.5.2.4.1 Random Vibration for ORU Connector(s) (Table 6-2)

3.2.5.2.5 Atomic Oxygen

b. Safety requirements with respect to exposed corners/edges, holes, screws,

b. Weld repair is limited to the repair of welding defects in a production weld as

3.3.2.1 EMI Transfer Impedance (10 kHz to 100 MHz)

3.3.3.1 Connector and Accessories Marking

a. Polarization of the same size connector shells shall be accomplished by means

3.3.10.1 Actuation Force (Room Temperature)

requirements specified herein. Minor defects on non-functioning surfaces can be treated in

3.3.21 Fastener Torque

See Appendix II for physical characteristics and dimensions.

See Appendix III for physical characteristics and dimensions.

3.3.23.1 Protective Covers