PF95590
PF95590
PF95590
Performance Standard
Category Code: M-3
EASL Req.: No
RESTRICTED: No
No: PF-9590
Date Published: 2004-04-08
Change: B
B. Retain records as needed to assist in evidencing the exercise of "due care" in matters relating to
product
compliance to government requirements or product liability.
C. Comply with statutory requirements for the maintenance and retention of specific records to
substantiate
compliance with legal requirements.
2.1.4.2 Retention Methods
Method of retention must conform to the suppliers corporate procedures and may include retention of
original documents, the use of film, or electronic storage equipment. Records must be stored so that they
are accessible in a reasonable amount of time. Storage areas should provide adequate protection from
unauthorized access, moisture, and fire.
2.2 Test Equipment
Table 1 contains a summary of the required equipment. Unless otherwise specified, voltage regulated DC
power sources that comply with SAE J823 requirements shall be used for all tests except that the output
voltage from the power supply shall be capable of supplying to the input terminals of the Standard Circuit
in SAE J823, from 9 - 16 VDC. Production intent wire harnesses are listed as equipment under several of
the tests in this standard. These harnesses must be supplied by the production wire harness supplier.
Description
DC Power Supply
(Regulated)
0-20 V
0-10 A
DC Power Supply
(Regulated)
0-20 V
0-150 A
0-20 mV
0-10 mA
Digital Multimeter
Current Shunts
Millivolt Meter
Thermocouples
Insertion/Extraction Force
Tester
Data Logger
As required
Temperature Chamber
(Non-circulating)
(2003-07-08)
Make/Model (1)
Description
Vibration Controller
As required
Vibration Table
Vacuum
As required
DC Power Supply
(Regulated)
0-500 V
0-100 mA
Make/Model (1)
Megohmmeter
NOTE 1: If applicable.
2.2.1 Test Default Conditions
When specific test conditions are not given either in the product design specification or elsewhere in this
specification, the following basic conditions shall apply:
Room Temperature:
Relative Humidity:
Atmospheric Pressure:
Voltage:
23 +/- 5 DEG C
50 +/- 30%
650 - 800 mm mercury
12.8 +/- 0.1 VDC
+/- 3 DEG C
+/- 1%
+/- 1%
+/- 1%
+/- 1%
+/- 5%
+/- 5%
+/- 5%
+/- 1%
NOTE: Not to be used for performance dependent variable(s). (See section 3.3)
2.3 Functional Requirements and Testing
The tests detailed in 2.5 through 2.7 are quantitative or semi-quantitative in nature and are not expected to
stress any part beyond its anticipated application limit.
2.3.1 Performance Requirements
All connection systems must meet all performance test requirements under the conditions listed in table 2.
2.3.2 Dimensional Characteristics
Part construction shall conform to the dimensions, shape, and detail attributes specified on the latest
revision of the applicable part drawing(s)
2.3.3 Material Characteristics
The material used shall conform to the material standards specified on the latest revision of the applicable
part drawing(s).
The material hardness specified for the terminals refers to the blank strip material and not the finished
product because the manufacturing process of stamping, forming tin plating, etc. can modify the hardness
values.
2.3.4 Temperature Classifications
Connection systems to be tested will be classified as one of the following;
TABLE 2: CONNECTION SYSTEM TEMPERATURE CLASSES
Class
1
2
3
4
Maximum Temperature
(Ambient + Rise)
+105 DEG C
+120 DEG C
+145 DEG C
+175 DEG C
GAUGE
ACTUAL PART
Engage
Disengage
Engage
Disengage
Max. (N)
Min. (N)
Max. (N)
Min. (N)
Typical
Blade
--12
2
Typical
Pin
--12
2
NOTE: Values to be specified on device drawing. Gauge information is for devices with female terminals
2.5.2 Terminal Bend Resistance
This test is required for devices with molded on pigtail connections and for devices with integral
PF-9590, Change B, 2004-04-08, Page 6
Copyright DaimlerChrysler Corporation
(2003-07-08)
connectors, i.e., the connector features are molded into the device.
2.5.2.1 Purpose
This test ensures that the terminal will not severely bend or break during crimping, assembly, or service.
2.5.2.2 Equipment
- Insertion/Extraction Force Tester
- Molded on Pigtails
A. Using the smallest gauge size wire with the thinnest insulation applicable to test the design and using
the applicable wire size for subsequent testing, machine crimp samples until one meets the crimp height,
crimp width, and tensile strength requirements of PF-9600, attachment A, or as required by terminal
maker. Then machine crimp the remaining samples at that crimp setting. Crimp both the conductor and
insulation grips. Assemble insulation displacement style terminals in accordance with their recommended
assembly criteria.
B. Repeat step A but use the largest wire gauge size with the thickest insulation applicable to the design.
C. Number each terminal and record crimp height and width if applicable.
D. Determine the design style the terminal under test (TUT) most closely resembles from Figure 1.
Repeat steps A and B for style "B" terminals.
E. Secure the TUT in a fixture at location "1" as shown in Figure 2.
F. Use the chart below to set the force tester to apply a perpendicular force to the TUT as shown in Figure
2.
SPEED (mm/Min)
50 +/-10
50 +/-10
DMM
DC Power Supply (0-20 VDC @ 0-150 A)
Current shunts
Production intent wire harnesses
2.5.4.3 Procedure
NOTE: If this test is used sequentially with other tests of a test plan, omit steps A & C.
A. Machine crimp samples until one meets the crimp height, crimp width, and tensile strength
requirements of PF-9600, attachment A, or as required by terminal maker. Then machine crimp the
remaining samples at that crimp setting. Crimp both the conductor and insulation grips. Assemble
insulation displacement style terminals according to their recommended assembly criteria.
B. Number each terminal and record crimp height and width if applicable.
C. Completely mate and unmate each terminal pair a total of 10 times and then mate them again for
testing.
D. Pre-set the power supply to output the maximum rated current for the terminal pair to be tested as
shown in Figure 3 Voltage Drop Test Setup. More than one terminal pair may be tested in series as long
as each terminal pair receives the maximum rated current. Refer to Figure 4 Test Lead Locations, for
placement of the millivolt test leads.
E. Measure and record the voltage drop across 150 +/-1 mm of the wire used during testing, using the
rated current for the test.
F. Assemble the circuit shown in Figure 3. Solder, weld or epoxy the millivolt leads as shown. All millivolt
lead wire shall be 28 AWG or smaller. Attach the circuit to a non-conductive surface, such as wood or
high-temp plastic, leaving a minimum of 50 mm between test samples.
G. Turn on the power supply and wait 15 minutes for the circuit to stabilize.
H. Measure and record the millivolt drop (mVD) readings between test points T1-T2 and T3-T4, and use
these values in the equations below to calculate the voltage drop across the crimp areas.
mVD Crimpmale= mVD(T1-T2) - [mVD Wire(step #E)/6]
mVD Crimpfemale= mVD(T3-T4) - [mVD Wire(step #E)/6]
Use these calculated values for the acceptance criteria.
PF-9590, Change B, 2004-04-08, Page 10
Copyright DaimlerChrysler Corporation
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I. Measure and record the mVD between test points T2-T3 and use this value in the equation below to
calculate the voltage drop across the contact interface area.
mVD Interface = mVD (T2-T3)
Use this value to verify the acceptance criteria.
Crimp
(mV/Amp) Max.
Interface
(mV/Amp) Max.
After Test
(mV/Amp)
Max.
0.50
1.00
1.00
3.00
10
NOTE : A. The after test values are for crimp to crimp measurements
2.5.5 Dry Circuit Voltage Drop
This a stand-alone-test for devices with pigtail connections, and should be performed with the wires or
ribbon cable not attached to the device.
For devices with integral connectors or with header connectors, this is a stand-alone-test for ED and DV
only. It is also used as acceptance criteria for other tests.
2.5.5.1 Purpose
This test determines the resistance level at the crimp and contact interface of a terminal system under low
energy (dry circuit) conditions.
2.5.5.2 Equipment
-
2.5.5.3 Procedure
NOTE: If this test is used sequentially with other tests of a test plan, omit steps A & C.
A. Machine crimp samples until one meets the crimp height, crimp width, and tensile strength
requirements of PF-9600, attachment A, or as required by terminal maker. Then machine crimp the
remaining samples at that crimp setting. Crimp both the conductor and insulation grips. Assemble
insulation displacement style terminals per their recommended assembly criteria.
B. Number each terminal and record crimp height and width if applicable.
C. Completely mate and unmate each terminal pair a total of 10 times and then mate them again for
testing.
D. Perform the Low Signal Contact Resistance test per the latest revision of Military Standard 1344A,
Method 3002.1 with the exception that the current level is to be set at a constant regulated 10 mA.
E. Verify the acceptance criteria.
PF-9590, Change B, 2004-04-08, Page 12
Copyright DaimlerChrysler Corporation
(2003-07-08)
2.6.3.3 Procedure
A. Prepare the Component Under Test (CUT) by assembling all applicable parts and bundling (with tape,
convolute, scroll, etc.) the wires per its intended application. Consult the responsible engineer for details
on intended bundling. Refer to Figure 6 for examples of test mounting arrangements. Positions D, E, and
F utilize a fixed post.
B. Construct a suitable mounting apparatus using the following design criteria:
1. The mounting apparatus shall be constructed and secured, to minimize added effects (harmonics,
dampening, resonances, etc).
2. The distance between attachment points of the fixture must not exceed 750 mm, in overall length, and
the attachment points are at the same height above the plane of the vibration plate.
PF-9590, Change B, 2004-04-08, Page 14
Copyright DaimlerChrysler Corporation
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3. The fixture should be designed so that when the orientation of the assembly is freely hanging, the CUT
will not impact the vibration plate during testing.
C. Securely attach the wire bundle ends to the mounting fixture such that there is 10 +/- 5 mm of sag
relative to the horizontal bisecting plane of the attachment points.
D. For dummy devices in Engineering Development testing and Design Verification testing, solder all
wired terminals of the CUT in series to form one continuous current path with only two free ends. Solder
one of the free wire ends to a 2 watt, 120 +/- 1.2 ohm resistor. Preset the power supply to provide 12 VDC
@ 100 mA to the circuit. Solder the "-" (Neg.) lead to the free end of the resistor and the "+" (Pos.) lead to
the remaining free wire of the CUT. Connect the Continuity Totalizer/Analyzer (CT/A) across the resistor,
making sure that the "-" lead of the CT/A is connected to the negative side of the resistor. Set the CT/A to
record any change in current through the resistor below 95mA.
For Product Verification testing and Continuing Conformance testing, power the device and monitor for
intermittencies in operation.
A reference illustration of the test setup is shown by Figure 10.
The test fixtures, system layout, and test setup must be approved by the responsible engineer prior to
testing.
F. All CUTs shall be vibrated for 8 hours on each of the 3 mutually perpendicular axes (X,Y,Z). Vibrate
the CUT using the vibration profile in the device specification, or the following profiles according to its
location in the vehicle:
- Engine compartment CUTs -- Use Figure 7
- Body and I/P mounted CUTs -- Use Figure 8
NOTE: If discontinuities existed that were longer than the allowable duration or too numerous, a sweep of
frequencies between 10 to 50 Hz, using a sinusoidal motion, may help in determining the cause.
G. After performing the above procedure subject the CUT to 10 impulses (10-20 millisecond duration @
35 Gs force) in each of the three mutually perpendicular axes.
H. Record the results, inspect the CUT, and verify the acceptance criteria.
Magnitude (G sqrd/Hz)
0.00100
1.50000
0.10000
0.10000
Magnitude (G sqrd/Hz)
0.00100
0.12420
0.00160
0.00100
0.00590
0.00016
0.00001
engineer.
B. Use the megohmmeter to measure the resistance between the terminals and between the outermost
terminals and the body of the device.
C. Record the measurement and verify the acceptance criteria.
D. Repeat steps A - C so that each terminal in the connector system is measured against all adjacent
terminals. Test the device half of the connector system.
2.6.4.4 Acceptance Criteria
The resistance between cavities must exceed 20 MOhms @ 500 VDC.
2.6.5 Connector System 500 Hour Current Cycle
This test can be combined with a device operating life test if the device test runs at least 500 hours with
temperature and humidity cycling.
2.6.5.1 Purpose
This test simulates the main function of the connector system over the expected life of the vehicle. This
test cycles the maximum current for the connector system 'ON' and 'OFF' at the maximum temperature in
which the connector system may have to operate.
2.6.5.2 Equipment
-
DMM
DC Power Supply (0-20 VDC @ 0-150 A, timer controlled)
Current shunts (100 mA @ +/- 1%)
Thermo-couples (Type "J")
Data Logger (As required)
Temp. Chamber (-40 DEG C to +155 DEG C,0-95% RH)
Production intent wire harnesses
2.6.5.3 Procedure
A. Completely mate and unmate the pairs of connector systems 10 times. And then mate again for
testing.
B. Assemble the circuit shown in Figure 3 except use a timer controlled power supply and connector
assemblies in place of the terminals. Set the power supply to provide 45 minutes 'ON' and 15 minutes
'OFF' at the maximum device operating current. Also connect a data logger to monitor device operation.
C. Determine the temperature class of the connector system design and application intent from Table 2.
Test the first set of connector pairs @ 25 DEG C (room temp.), and the remaining pairs at the maximum
ambient temperature for the applicable temperature class. Allow the temp. chamber to stabilize before
starting the test. Keep a continuous chart of the chamber temperature during testing.
D. Turn 'ON' the power supply, DMM's, and data logger.
E. For Design Verification testing, after 35 minutes into the first 'ON' cycle record terminal crimp and
interface millivolt drop readings as well as thermocouple readings for each pair.
F. Cycle for 500 hours. For Design Verification testing, take readings at the start and end of each day, 35
minutes into the 'ON' cycle, and at the conclusion of the test. For Production Validation testing, record any
PF-9590, Change B, 2004-04-08, Page 20
Copyright DaimlerChrysler Corporation
(2003-07-08)
2.6.6.3 Procedure
A. Mate the device and harness connector pairs using all applicable components such as terminals,
wedges, and seals.
B. Number each assembly and verify device operation.
C. For dummy devices in Engineering Development testing and Design Verification testing, connect all
wired terminals of the connector pairs in series to form one continuous current path with only two free
ends. Solder one of the free wire ends a 2 watt, 120 +/- 1.2 ohm resistor. Preset the power supply to
provide 12 VDC @ 100 mA to the circuit. Solder the "-" (Neg.) lead to the free end of the resistor and the
"+" (Pos.) lead to the remaining free wire of the connector pairs. Connect the Continuity Totalizer/Analyzer
(CT/A) across the resistor, making sure that the "-" lead of the CT/A is connected to the negative side of
the resistor. Set the CT/A to record any change in current through the resistor below 95 mA. A reference
illustration of the test setup is shown by Figure 10. The test fixtures, system layout, and test setup must be
approved by the responsible engineer prior to testing.
D. Determine the class temperature of the connector system from Table 2, and set the chamber to the
minimum temperature for that class. Allow the chamber to stabilize before proceeding.
E. Place the assembly in the chamber set to the minimum temperature such that there is no substantial
obstruction to air flow across and around the samples, and the samples are at least 50 mm apart in all
directions. Any mounting plates used must be made of non-conductive material such as wood or high
temperature plastic. Leave the assembly in the chamber for 1.5 hours.
PF-9590, Change B, 2004-04-08, Page 21
Copyright DaimlerChrysler Corporation
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F. In less than 5 minutes transfer the assembly to another chamber, or transition the chamber, set to the
maximum temperature for that class. Allow the assembly to soak for 2 hours.
G. In less than 5 minutes transfer the assembly to another chamber, or transition the chamber, set to the
minimum temperature for that class. Allow the assembly to soak for 2 hours.
H. Repeat steps F and G fifty (50) more times.
I. Verify the acceptance criteria. For Production Validation testing, verify device operation.
2.6.6.4 Acceptance Criteria
For Engineering Development and Design Verification testing, verify the requirements of the Dry Circuit
Voltage Drop test of 2.5.5 first, then the Voltage Drop test of 2.5.4 second, and then the Isolation
Resistance test of 2.6.4.
If the device specification has a Temperature/Humidity Cycling test, use those test parameters. This test
can be combined with a device operating life test with temperature and humidity cycling. For Design
Verification testing use dummy devices constructed to monitor connector performance. For Production
Validation tests use production intent devices.
2.6.7.1 Purpose
This test simulates actual operating conditions using temperature and humidity as aging mechanisms for
evaluation of a connector system's electrical functionality. High humidity and temperature can promote
galvanic and electrolytic corrosion of the terminals which would cause electrical and physical degradation.
PF-9590, Change B, 2004-04-08, Page 22
Copyright DaimlerChrysler Corporation
(2003-07-08)
2.6.7.2 Equipment
-
2.6.7.3 Procedure
A. Mate the device and harness connector pairs using all applicable components such as terminals,
wedges, and seals.
B. Number each connector assembly and verify device operation.
C. For Design Verification testing, connect all wired terminals of the connector pairs in series to form one
continuous current path with only two free ends. Solder one of the free wire ends to a 2 watt, 120 +/- 1.2
ohm resistor. Preset the power supply to provide 12 VDC @ 100 mA to the circuit. Solder the "-" (Neg.)
lead to the free end of the resistor and the "+" (Pos.) lead to the remaining free wire of the connector pairs.
Connect the Continuity Analyzer/Totalizer (CA/T) across the resistor, making sure that the "-" lead of the
CA/T is connected to the negative side of the resistor. Set the CA/T to record any change in current
through the resistor below 95 mA.
A reference illustration of the test setup is shown by Figure 10.
For Production Validation testing, power the device and monitor operation.
The test fixtures, system layout, and test setup must be approved by the responsible engineer prior to
testing.
D. Determine the class temperature of the connector system from Table 2.
E. Place the assembly in the chamber such that there is no substantial obstruction to air flow across and
around the samples, and the samples are at least 50 mm apart in all directions. Any mounting plates used
must be made of non-conductive material such as wood or high temperature plastic.
F. Cycle the assembly 40 times using the cycling schedule shown in the device specification or Figure 11.
Use the maximum class temperature for hours 5 - 7 in Figure 11, currently Class 4 is illustrated.
G. Verify the acceptance criteria.
2.6.9.3 Procedure
This test shall be performed in accordance with the latest revision of ASTM B117 with the following
changes:
A. Mate the connector device and harness pairs using all applicable components such as terminals,
wedges, connector, and seals.
B. Number each connector assembly and verify device operation.
C. Solder one millivolt drop lead to each terminal wire on test at T1 and T4 per Figure 4. All millivolt drop
leads shall be single conductor, 28 gauge insulated wire. Install heat shrinkable tubing over each millivolt
drop lead to wire attachment.
D. Secure the connector assemblies to a steel ground plane with a plastic locator (or appropriate
substitute) with devices mounted in vehicle orientation.
E. Position the ground plane in the salt fog chamber per ASTM B117 paragraph 5.1.1 such that the test
samples are directly exposed to the fog spray.
F. Except during electrical measurements, continuously apply 14 +/- 0.5 VDC across adjacent terminals in
each multi-cavity connector. For single terminal connectors, apply 14 +/- 0.5 VDC across the ground
plane and terminal under test.
G. The samples shall be subjected to the salt spray test per ASTM B117 for a period of 96 hours.
H. Measure and record the total terminal connection millivolt drop per ampere (contact resistance) at the
start of the test, second hour, twenty fourth hour, and every twenty four hours thereafter for each test
terminal. Test current shall be 5.0 +/- 0.5 amps. Test current shall be "on" only for the duration of the
millivolt drop measurements. The power supply voltage for the millivolt drop test shall not exceed 12.0
VDC. The terminal connection millivolt drop values are obtained by taking the reading obtained above and
PF-9590, Change B, 2004-04-08, Page 26
Copyright DaimlerChrysler Corporation
(2003-07-08)
subtracting the millivolt drop due to the wires between the test leads.
I. Measure and record the isolation resistance at 500 VDC (unless otherwise specified) across adjacent
terminals for each multi-cavity connector hard shell. For terminals installed in single cavity connector hard
shells, measure isolation resistance at 500 VDC across the ground plane and each terminal under test.
During this test, open the circuit for the millivolt drop leads. Measure insulation resistance at the second
hour, twenty fourth hour, and every 24 hours thereafter for each terminal.
J. Verify the acceptance criteria.
2.6.9.4 Acceptance Criteria
For Engineering Development tests and Design Verification tests:
A. No evidence of corrosion may be visible under 10X magnification.
B. Contact resistance after the test must be no greater than 3 times the initial contact resistance for the
crimp and interface.
C. Verify the requirements of the Isolation Resistance test of 2.6.4.
For Production Validation tests:
A. No intermittencies during device operation.
B. No evidence of corrosion may be visible under 10X magnification.
2.6.10 Salt Water and Soap Shower
If the device specification has a Salt Water and Soap Shower test, use those test parameters.
For Engineering Development tests use fully sealed devices constructed without electrically connecting
the terminals to the device.
For Design Verification tests use dummy devices constructed to monitor connector performance.
For Production Validation testing, use production intent devices.
2.6.10.1 Purpose
This test evaluates the sealing performance of a connection system when subjected to a salt water and
soap solution shower.
2.6.10.2 Equipment
-
2.6.10.3 Procedure
This test shall be performed according to the latest revision of ASTM B117 with the following changes:
A. Mate the device and harness connector pairs using all applicable components such as device and
harness terminals, wedges, and seals.
PF-9590, Change B, 2004-04-08, Page 27
Copyright DaimlerChrysler Corporation
(2003-07-08)
D. Perform the Visual Inspection test per 2.4 and verify the acceptance criteria.
2.6.11.4 Acceptance Criteria
For Engineering Development testing verify the requirements of the following test:
A. Isolation Resistance test of 2.6.4.
For Design Verification testing verify the requirements of the following tests in the presented order:
A. Dry Circuit Voltage Drop test of 2.5.5
B. Voltage Drop test of 2.5.4
C. Isolation Resistance test of 2.6.4
2.6.12 Immersion
If the device specification has an Immersion test, use those test parameters.
For Engineering Development tests use fully sealed devices constructed without electrically attaching the
terminals to the device.
For Design Verification tests use dummy devices constructed to monitor connector performance.
For Production Validation tests use production-intent devices.
2.6.12.1 Purpose
This test evaluates the sealing capability of a sealed connection system when immersed in salt water for
extended periods of time.
PF-9590, Change B, 2004-04-08, Page 29
Copyright DaimlerChrysler Corporation
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2.6.12.2 Equipment
-
2.6.12.3 Procedure
A. Mate the device and harness connector pairs using all applicable components such as terminals,
wedges, and seals.
B. Number each connector assembly and verify device operation.
C. Use the maximum operating temperature of the device or determine the class temperature of the
connector system from Table 2, and set the chamber to the maximum temperature for that class. Allow
the chamber to stabilize before proceeding.
D. Place the samples in the chamber such that there is no substantial obstruction to air flow across and
around the samples, and the samples are at least 50 mm apart in all directions. Any mounting plates used
must be made of non-conductive material such as wood or high temperature plastic. Soak the samples in
the temp. chamber for 2 hours.
E. Remove the samples from the chamber and immediately immerse them in a 25 DEG C, 5% salt water
solution. A dye may be added to assist in the visual inspection of any ingress of solution into the
connector assemblies. The samples shall be immersed until the device temperature stabilizes.
F. For Engineering Development testing, repeat steps D - E four more times.
G. Immediately following the last immersion, verify the acceptance criteria.
2.6.12.4 Acceptance Criteria
For Engineering Development testing verify the requirements of the following test:
A. Isolation Resistance test of 2.6.4
For Design Verification testing verify the requirements of the following tests in the presented order:
A. Dry Circuit Voltage Drop test of 2.5.5
B. Voltage Drop test of 2.5.4
C. Isolation Resistance test of 2.6.4
For Production Validation testing verify the following:
A. No intermittencies in device operation during the test.
2.6.13 Pressure/Vacuum Leak
If the device specification has a Pressure/Vacuum leak test, use those test parameters.
For Engineering Development tests use fully sealed devices constructed without electrically attaching the
terminals to the device.
For Design Verification tests use dummy devices constructed to monitor connector performance.
PF-9590, Change B, 2004-04-08, Page 30
Copyright DaimlerChrysler Corporation
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2.6.13.1 Purpose
This test evaluates the sealing capability of a connector system when subjected to a pressure differential.
2.6.13.2 Equipment
-
2.6.13.3 Procedure
A. Mate the device and harness connector pairs using all applicable components such as terminals,
wedges, and seals. Insert a tube of sufficient diameter, to ensure that it is not a possible leak path, into
one cavity of each sample. Bend all wires 90 DEG to the back of the connector, keep the wires bent @
90 DEG throughout the test, and seal off all loose cable ends to eliminate possible leak paths. Wires may
be looped from one cavity to another to reduce the number of loose cable ends.
B. Number each connector assembly and verify device operation.
C. Connect the free end of the tube to a regulated pressure source.
D. Mate the samples and place the samples in a temp. chamber, set to the maximum operating
temperature of the device or the maximum temperature for the class of connection systems for 70 to 74
hours. Refer to Table 2 to determine the connection class.
E. Completely immerse the samples into a container of 25 DEG C, 5% salt water solution. An ultraviolet
dye may be added to the solution to assist in leak detection.
F. Wait for the device temperature to stabilize and verify the acceptance criteria.
G. Turn on the pressure until the gauge reads 28 kPa of pressure.
H. Observe samples for 15 seconds and verify that there are no air bubbles or loss of pressure.
I. Remove the samples and carefully dry all excess fluid from the exterior surfaces of the samples.
2.6.13.4 Acceptance Criteria
A. When positive pressure is applied to the connector system there should be no loss in the applied
pressure and no bubbles.
B. When negative pressure (vacuum) is applied verify the requirements of the Isolation Resistance test of
2.6.4. Unmate the samples and verify that there is no ingress of fluid into the connector assembly. Use
an ultraviolet light to detect the dye.
2.7 Special Tests
2.7.1 Solderability
This test is required for devices with headers.
2.7.1.1 Purpose
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This test evaluates the ability of a terminal to be soldered or plated with solder for header applications.
2.7.1.2 Equipment
- Solder Bath
- Tin/Lead (70/30) Solder
- Flux and flux remover
2.7.1.3 Procedure
A. Coat the solderable area of the samples with flux and drain vertically for 60 seconds.
B. Dip the solderable areas of the samples into the solder bath containing eutectic 70/30 solder heated to
232 DEG C +/-6 DEG C for a period of 4 +/-1 seconds.
C. After removal from the solder bath, allow the samples to solidify by air drying vertically.
D. Remove excess flux with a non-abrasive solvent flux remover.
E. Verify the acceptance criteria.
2.7.1.4 Acceptance Criteria
The soldered area shall be at least 95% covered with a smooth, uniform coating when viewed at 10X
magnification. The balance shall show only non-concentrated pinholes or dewetting spots.
3.0 RELIABILITY & DURABILITY TESTING
3.1 Failure Mode and Effects Analysis (FMEA)
Within 90 days of source selection the supplier must submit a preliminary design FMEA, based on the
current design concept to the design engineer for review. A revised FMEA must be submitted ten (10)
weeks prior to program tooling release and must be fully approved by the responsible engineer before
tooling release. The supplier must complete a process FMEA and submit it to the responsible engineer
and the applicable Supplier Quality representative at least ninety (90) days prior to start of production
validation testing. Additional information regarding FMEA preparation is contained in the Chrysler, Ford,
and General Motors, Potential Failure Mode and Effects Analysis (FMEA) manual.
3.2 Part Endurance
The objective of the design and construction of the components and connector systems is to be capable of
operating in its intended environment and application, without malfunction, for at least 10 years or 240,000
kilometers (150,000 miles) whichever occurs first.
Successful completion of Sec. 2.6.5 specified in this document is intended to show 95% reliability, with
90% confidence.
4.0 CONTROL
The supplier shall not change any material or process requirements subsequent to Design Verification
approval without the written consent of the appropriate Vehicle Engineering Office.
Production items shall meet all the requirements of this standard.
PF-9590, Change B, 2004-04-08, Page 32
Copyright DaimlerChrysler Corporation
(2003-07-08)
A supplier who furnishes finished parts to Chrysler Corporation is responsible for the quality of all
components of the shipped assembly or end item; whether component parts are processed/manufactured
by him or purchased from another source.
Prior to the submission, the supplier shall submit a request for waiver of the requirements of this standard
that are not satisfied by the design or materials to be used.
5.0 QUALITY ASSURANCE
The general responsibilities regarding Design Verification, Production Part Approval Process, Product
Validation and Continuing Conformance are shown in PF-8500, General Requirements.
The supplier is responsible for satisfactorily completing all testing specified in this standard and showing
proof of conformance.
5.1 Sample Documentation
Engineering test samples shall be identified by part number and serial number unless otherwise noted.
5.2 Measurement Accuracy
Meters and gages used in measurements of the test sample shall be capable of measuring to one count
less than the specified value. For example, even though a 0.1 mm and 0.10 mm might be the same
diameter, calipers capable of 0.01 mm resolution may be used to measure the first wire but a micrometer
with 0.001 mm resolution is required to measure the second wire.
5.3 Test Repeatability & Calibration
Repeatability studies shall be performed on all laboratory equipment after initial calibration and before use
for product evaluation. Individual gages and meters may be certified by manufacturer specifications. All
equipment used for product evaluation shall be repeatable to within 10% of the specification value (i.e. 10
consecutive readings of the same dimension, which is 0.10 mm and must be within a 0.01 mm range).
5.4 Conformance Determination
Test conformance shall be determined by the performance requirements of the test being performed. All
samples shall satisfy the performance requirements regardless of age, cycles, or temperature.
5.5 Disposition of Samples
Should a premature test non-conformance occur, contact the requesting party to determine if the test is to
be continued to gain additional product experience or if testing is to be suspended. When contact cannot
be immediately made, the type of test shall determine the disposition of the samples. If the test order
indicates that the test is investigative in nature, continue until the requesting party or parties are available.
If the test order is for sample approval or validation, stop the test until the requesting party can be
contacted.
5.6 Test Sequence
Test sequence is the order in which tests are performed. The sequence should be logical, and
interrelated, in order to establish the performance characteristics of the component or assembly.
A. Destructive tests should be performed on samples which are not used in further test sequences.
B. The Dry Circuit Voltage Drop test should always be performed before any other electrical test and prior
PF-9590, Change B, 2004-04-08, Page 33
Copyright DaimlerChrysler Corporation
(2003-07-08)
to sample movement.
C. Each major environment should have its own sequence.
D. Fixtures and test setups should be reviewed by the responsible engineer prior to testing.
E. The following tables are base sequences and may be altered according to the responsible engineer's
request.
TABLE 6: ENGINEERING DEVELOPMENT TESTS
Test
Section
Module Type
Sample Size
Visual Inspection
2.4
All
100%
TERMINAL - MECHANICAL
Terminal -Terminal
2.5.1
Production
As specified
Engage/Disengage
Terminal Bend Resistance
2.5.2
Production
As specified
Terminal Retention
2.5.3
Production
As specified
TERMINAL - ELECTRICAL
Voltage Drop
2.5.4
Dummy
6
Dry Circuit Voltage Drop
2.5.5
Dummy
6
CONNECTOR MECHANICAL
Connector - Connector
2.6.1
Production
15
Engage/Disengage
Cavity strength
2.6.2
Production
6
Vibration/Mechanical Shock
2.6.3
Dummy
6
CONNECTOR ELECTRICAL
Isolation Resistance
2.6.4
Dummy
6
CONNECTOR ENVIRONMENTAL
Thermal Shock
2.6.6
Dummy
6
Salt Fog
2.6.9
Dummy
6
Requirements
Note 1
Note 2
No failures
No failures
Note 2
Note 2
No failures
No failures
Note 2
Note 2
Note 2
Failure or
142 hours
Test
Visual Inspection
TERMINAL - MECHANICAL
Terminal-Terminal
Engage/Disengage Force
Terminal Bend Resistance
Terminal Retention
TERMINAL - ELECTRICAL
Voltage Drop
Dry Circuit Voltage
CONNECTOR -
Production
As specified
No failures
2.5.2
2.5.3
Production
Production
As specified
30
No failures
No failures
2.5.4
2.5.5
Dummy
Dummy
9
9
No failures2
No failures
Requirement
Note 1
Requirement
Note 1
No failures
No failures
No failures
No failures
CONNECTOR ENVIRONMENTAL
Temperature/Humidity
2.6.7
Production
4
No failures
Cycling
High Temperature Exposure
2.6.8
Production
4
No failures
Salt Water and Soap Shower
2.6.10
Production
4
No failures
Immersion
2.6.12
Production
4
No failures
Pressure/Vacuum Leak
2.6.13
Production
4
No failures
NOTE 1: Photographs and/or video recordings are required to document the physical appearance of
untested, as manufactured samples.
Three asterisks *** after the section/paragraph header denotes multiple technical changes to the
section/paragraph. A triple asterisk before and after a string of text (***text***) identifies a single change.
Certain important information relative to this standard has been included in separate standards. To assure
the parts submitted meet all of DaimlerChrysler requirements, it is mandatory that the requirements in the
following standards be met.
CS-9800 - Application of this standard, the subscription service, and approved sources
CS-9003 - Regulated substances and recyclability
QS-9000 - Quality system requirements
CS-CORROSION
Within Engineering Standards, the Regulatory (Government-mandated) requirements are designated by
<S>, <E> and <H> which correspond to Safety, Emission and Homologation Shields respectively. The
DCC-mandated requirements are designated by <D>, <A> and <T> and correspond to the Diamond,
Appearance and Traceability symbols respectively.
For specific information on this document, please refer to the contact person shown in the "Publication
Information" Section of this document. For general information on obtaining Engineering Standards and
Laboratory Procedures, see CS-9800 or contact the Engineering Standards Department at
[email protected].
8.0 REFERENCES
ASTM B117
Chrysler, Ford, and General Motors, Potential Failure Mode and Effects Analysis (FMEA) manual
Chrysler, Ford, and General Motors, Production Part Approval Process (PPAP) manual
Military Standard 1344A
PF-8500
PF-9600, Attachment A
QS-9000
SAE J823
CS-9003
CS-9800
CS-CORROSION
DaimlerChrysler, "Product Assurance Testing" manual (84-231-1311)
Quality System Requirements QS-9000
DaimlerChrysler Process Sign-Off (84-231-1227)
9.0 ENGINEERING APPROVED SOURCE LIST
Not Applicable.
10.0 PUBLICATION INFORMATION
Contact/Phone No: William R. Tabor / (313) 493-2461
Alternate Contact/Phone No: Neil Martinuzzi / (313) 714-0906
Dept. Name & Dept. No./Tech Club/Organization: Electrical / Electronic Core Engineering Dept. 6960
Date Standard Originally (Initially) Issued: 1995-03-22
Date Published: 2004-04-08
Change Notice:
Description of Change:
Removed <S> reference
PF-9590, Change B, 2004-04-08, Page 38
Copyright DaimlerChrysler Corporation
(2003-07-08)
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