MIL-DTL-32812 DRAFT2.1 7Oct2026_Release.pdf

APPROVED FOR PUBLIC RELEASE

DETAIL SPECIFICATION SHEET

CABLES, CONNECTORS, ELECTRICAL, RUGGED, USB TYPE-C®, QUICK DISCONNECT

ENVIRONMENT RESISTANT WITH FIXED CONTACTS, GENERAL SPECIFICATION FOR

This specification is approved for use by all Departments and Agencies of the Department of War.

FIGURE 1: USB-CM CONNECTORS

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INCH-POUND

DRAFT 2.1

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CONTENTS

SECTIONS

1. SCOPE

1.1. Scope

2. APPLICABLE DOCUMENTS

2.1. General

2.2. Government documents

2.3. Non-Government publications

2.4. Order of precedence

3. REQUIREMENTS

3.1. Specification sheets

3.2. Qualification

3.3. Materials

3.4. Assembly Types

3.5. Assembly Components

3.6. Assembly Rating

3.7. Part Numbering

3.8. Configuration interface and features

3.9. USB Type-C® cable & connector

3.10. Interchangeability

3.11. Temperature shock

3.12. Reserved

3.13. Coupling and uncoupling force

3.14. Mating / Unmating cycles

3.15. Insulation resistance

3.16. Dielectric withstanding voltage

3.17. Water Jets (IP X6)

3.18. Connector and cable

3.19. Low pressure (Altitude)

3.20. Vibration

3.21. RESERVED

3.22. Humidity

3.23. EMI/EMC

3.24. Ozone exposure

3.25. Immersion

3.26. Solar Radiation (UV Exposure)

3.27. Contamination by fluids

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3.28. High temperature exposure

3.29. Low temperature exposure

3.30. Rain

3.31. Dust or fine sand

3.32. Freezing rain

3.33. Salt Fog

3.34. Marking

3.35. Workmanship

3.36. Change effectivity

3.37. Disposition of stock

4. VERIFICATION

4.1. Classification of inspection

4.2. Inspection conditions

4.3. Material Inspection

4.4. Conformance inspection

4.5. Qualification inspection

4.6. Basic Operational Test (BOT)

4.7. RESERVED

4.8. RESERVED

4.9. USB Type-C® cable & connector

4.10. Interchangeability

4.11. Temperature shock

4.12. RESERVED

4.13. Coupling and uncoupling force

4.14. Mating / Unmating cycles

4.15. Insulation resistance (IR)

4.16. Dielectric withstanding voltage (DWV)

4.17. Water Jets (IP X6)

4.18. Connector and cable testing

4.19. Low Pressure (Altitude)

4.20. Vibration

4.21. RESERVED

4.22. Humidity

4.23. EMI/EMC

4.24. Ozone exposure

4.25. Immersion

4.26. Solar Radiation (UV Exposure)

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4.27. Contamination by fluids

4.28. High temperature exposure

4.29. Low temperature exposure

4.30. Rain

4.31. Dust or fine sand

4.32. Freezing rain

4.33. Salt Fog

4.34. Post test examination

5. PACKAGING

5.1. Packaging

6. NOTES

6.1. Intended use

6.2. Application guidance and restrictions

6.3. Derating factors

6.4. Military unique statement

6.5. Acquisition requirements

6.6. Qualification

6.7. Definitions

6.8. Subject term (key word) listing

6.9. Guidance information

6.10. Tin whisker growth

6.11. Changes from previous issue

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FIGURES

Figure 1: USB-CM Connectors Figure 2: USB-CM connector component references Figure 3. MIL-DTL-32812 cable/connector family Figure 4: Part Number designation Figure 5: Connector and cable flex setup Figure 6: Axial Pull test setup Figure 7. Interfacing Dimensions, Female Figure 8. Interfacing Dimensions, Male Figure 9. Full Featured Plug, Receptacle, and Cable General Dimensions Figure 10. USB 2.0 Plug and Cable General Dimensions Figure 11. Right Angle Plug General Dimensions Figure 12. Locking Receptacle Reference Strategies Figure 13 Locking receptacle max dimensions Figure 14. Bulkhead Receptacle Reference Designs Figure 15. Labeling

TABLES

Table 1: Group A inspection Table 2: Sampling plan Table 3: Group B inspection Table 4: Sampling plan Table 5: sample groups Table 6: Qualification and group C periodic tests Table 7: Basic Operational test Table 8: CS118 Discharge table

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1. SCOPE

1.1. Scope.

This specification covers a series of environmentally resistant electrical cables and connectors based on the USB Type-C® specification, called USB-C Military (USB-CM). The connectors designated herein are intended to meet all the performance requirements of the USB Type-C® cables and connectors commercial specification and are enhanced to operate under extreme environmental and temperature conditions required for US Department of War use. Where a conflict between the Type-C® specification and this document exists, the specification in this document shall take precedence. See 6.1 for intended use, application notes, application restrictions, and derating factors.

2. APPLICABLE DOCUMENTS

2.1. General.

The documents listed in this section are specified in sections 3 and 4 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3 and 4 of this specification, whether or not they are listed.

2.2. Government documents.

2.2.1. Specifications, standards, and handbooks.

The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract (see 6.5).

DEPARTMENT OF WAR STANDARDS

MIL-STD-790 Standard Practice for Established Reliability and High Reliability Qualified Products List (QPL) Systems for Electrical, Electronic, and Fiber Optic Parts.

MIL-STD-461G REQUIREMENTS FOR THE CONTROL OF

ELECTROMAGNETIC INTERFERENCE

CHARACTERISTICS OF SUBSYSTEMS AND

EQUIPMENT

MIL-STD-810H

w/Change 1

ENVIRONMENTAL ENGINEERING CONSIDERATIONS

AND LABORATORY TESTS

MIL-STD-889 Dissimilar Metals.

MIL-STD-1285 Marking of Electrical and Electronic Parts.

(Copies of these documents are available online at http://quicksearch.dla.mil.)

2.2.2. Other Government documents, drawings, and publications.

The following other Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues are those cited in the solicitation or contract.

NONE.

2.3. Non-Government publications.

The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract (see 6.5).

ELECTRONIC COMPONENTS INDUSTRY ASSOCIATION (ECIA)

EIA-364 Electrical Connector/Socket Test Procedures including Environmental Classifications.

http://quicksearch.dla.mil/

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EIA-364-14 Ozone Exposure Test Procedure for Electrical Connectors.

EIA-364-32 Thermal Shock (Temperature Cycling) Test Procedure for Electrical

Connectors and Sockets.

EIA-364-114 Coupling and Uncoupling Force Test Procedure for Electrical Connectors, Sockets and Applicable Accessories.

(Copies of these documents are available online at http://eciaonline.org or from the Electronic

Components Industry Association (ECIA), 1111 Alderman Dr., Suite 400, Alpharetta, GA 30005-4175.)

ASME INTERNATIONAL

ASME Y14.5 Dimensioning and Tolerancing.

(Copies of this document are available online at https://www.asme.org or from the ASME International, Three Park Avenue, New York, NY 10016-5990.)

ASTM INTERNATIONAL

ASTM B545 Standard Specification for Electrodeposited Coatings of Tin.

ASTM D570 Standard Test Method for Water Absorption of Plastics.

(Copies of these documents are available at https://www.astm.org or ASTM International, 100 Barr

Harbor Drive, PO Box C700, West Conshohocken, Pennsylvania 19428-2959.)

SAE INTERNATIONAL

SAE-AIR1351 Manufacturers’ Identification of Aerospace Electrical and Electronic Wiring Devices and Accessories.

SAE-EIA557 Statistical Process Control Systems.

(Copies of these documents are available at https://www.sae.org or SAE International, 400

Commonwealth Drive, Warrendale, PA 15096-0001, and Tel: 877-606-7323 (inside USA and Canada) or

724-776-4970 (outside USA), or email: CustomerService@sae.org.)

USB-IF

USB Type-C® r2.4 Universal Serial Bus Type-C® Cable and Connector Specification USB PD r3.2 v1.1 Universal Serial Bus Power Delivery Specification

(Copies of these documents are available at https://www.usb.org/)

2.4. Order of precedence.

Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein (except for related specification sheets), the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1. Specification sheets.

The individual item requirements shall be as specified herein and in accordance with the applicable specification sheet. In the event of any conflict between the requirements of this specification and the specification sheet, the latter shall govern.

3.2. Qualification.

Connectors and accessories furnished under this specification shall be products that are authorized by the qualifying activity for listing on the applicable qualified products list before contract award (see 4.5 and

6.6). After qualification, if the manufacturer seeks to make design changes or process changes to qualified product, or if the manufacturer seeks to use alternate / substitute materials, then the manufacturer shall coordinate with the qualifying activity and obtain its approval for proposed changes prior to implementing design or process changes to qualified product.

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3.2.1. Qualified Products List (QPL) system.

The manufacturer shall establish and maintain a quality system that allows its parts that are covered by this specification to be listed on the QPL. Requirements for this system are specified in MIL-STD-790. In addition, the manufacturer shall establish a Statistical Process Control (SPC) system that meets the requirements specified in SAE-EIA557.

3.3. Materials.

3.3.1. Critical interface materials.

Materials shall be as specified herein. When a definite material is not specified, a material shall be used which shall enable the connector to meet the performance requirements of this specification.

3.3.1.1. Metals.

Metals shall be of a corrosion-resistant type or shall be plated or treated to resist corrosion.

3.3.1.2. Dissimilar metals and compatible couples.

When dissimilar metals are used in intimate contact with each other, protection against galvanic corrosion shall be provided. The use of dissimilar metals in contact, which tend toward active galvanic corrosion

(particularly brass, copper, or steel used in contact with aluminum or an aluminum alloy) is not acceptable. However, metal plating of dissimilar base metals to provide similar or suitable abutting surfaces is permitted. The use of dissimilar metals separated by a suitable insulating material is also permitted. Dissimilar metals and compatible couples are specified in MIL-STD-889.

3.3.2. Components.

Materials for specific components of the connector shall be as follows:

FIGURE 2: USB-CM connector component references

a. Cable –

a. Conductor – copper with tin or silver plating.

b. SDP Shield – AL foil or AL/mylar foil.

c. Coaxial shield – copper strand.

d. Braid – tin plated copper or aluminum.

e. Jacket – Thermoplastic Polyurethane (TPU) or Thermoplastic Elastomer (TPE), or suitably performing substitute. Woven outer jacket optional

b. Strain Relief – Thermoplastic elastomer (TPE) or equivalent

c. Backshell – Coated aluminum or equivalent material

d. Connector shells – Corrosion-resistant steel.

e. Retention Spring – Heat-treated beryllium copper, corrosion-resistant steel, or equivalent

f. Potting compound – epoxy adhesive or suitable substitute

g. Gaskets, grommet, and interface seals – Silicone or fluorosilicone elastomer.

h. Colors – Black, Tan499, Green 528 or equivalent. All cable components must be lusterless/matte minus the USB-C connector itself.

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3.3.3. Fungus resistance.

Materials used in the construction of these cables and connectors shall be fungus inert (see 4.3.1).

3.3.4. Recycled, recovered, or environmentally preferable, or biobased materials.

Recycled, recovered, or environmentally preferable, or biobased materials should be used to the maximum extent possible, provided that the material meets or exceeds the operational and maintenance requirements, and promotes economically advantageous life cycle costs.

3.3.5. Hazardous materials.

The use of environmentally preferable materials in the construction of these connectors is encouraged.

See 6.9 for guidance.

3.4. Assembly Types.

FIGURE 3. MIL-DTL-32812 cable/connector family.

Figure 3 is notional. Other panel mount or integrated receptacles are allowed on USB-CM enabled devices as long as they are interoperable with USB-CM plugs.

3.4.1. Cable – Plug-to-Plug.

This assembly consists of a single length of cable with a plug at each of the two ends.

3.4.2. Cable – Plug-to-Receptacle.

This assembly consists of a single length of cable with a plug at the first end and a receptacle at the second end.

3.4.3. Cable – Receptacle-to-Receptacle.

Assemblies of this type are disallowed.

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3.4.4. Connector – Bulkhead.

This class includes panel mount receptacles. Only one connector is specified. There is no cable associated with this assembly type.

3.5. Assembly Components.

3.5.1. Plug.

All plug components shall share common interfacing dimensions and be compatible with breakaway or locking receptacles.

3.5.1.1. Straight Plug – 2.0 Version.

Dimensions shall be as shown in Figure 10.

3.5.1.2. Straight Plug – 3.2 Version.

Dimensions shall be as shown in Figure 9.

3.5.1.3. Horizontal Right-Angle Plug.

Dimensions shall be as shown in Figure 11.

3.5.1.4. Vertical Right-Angle Plug.

RESERVED.

3.5.2. Receptacle.

3.5.2.1. Breakaway Receptacle.

Dimensions shall be as shown in Figure 7. The spring material and dimensions shall be selected to provide between 13 ± 3 lbs. uncoupling force in accordance with 3.14 procedure for mating/unmating cycles.

3.5.2.2. Locking Receptacle.

Dimensions shall be as shown in Figure 13. The sliding retention collar locking female connectors shall provide a minimum uncoupling force of 45 lbs. The sliding retention collar lock disengagement force shall be between 4 and 6 lbs.

3.5.2.3. Bulkhead Receptacle.

Dimensions shall be as shown in Figure 14.

3.5.3. Cable.

Applicable to Plug to Plug and Plug to Receptacle cable assemblies. Cable lengths shall be specified from the end of the strain relief (ex. Figure 9).

3.6. Assembly Rating.

Assemblies shall be assigned and adhere to USB power and data rates. See 3.34 for marking information.

3.6.1. Power Rating.

Assemblies shall be identified with a USB-PD power rating (see 3.9.1).

3.6.2. Data Rate.

Assemblies shall be identified with a USB data rate specification (see 3.9.1).

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3.7. Part Numbering.

32812- 60 20HS SP SP XX

Designator 32812- =USB-CM Product

60 = 60 Watt

240 = 240 Watt

20HS = USB 2.0/Hi-Speed

3211 =USB 3.2 Gen 1x1 // 5 Gbps

3221 =USB 3.2 Gen 2x1 // 10 Gbps

3212 =USB 3.2 Gen 1x2 // 10 Gbps

3222 =USB 3.2 Gen 2x2 // 20 Gbps

4022 =USB 4.0 Gen 2x2 // 20 Gbps

4032 =USB 4.0 Gen 3x2 // 40 Gbps

SP Straight Plug

HP Horizontal Right-Angle Plug

VP Vertical Right-Angle Plug

BR Breakaway Receptacle

LR Locking Receptacle

BF Bulkhead Receptacle, Front Panel Mount /1

BR Bulkhead Receptacle, Rear Panel Mount /1

SP Straight Plug

HP Horizontal Right-Angle Plug

VP Vertical Right-Angle Plug

BR Breakaway Receptacle

LR Locking Receptacle

BF Bulkhead Receptacle, Front Panel Mount /1

BR Bulkhead Receptacle, Rear Panel Mount /1

Length XX

Cable Length, rounded to nearest whole inch /2

Cable only - measured from back of strain reliefs

Part Number

USB Power

USB Data Rate

Termination 1

Termination 2

Notes:

/1 Bulkhead Receptacle is repeated as termination 2 for this type i.e. "BFBF".

/2 Use "00" for Bulkhead Receptacle.

/3 Government does not intend to buy all variants. Table notes general part number formatting.

FIGURE 4: PART NUMBER DESIGNATION

3.8. Configuration interface and features.

Connectors and accessories shall be configured to withstand normal handling during installation and maintenance while in service. All accessories designed to be used with MIL-DTL-32812 connectors shall conform to these dimensions. Dimensioning and tolerancing shall be in accordance with ASME Y14.5.

Unless otherwise specified, dimensions apply after plating.

3.8.1. Contacts.

Contacts shall be fixed, as specified.

3.8.1.1. Dust caps/containers

Dust caps shall be placed on the mating end of each connector for shipping. In lieu of dust caps on both ends, receptacles may be packaged in rigid or semi-rigid containers designed to prevent damage to the end of the connector.

3.8.1.2. Operational Dust caps

When necessary, an operational dust cap shall be placed on the end of each connector for operational use cases and provide environmental protection while capped.

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3.8.2. Coupling.

Connectors shall be coupled to counterpart connectors by the following coupling methods:

Plugs shall use a common set of dimensions and materials for their mating interface and shall be interchangeable with one another.

Breakaway receptacles shall use a common set of dimensions and materials for their mating interface and shall be interchangeable with one another and compatible with plugs.

Locking receptacles shall use a common set of dimensions and materials for their mating interface and shall be interchangeable with one another and compatible with plugs.

All plugs shall be mateable and interoperable with both breakaway or locking receptacles.

3.8.2.1. Ease of coupling.

Counterpart connectors of any arrangement shall be capable of being fully coupled and uncoupled in a normal and accessible location without the use of tools.

Regardless of retention method, the design shall facilitate mating and unmating while wearing standard and fitted combat gloves, mechanix style gloves, or equivalent. Specifically, the connector overmold tail and cable should be of sufficient size and rigidity to grasp and manipulate the retention feature while wearing gloves.

3.8.2.2. Breakaway connectors.

Breakaway receptacles shall use an internal retention spring or equivalent retention mechanism. This mechanism is intended to interface with the retention indent feature. Breakaway connectors shall disconnect without the use of tools.

3.8.2.3. Locking connectors.

Multiple approaches to locking receptacles are allowed. Locking receptacles may utilize a techniques shown in Figure 12. This mechanism is intended to interface with the retention indent feature.

Dimensions of this mechanism shall be specified as shown in Figure 13.

3.8.2.4. Polarization of connector shells.

Plugs and receptacles shall be mateable in a bidirectional manner. Connectors shall not rely on any keying mechanism to establish orientation.

3.8.2.5. Lubrication.

Coupling ramps, retention springs, gaskets, and locking springs of connectors may be coated during the manufacturing process with a suitable lubricant. Lubricants shall be non-flaking and galvanically compatible. Lubricants shall not migrate into contact areas.

3.9. USB Type-C® cable & connector.

3.9.1. Applicable specifications.

All requirements of the Universal Serial Bus Type-C® Cable and Connector Specification, Release 2.4, October 2024 (Hereafter, “Type-C® specification”) are applicable to cables and connectors defined by this specification. Where a conflict between the Type-C® specification and this document exists, the specification in this document shall take precedence.

3.9.1.1. USB 3.2 GEN 2x2, 240W.

Cable/connector assemblies of this type shall utilize USB Full-Featured Type-C® receptacles for USB 3.2 platforms.

Cable/connector assemblies of this type shall utilize USB Full-Featured Type-C® plugs.

Cable/connector assemblies of this type shall utilize USB Full-Featured Type-C® cable.

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All cable/connector assemblies of this type shall be electronically marked.

All cables/connector assemblies of this type shall be physically marked with data/power capabilities.

Utilize USB-IF markings for power and data rates on the backshell where possible. Additional information should be on a heat-shrink wire information band.

3.9.1.2. USB 2.0, 60W.

Cable/connector assemblies of this type shall utilize USB 2.0 Type-C® plugs and may utilize USB Full-

Featured Type-C® plugs. Only the contacts necessary to support USB PD and USB 2.0 are required in the plug.

Cable/connector assemblies of this type may be electronically marked.

All cables/connector assemblies of this type shall be physically marked with data/power capabilities.

Utilize USB-IF markings for power and data rates on the backshell where possible. Additional information should be on a heat-shrink wire information band.

3.9.1.3. Vconn

Cable/connector assemblies shall include the optional Vconn if Fully Featured. Cable/connector assemblies may include the optional Vconn if USB 2.0.

3.10. Interchangeability.

All connectors having the same Part or Identifying Number (PIN) shall be completely interchangeable with each other with respect to installation and performance. Verify in accordance with 4.10.

3.11. Temperature shock.

When tested as specified in 4.11, there shall be no damage detrimental to the operation of the cable or connector.

3.12. Reserved

3.13. Coupling and uncoupling force.

See 3.5.2. When tested as specified in 4.13, the coupling force for mating and the uncoupling force for unmating of counterpart plugs and receptacles shall apply to mating of connectors. Coupling and uncoupling force requirements do not apply to mating plugs to and from dummy stowage receptacles and/or covers.

3.14. Mating / Unmating cycles.

The durability rating shall be 10,000 cycles minimum. The durability test shall be done at a rate of 500 ±

50 cycles per hour. When tested as specified in 4.14, the connectors shall show no defects detrimental to the operation of the connectors and shall meet the subsequent test requirements (see 4.5.3).

3.15. Insulation resistance.

3.15.1. Insulation resistance at ambient temperature.

When tested as specified in 4.15.1, the insulation resistance between any pair of contacts and between any contact and the shell shall be greater than 100 MΩ. Insulation resistance after altitude immersion shall be 100 MΩ minimum. Insulation resistance after humidity shall be 100 MΩ minimum.

3.15.2. Insulation resistance at elevated temperature.

When tested as specified in 4.15.2, the insulation resistance between any pair of contacts and between any contact and the shell shall be greater than 100 MΩ.

3.16. Dielectric withstanding voltage.

When tested as specified in 4.16.1, the maximum leakage current shall be 2 milliamperes, and there shall be no evidence of electric breakdown or flashover.

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3.17. Water Jets (IP X6).

Unmated connectors and cables shall meet the ingress protection IP X6 standard. When tested as specified in 4.17, unmated connectors shall show no lifting of plating or exposure of basis material under three power (3X) magnification which adversely affects performance.

3.18. Connector and cable.

3.18.1. Connector and cable flexing.

When tested as specified in 4.18.1, connectors and cables shall show no evidence of damage detrimental to their normal operation, nor shall there be any interruption of electrical and/or data continuity.

3.18.2. Axial pull.

When tested as specified in 4.18.2. All wire cable overmold points shall not part from the backshell when subjected to pulling force. Cables shall withstand 100 pounds of tension. The device interface cable shall withstand 30 pounds of tension.

3.19. Low pressure (Altitude).

When tested as specified in 4.19, the connectors and cables shall meet the requirements of dielectric withstanding voltage at sea level specified in 3.16 and insulation resistance at ambient temperature specified in 3.15.1.

3.20. Vibration.

When tested as specified in 4.20, there shall be no electrical discontinuity and there shall be no disengagement of the mated connectors, backing off of the coupling mechanism, evidence of cracking, breaking, or loosening of parts.

3.21. RESERVED.

3.22. Humidity.

When tested as specified in 4.22, mated and unmated connectors and cables shall show no deterioration which will adversely affect performance of the connector.

3.23. EMI/EMC.

Cables and connectors shall comply with the following emission and susceptibility requirements of MIL-

STD-461.

3.23.1. CS118 (Conducted Susceptibility, Personnel Borne Electrostatic Discharge).

Cables and connectors shall withstand (survive) ESD to ±8kV contact discharge and ± 15kV air discharge on any surface, including exposed pins, in both operating and non-operating mode. Verify in accordance with 4.23.1.

3.23.2. RE102 (Radiated Emissions, Electric Field).

Cables and connectors, when operating at their maximum rated data transfer rate and power delivery capacity, shall control radiated electric field emissions. The emissions shall not exceed the "Ground, Army" limits specified in MIL-STD-461, Method RE102, over the frequency range of 2 MHz to 18 GHz.

Verify in accordance with 4.23.3.

3.23.3. RS103 (Radiated Susceptibility, Electric Field).

Cables and connectors shall operate without any sign of susceptibility, performance degradation, or deviation from specified functionality when subjected to radiated electric fields over the frequency range of 2 MHz to 2.7 GHz. Verify in accordance with 4.23.3.

3.24. Ozone exposure.

When tested as specified in 4.24, cables and connectors shall show no evidence of cracking of dielectric material or other damage due to ozone exposure that will adversely affect performance.

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3.25. Immersion.

Applicable to initial qualification only. When tested as specified in 4.25, cables and connectors shall meet the requirements for Basic Operational Test (see 4.6). Mated and unmated connectors shall demonstrate immersion in fresh water and salt water to a specific profile.

3.25.1. Surface Swimmer

Mated and unmated connectors and cables shall withstand depth of 3 Feet Sea Water (FSW) for ≥30min

3.25.2. Combat swimmer.

Mated connectors and cables shall withstand depth of 33FSW for ≥10 hours

3.25.3. RESERVED

3.26. Solar Radiation (UV Exposure)

When tested as specified in 4.26, cable and connector shall perform satisfactorily and pass succeeding tests in the qualification test sequence.

3.27. Contamination by fluids

When tested as specified in 4.27, cables and connectors shall perform satisfactorily and pass succeeding tests in the qualification test sequence.

3.28. High temperature exposure.

When tested as specified in 4.28, cables and connectors shall perform satisfactorily and pass succeeding tests in the qualification test sequence.

3.28.1. High temperature storage.

Mated and unmated connectors and cables shall withstand storage temperatures of 160°F, constant temperature exposure.

3.28.2. High temperature operation.

Mated and unmated connectors and cables shall withstand operational temperatures of 130°F, constant temperature exposure.

3.29. Low temperature exposure.

When tested as specified in 4.29, connectors and cables shall perform satisfactorily and pass succeeding tests in the qualification test sequence.

3.29.1. Low temperature storage.

Mated and unmated connectors and cables shall withstand storage temperatures of -40°F.

3.29.2. Low temperature operation.

Mated and unmated connectors and cables shall withstand operational temperatures of -40°F.

3.30. Rain.

When tested as specified in 4.30, mated and unmated connectors and cables shall exhibit no detrimental effects following exposure. Mated pairs shall be capable of operating while exposed without degradation in performance or damage to the connectors or cables.

3.31. Dust or fine sand.

When tested as specified in 4.31, Mated and unmated connectors and cables shall pass succeeding tests in the qualification table. When tested as specified in 4.13, uncoupling and recoupling force shall not exceed the values specified in 3.13 by more than 25 percent.

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3.32. Freezing rain.

When tested as specified in 4.32, cables and connectors shall pass succeeding tests in the qualification table. When tested in accordance with 4.13, uncoupling and recoupling force shall not exceed the values specified in 3.13 by more than 25 percent.

3.33. Salt Fog.

When tested as specified in 4.33, mated and unmated connectors and cables shall exhibit no detrimental effects following exposure. Mated pairs shall be capable of operating while exposed without degradation in performance or damage to the connectors or cables.

3.34. Marking.

Cable labeling shall be as specified in Figure 15. Cable wrap shall be marked with the appropriate Part

Number (see 3.7) at each end.

3.35. Workmanship.

The connector shall be fabricated in a manner such that the criteria for appearance, fit and adherence to specified tolerances are observed. Particular attention shall be given to neatness and thoroughness of marking parts, plating, welding, soldering, riveting, staking, and bonding. The visual examination under three power (3X) magnification shall include examination of each retention cavity for molding discrepancies, retention features, and excessive adhesive. The connectors shall be free from crazing, cracks, voids, pimples, chips, blisters, pinholes, sharp cutting edges, burrs, and other defects that will adversely affect life, serviceability, or appearance.

3.36. Change effectivity.

Unless otherwise specified by the preparing activity and/or the qualifying activity, all changes from the previous revision of MIL-DTL-32812 shall become effective within 90 days of the date of publication of the latest revision. If unable to implement changes within the 90-day time period, additional time shall be requested from the qualifying activity. Manufacturers that are QPL-listed and have concerns regarding possible changes to retention reporting requirements should contact the qualifying activity for clarification.

3.37. Disposition of stock.

If connectors and accessories produced to the previous revision continue to meet the requirements of this specification, then products manufactured in accordance with the previous revision may continue to be shipped from stock for an indefinite period. If the qualified products meet the requirements of the previous revision, but do not meet the requirements of the current revision, then the manufacturer and their selling agents or distributors have a period of 18 months from the date of the latest revision to purge or ship all inventory, unless otherwise coordinated with, and authorized by, the qualifying activity. Revision changes to connector marking requirements, such as changes and / or additions of tracer markings to the grommet or connector mating face, do not impact form, fit, or function, Products produced in accordance with previous revisions with the above-referenced types of changes that do not impact form, fit, or function, may be sold until stocks are depleted.

4. VERIFICATION

4.1. Classification of inspection.

The examination and testing of connectors shall be tested in groups as follows:

a. Group A inspection: Non-destructive testing of subset of cable lot

b. Group B inspection: Destructive testing of subset of cable lots

c. Group C/Group 6 inspection: Periodic testing for continued approval as a QPL USB-CM manufacturer

d. Group 1-5 testing protocols: Full qualification (First Article Testing/FAT) protocol to gain initial

QPL USB-CM manufacturer

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4.2. Inspection conditions.

Unless otherwise specified herein, all inspections shall be performed in accordance with the test conditions specified in the "GENERAL REQUIREMENTS" of EIA-364.

4.2.1. 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 contractor. The establishment and maintenance of a calibration system to control the accuracy of the measuring and test equipment (i.e., industry standard, military standard) shall be required.

4.2.1.1. QPL system.

The manufacturer shall establish and maintain a system to meet the requirements of MIL-STD-790 and the requirements herein (see 3.2.1). Evidence of such compliance shall be verified by the qualifying activity as a prerequisite for qualification and retention of qualification. Assembly plants shall be approved by the qualifying activity and listed on the applicable Qualified Products List. The qualified connector manufacturer shall certify that the assembly plant is approved for the distribution of the manufacturer’s parts. Assembly plants shall use only piece parts (i.e. subcomponents, such as connector shells and inserts) produced by the qualified manufacturer. No incoming inspection other than visual examination is required of certified piece parts obtained from the qualified manufacturer, except when there is cause for rejection. Assemblies produced at the assembly plant shall be subjected to inspection to ensure that the assembly process conforms with that established at the qualified manufacturing plant. Quality control requirements, including Government inspection surveillance, shall be the same as required for the qualified connector manufacturer.

4.3. Material Inspection

Material inspection performed through certification (see 4.4)

4.3.1. Fungus resistance certification.

Certification to method 508 of MIL-STD-810 and MIL-HDBK-454 Guideline 4 is required (see 3.3.3).

Testing is not required for materials listed as fungus inert.

4.4. Conformance inspection.

4.4.1. Inspection of product for delivery.

Inspection of product for delivery shall consist of groups A and B inspections. The documentation requirements of the applicable military or industry test procedures do not apply.

4.4.1.1. Group A inspection.

Group A inspection shall consist of the inspections specified in Table 1.

4.4.1.1.1. Visual examination (group A inspection).

Each connector and accessory shall be visually examined for completeness, workmanship, and identification requirements. For those assemblies that require a gasket, the condition of the gasket shall be visually examined. Gaskets missing, twisted, buckled, kinked, or damaged in any way shall be cause for rejection.

4.4.1.1.2. Critical examinations (group A inspection).

The following dimensions and features shown on the pertinent military standard are considered critical.

a. Mating diameters H, W, and R.

b. Cable lengths.

d. Marking features (see 3.34).

e. (locking receptacles) Retention collar operation.

Inspection Requirement paragraph Test paragraph

Visual and mechanical examination. 1/ 3.1, 3.3, 3.4, 3.10, 3.34 and 3.35

Critical examination. 1/ 3.1 4.4.1.1.2

Insulation resistance (IR). 1/ 2/ 3.15 4.15

Dielectric withstanding voltage (DWV). 1/ 2/ 3.16 4.16

1/ The contractor may use in-process controls for this requirement.

2/ Test 100 percent of contacts. Points of measurement and application of voltage shall be between circuits consisting of each contact and its closest adjacent contact and between connector shell and closest contacts adjacent to the shell. Multiple circuits may be tested concurrently.

TABLE 1: Group A inspection.

4.4.1.1.3. Sampling plan (group A inspection).

A sample size shall be randomly selected as specified in Table 2. If one or more defects are found, then the lot shall be rescreened and defects removed. A new sample as specified in Table 4 shall then be randomly selected. If one or more defects are found in the second sample, then the lot shall not be supplied to this specification.

Lot Size Sample Size Accept (Ac) Reject (Re)

1 to 13 100 percent 0 1

14 to 150 13 units 0 1

151 to 280 20 units 0 1

281 to 500 29 units 1 2

501 to 1,200 34 units 1 2

1,201 to 3,200 42 units 1 2

3,201 to 10,000 50 units 2 3

10,001 to 35,000 80 units 3 4

TABLE 2: Sampling plan.

4.4.1.2. Group B inspection.

Group B inspection shall consist of the inspections specified in Table 3 in the order shown and shall be made on sample units which have been subjected to and have passed the group A inspection.

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Inspection Requirement paragraph Test paragraph Number of samples

Coupling and uncoupling force. 1/ 2/ 3.13 4.13

As specified in Table 4

Connector and cable testing Connector and cable flexing. 1/ 2/ 3/

3.18 4.18

Post test examination. 1/ 2/ 3/ 3.34 and 3.35 4.34

1/ The contractor may use in-process controls for this requirement.

2/ No failures permitted.

3/ Test 5 pieces.

TABLE 3: Group B inspection.

4.4.1.2.1. Sampling plan (group B inspection).

A sample size shall be randomly selected as specified in Table 4. If one or more defects are found, then the lot shall be rescreened and defects removed. A new sample as specified in Table 4 shall then be randomly selected. If one or more defects are found in the second sample, then the lot shall not be supplied to this specification.

Lot Size Sample Size Accept (Ac) Reject (Re)

1 to 13 100 percent 0 1

14 to 150 13 units 0 1

151 to 280 20 units 0 1

281 to 500 29 units 1 2

501 to 1,200 34 units 1 2

1,201 to 3,200 42 units 1 2

3,201 to 10,000 50 units 2 3

10,001 to 35,000 80 units 3 4

TABLE 4: Sampling plan.

4.4.1.2.2. Lot definition (group B inspection).

The production lot, as defined in MIL-STD-790, is further specified as follows:

a. A production lot consists of all connectors covered under one military specification or standard, manufactured from the specified raw materials, processed under the same specification and procedures, produced by the same type of equipment, and submitted for inspection at one time.

Each production lot of assembled connectors shall be a group identified by a common manufacturing record through all significant assembly operations.

b. Common manufacturing records and traceability shall begin with machining and molding and shall include connector assembly. Traceability of connectors to specific physical/chemical test reports of incoming raw material is not required.

4.4.1.2.3. Disposition of sample units.

Sample units which have been subjected to group B inspection shall not be delivered on the contract or purchase order.

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4.4.2. Periodic inspection.

Periodic inspection shall consist of group C inspection. Except where the results of this inspection show noncompliance with the applicable requirements (see 4.4.2.1.4), delivery of products which have passed groups A and B inspections shall not be delayed pending the results of this periodic inspection.

4.4.2.1. Group C inspection (periodic tests).

Periodic tests shall be performed on a 36-month basis. Samples submitted to periodic tests shall have passed groups A and B inspections.

4.4.2.1.1. Thirty-six month periodic tests.

Every 36 months, mated connector pair sample units shall be selected, configured and tested as specified below (Note: At the discretion of the qualifying activity, an alternate test sequence may be performed):

a. Group 6, test sample quantity and configuration: Two mating plugs and receptacles shall be provided.

4.4.2.1.2. Failures.

If one or more sample units fail to pass group C inspection, the sample shall be considered to have failed and corrective action shall be taken in accordance with 4.4.2.1.4.

4.4.2.1.3. Disposition of sample units.

Sample units which have been subjected to group C inspection shall not be delivered on the contract or purchase order.

4.4.2.1.4. Noncompliance.

If a sample fails to pass group C inspection, the manufacturer shall take corrective action on the materials or processes or both, as warranted, and on all units of product which are to be corrected and which were manufactured with essentially the same materials and processes, and which are considered subject to the same failure. Acceptance and shipment of the product shall be discontinued until corrective action acceptable to the qualifying activity has been taken. After the corrective action has been taken, group C inspection shall be repeated on additional sample units (all inspections, or the inspection which the original sample failed, at the option of the qualifying activity). Groups A and B inspections may be reinstituted; however, final acceptance shall be withheld until the group C reinspection has shown that corrective action was successful. In the event of failure after reinspection, information concerning the failure shall be furnished to the cognizant inspection activity and the qualifying activity.

4.4.3. Failures of groups A, B or C.

Lots which fail groups A, B or C and also either fail retesting or are not submitted for retesting, shall not be shipped

4.5. Qualification inspection.

Qualification inspection shall be performed at a laboratory acceptable to the Government (see 6.6) on sample units produced with equipment and procedures normally used in production. Qualification approval may be granted upon successful completion of the inspections and tests of 4.5.3 conducted on samples of 4.5.1; such approval to include classes, finishes, shell configurations, and insert arrangements other than those actually tested, providing that the capability to manufacture these parts is demonstrated by providing exhibit samples or equivalent listing. Unless otherwise specified, qualification of receptacles must be demonstrated with all compatible plugs, and qualification of plugs must be demonstrated with all compatible receptacles. Qualification of a new plating material or other specified characteristic on a connector also qualifies the same characteristic by similarity of a product with lower performance requirements, such as protective caps and covers or dummy stowage receptacles. However, qualification of a specified characteristic on a cap, cover or dummy stowage receptacle shall not qualify a connector with the same characteristic.

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4.5.1. Sample size.

The following test samples, for each assembly manufactured by normal production methods, shall be provided. Tested and untested connectors, accessories and materials may be required at no cost to the

Government for qualification verification by the responsible qualification activity (see 6.6).

a. Sample sizes:

Group Number Sample Size

Group 1 1 per cable assembly type

Group 2 10 mated pairs

Group 3 1 per cable assembly type

Group 4 1 per cable assembly type

Group 5 1 per cable assembly type

Group 6 1 per cable assembly type

TABLE 5: SAMPLE GROUPS

b. For groups 1 and 3, each verification shall be performed with each assembly type (see 3.4) and each unique combination of components (see 3.5).

c. For groups 1 and 3, verification of mated pairs shall be performed with each plug type (see 3.5.1) mated to each receptacle type (see 3.5.2).

d. For group 2, ten mated pairs of each plug type (see 3.5.1) mated to each receptacle type (see

3.5.2).

e. For group 4, verification shall be performed with each complete cable assembly of each type.

f. For group 5, verification shall be performed with each complete cable assembly of each type.

g. For group 6, each verification shall be performed with each assembly type (see 3.4) and each unique combination of components (see 3.5).

4.5.1.1. Sample size (limited qualification).

Manufacturers that do not intend to qualify all connector types shall verify candidate connector and cables with all possible qualified mating cables and connectors. Future qualification of additional cables and connectors will require qualification as determined by the qualifying activity.

4.5.2. Preparation of samples.

Except as otherwise specified, samples shall be provided in their as-built configuration.

4.5.3. Qualification tests.

a. Samples provided under 4.5.1a and 4.5.1b shall be divided into two similar groups. One group shall be subjected to the tests of group 1,Table 1, in the sequence specified. The other group shall be subjected to the tests of group 3, Table 1, in the sequence specified.

b. Samples provided under 4.5.1c shall be subjected to the test of group 2, Table 1, in the sequence specified.

c. Samples provided under 4.5.1d shall be subjected to the tests of group 4, Table 1, in the sequence specified.

d. Samples provided under 4.5.1e shall be subjected to the tests of group 5, Table 1, in the sequence specified.

e. Samples provided under 4.5.1f shall be subjected to the tests of group 6, Table 1, in the sequence specified.

4.5.3.1. Failures.

One or more failures, as defined in their respective requirements paragraphs, shall be cause for refusal to grant qualification.

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4.5.4. Retention of qualification.

To retain qualification, the qualified manufacturer shall periodically forward reports to the Qualifying

Activity (see 6.6) as follows:

4.5.4.1. At 24-month intervals, unless otherwise specified by the Qualifying Activity, the qualified manufacturer shall forward a report with a summary of the results of groups A and B testing (see 4.4).

The results of tests for all reworked lots shall be identified and accounted for.

4.5.4.2. At 36-month intervals, unless otherwise specified, the qualified manufacturer shall submit requalification, group C test reports (see 4.4.2.1), including the number and mode of failures. The summary shall include results of all qualification verification inspection testing performed during that period.

4.5.4.3. Reports shall include certification that the qualified source continues to produce qualified product under the same conditions as originally qualified (i.e., same processes, materials, design, construction, etc., including manufacturing locations), unless such changes have been authorized by the

Qualifying Activity.

Note: The qualified source shall immediately notify the Qualifying Activity at any time during the reporting period when inspection data indicates failure of the qualified product to meet the requirements of the specification. If the summary of test results indicates nonconformance with the specification requirements, and corrective action acceptable to the Qualifying Activity has not been taken, then action may be taken to remove the failing product from the QPL. In addition, failure to submit the report within thirty days after the end of each reporting period may result in loss of qualification for that product. In the event that no production occurred during the reporting period, the qualified manufacturer shall submit a report certifying that the company still has the capability and facilities required to produce the qualified product. If there has been no production during two consecutive reporting periods, the Qualifying Activity, at their discretion, may require the manufacturer submit a representative product of each type, class, etc., to retention testing in accordance with qualification inspection requirements.

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Inspection Requirement paragraph Test paragraph Group 1 (environmental)

Visual and mechanical examination.

3.1, 3.3, 3.4, 3.10, 3.34 and 3.35

Basic Operational Test (BOT). 3.9 4.6

Temperature shock. 3.11 4.11

High temperature exposure. 3.28 4.28

Low temperature exposure. 3.29 4.29

Low Pressure (Altitude). 3.19 4.19

Vibration. 3.20 4.20

Humidity. 3.22 4.22

Ozone exposure. 3.24 4.24

High temperature exposure. 3.28 4.28

Dust or fine sand. 3.31 4.31

Rain. 3.30 4.30

Freezing rain. 3.32 4.32

Salt Fog. 3.33 4.33

Immersion. 3.25 4.25

Coupling and uncoupling force. 3.13 4.13

Basic Operational Test (BOT). 3.9 4.6

Post test examination. 3.34 and 3.35 4.34

Group 2 (durability)

Visual and mechanical examination.

3.1, 3.3, 3.4, 3.10, 3.34 and 3.35

Basic Operational Test (BOT). 3.9 4.6

Temperature shock. 3.11 4.11

Immersion. 3.25 4.25

Mating / Unmating cycles. 3.14 4.14

Coupling and uncoupling force. 3.13 4.13

Connector and cable. 3.18 4.18

Basic Operational Test (BOT). 3.9 4.6

Post test examination. 3.34 and 3.35 4.34

Group 3 (Water Jets)

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Visual and mechanical examination.

3.1, 3.3, 3.4, 3.10, 3.34 and 3.35

Basic Operational Test (BOT). 3.9 4.6

Water Jets (IP X6). 3.17 4.17

Basic Operational Test (BOT). 3.9 4.6

Post test examination. 3.34 and 3.35 4.34

Group 4

(EMI)

3.10, 3.34 and 3.35

Basic Operational Test (BOT). 3.9 4.6

EMI/EMC. 3.23 4.23

Post test examination. 3.34 and 3.35 4.34

Group 5 (USB compliance)

3.10, 3.34 and 3.35

USB Type-C® cable & connector. 3.9 4.9

Post test examination. 3.34 and 3.35 4.34

Group 6 (36-month periodic inspection)

3.10, 3.34 and 3.35

Basic Operational Test (BOT). 3.9 4.6

Temperature shock. 3.11 4.11

High temperature exposure. 3.28 4.28

Low temperature exposure. 3.29 4.29

Coupling and uncoupling force. 3.13 4.13

Mating / Unmating cycles. 3.14 4.14

Insulation resistance (IR). 3.15 4.15

Dielectric withstanding voltage (DWV). 3.16 4.16

Water Jets (IP X6). 3.17 4.17

Connector and cable. 3.18 4.18

Vibration. 3.20 4.20

Humidity. 3.22 4.22

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Immersion. 3.25 4.25

Freezing rain. 3.32 4.32

Basic Operational Test (BOT). 3.9 4.6

Post test examination. 3.34 and 3.35 4.34

TABLE 6: Qualification and group C periodic tests.

4.5.5. Connectors, accessories and piece parts.

The connectors, accessories and piece parts covered by this specification shall be visually and mechanically examined to ensure conformance with the specification and the applicable military standards (see 3.1, 3.3, 3.4, 3.10, 3.34 and 3.35). The contractor may use in-process controls to satisfy these requirements.

4.5.6. Contacts.

The contacts shall be visually examined for mechanical defects (see 3.1, 3.3, 3.4, and 3.35). The contacts shall be inspected through a device having approximately three power (3X) magnification. The contractor may use in-process controls to satisfy these requirements.

4.5.7. Test methods.

The following identified tests and methods assure connector integrity within typical operating conditions and applications. Alternate commercial industry standard test methods are allowed when determined to provide equivalent results; however when an alternate method is proposed, the manufacturer shall submit details of the alternate method to the qualifying activity for their review and approval prior to the performance of the test. The test methods described herein are proven methods and shall be the referee methods in the event of a dispute.

4.6. Basic Operational Test (BOT).

The following USB electrical compliance tests shall be used to demonstrate basic functionality:

Category Test Name

Power & Safety Insulation Resistance Drop (Voltage Drop)

Power & Safety Dielectric Withstanding Voltage (Hipot)

Power & Safety Low-Level Contact Resistance (LLCR)

C…