30008764 PDF BRITISH STANDARD BS CECC 299001 1999 CECC 299001 1999 Technology Approval Schedule — Manufacture of electrical connectors ICS 29 120 20 BS CECC 299001 1999 This British Standard, having b[.]
BRITISH STANDARD Technology Approval Schedule — Manufacture of electrical connectors ICS 29.120.20 BS CECC 299001:1999 CECC 299001: 1999 BS CECC 299001:1999 National foreword This British Standard is the English language version of BS CECC 299001:1999 It is identical with CECC 299001:1999 The UK participation in its preparation was entrusted by Technical Committee EPL/46, Cables, wires, waveguides, RF connectors and accessories for communication and signalling, to Subcommittee EPL/46/2, RF connectors, which has the responsibility to: — aid enquirers to understand the text; — present to the responsible international/European committee any enquiries on the interpretation, or proposals for change, and keep the UK interests informed; — monitor related international and European developments and promulgate them in the UK A list of organizations represented on this subcommittee can be obtained on request to its secretary Cross-references Attention is drawn to the fact that CEN and CENELEC Standards normally include an annex which lists normative references to international publications with their corresponding European publications The British Standards which these implement international or European publications referred to in this document may be found in the BSI Standards Catalogue under the section entitled “International Standards Correspondence Index”, or by using the “Find” facility of the BSI Standards Electronic Catalogue A British Standard does not purport to include all the necessary provisions of a contract Users of British Standards are responsible for their correct application Compliance with a British Standard does not of itself confer immunity from legal obligations Summary of pages This document comprises a front cover, an inside front cover, pages i and ii, the CECC title page, pages to 16 and a back cover This standard has been updated (see copyright date) and may have had amendments incorporated This will be indicated in the amendment table on the inside front cover This British Standard, having been prepared under the direction of the Electrotechnical Sector Committee, was published under the authority of the Standards Committee and comes into effect on 15 November 1999 © BSI 04-2000 ISBN 580 35146 Amendments issued since publication Amd No Date Comments BS CECC 299001:1999 Contents National foreword Foreword Text of CECC 299001 © BSI 04-2000 Page Inside front cover i ii blank TECHNOLOGY CECC 299001 APPROVAL April 1999 SCHEDULE Technology Approval Schedule: Manufacture of electrical connectors Up-to-date lists and bibliographical references of other Technology Approval Schedules may be obtained on application to the Central Secretariat or to any CENELEC member CENELEC members are the national electrotechnical committees of Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece, Iceland, Ireland, Italy, Luxembourg, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and United Kingdom CENELEC European Committee for Electrotechnical Standardization Comité Européen de Normalisation Electrotechnique Europäisches Komitee für Elektrotechnische Normung Central Secretariat: rue de Stassart 35, B-1050 Brussels © 1999 CENELEC — All rights of exploitation in any form and by any means reserved worldwide for CENELEC members Ref No CECC 299001:1999 E CECC 299001:1999 Foreword This Technology Approval Schedule was prepared by DRA/PCS, connector manufacturers/users and CECC connector sub-committees The document has been adopted and accepted by the Technical Committees CENELEC TC 46D, RF connectors and CENELEC TC 48B, LF connectors The responsible ONC is the CECC Manager at BSI who may be contacted at: British Standards Institution Electrical, Fire and Health Department 289, Chiswick High Road London W4 4AL England Tel: 0181 996 9000 It is based wherever possible, on Publications of the International Electrotechnical Commission, the International Standards Organisation and existing publications of the CECC © BSI 04-2000 CECC 299001:1999 Contents Foreword Introduction General 1.1 Scope 1.2 Related documents 1.3 Units, symbols and technology 1.4 Standard and preferred values 1.5 Definitions Definition of the component technology 2.1 Scope 2.2 Description of activities and flow charts 2.3 Technology abstract Component design 3.1 Scope 3.2 Description of activities and flow charts 3.3 Interrelationships 3.3.1 Design manufacture 3.3.2 Customer/user 3.3.3 Subcontractors, vendors and internal suppliers Piece-part manufacture 4.1 Scope 4.2 Description of activities and flow charts 4.3 Materials, inspection and handling 4.4 Equipment 4.5 Rework 4.6 Validation and control of the process(es) 4.7 Subcontracting Assembly 5.1 Scope 5.2 Description of activities and flow charts 5.3 Materials, inspection and handling 5.4 Equipment 5.5 Rework 5.6 Validation and control of the process(es) 5.7 Subcontracting Testing 6.1 Scope © BSI 04-2000 Page Page 4 4 4 5 5 5 5 8 8 8 8 10 10 10 10 6.2 Description of activities and flow charts 6.3 Equipment 6.4 Test procedures 6.5 Interrelationships 6.5.1 Subcontracting 6.5.2 Verification of customer specification Verification and test vehicles 7.1 Process boundary verification 7.2 Product verification Process characterisation 8.1 Identification of process characteristics 8.2 Description of activities and flow charts Primary packaging and shipment 9.1 Description of activities and flow charts 9.2 Interrelationships 9.2.1 Verification of customer requirements 9.2.2 Subcontracting 9.3 Validity of release 10 Withdrawal of Technology Approval Annex A Example abstract of Technology Approval Figure — Example flow chart — Design/manufacturer/test Figure — Example flow chart — Design Figure — Example flow chart — Piece-part manufacturer Figure — Example flow chart — Connector assembly Figure — Example flow chart — Testing of connectors 12 12 12 12 12 12 14 14 14 14 14 14 14 14 15 15 15 15 15 16 11 13 10 10 10 10 10 10 12 12 CECC 299001:1999 Introduction The requirements for Technology Approval of manufacturers of electronic and electromechanical components are given in CECC 00114-VI The procedures for approval defined in that Rule of Procedure require the manufacturer to have available an appropriate Technology Approval Schedule (TAS) This schedule defines how the principles and requirements of CECC 00114-VI are applied to Electrical Connectors In particular it defines minimum technical requirements which must be met by a manufacturer writing a Technology Approval Declaration Document (TADD) in accordance with Annex D of CECC 00114-VI General 1.1 Scope This TAS specifies the terms, definitions, symbols, quality system, test, assessment and verification methods and other requirements relevant to the design, manufacture and supply of Electrical Connectors, in compliance with the general requirements of the CECC system for electronic components of assessed quality 1.2 Related documents CECC 00016, Basic Requirements for the use of Statistical Process Control (SPC) in the CECC systems CECC 00114-I, Quality Assessment Procedures: Approval of manufacturers and other organisations CECC 00114-VI, Quality Assessment Procedures: Technology Approval CECC 00200, Register of Approvals CECC 00401, Glossary of Abbreviations, terms and definitions of the CECC System CECC 00806, Guide to total quality management (TQM) for CECC approved organisations CECC 210000, Generic Specification: Radio Frequency coaxial connectors CECC 21000, Requirements for Technology Approval Schedules (TAS) EN 45001, General criteria for the operation of testing laboratories EN 175100, Sectional specification: Two part and edge socket connectors for printed board application EN 175200, Sectional specification: Circular connectors EN 175300, Sectional specification: Rectangular connectors for frequencies < MHz ISO 497, Guide to the choice of series of preferred numbers and of series containing more rounded values of preferred numbers ISO 1000, SI units and recommendations for the use of their multiples and of certain other units ISO 9001, Quality systems Model for quality assurance in design, development, production, installation and servicing IEC 60027-1, Letter symbols to be used in electrical technology: Part 1: General IEC 60050, International electrotechnical vocabulary IEC 60617, Graphical symbols for diagrams 1.3 Units, symbols and terminology Units, graphical symbols, letter symbols and terminology shall, whenever possible, be taken from the following documents: ISO 1000, SI units and recommendations for the use of their multiples and certain other units IEC 60027, Letter symbols to be used in electrical technology IEC 60050(581), International electromechanical vocabulary — Chapter 581: Electromechanical component for electronic equipment IEC 60617, Graphical symbols for diagrams Where further units, symbols and terminology are required, these shall be taken from the documents listed in 1.2 1.4 Standard and preferred vValues Technology approval allows values of ratings and characteristics to be selected to suit each customer, and so preferred values are therefore not mandatory However, when there are no over-riding customer needs, it is recommended that the established preferred values for electrical connectors are utilised These may be found in the following publications: CECC 22000 ) EN 175000 ) Series of specifications 1.5 Definitions Definitions relevant to the technology, in addition to those given in CECC RP14-V, CECC 00401, IEC 50 and the relevant Generic/Sectional specifications, are given below: DC/LF direct current/low frequency and high speed data applications RF radio frequency © BSI 04-2000 CECC 299001:1999 hybrid connector – A generic connector type incorporating elements from one or more other generic types The flow chart in Figure is an example showing such operations The manufacturer is expected to describe the specific stages, referencing relevant internal documentation TADD Technology Approval Declaration Document 2.3 Technology abstract connector assembly Assembly of the connector or the preparation of the kit of parts If any other definitions are required the manufacturer shall supply them in the TADD Definition of the component technology 2.1 Scope The manufacturing processes are listed below with the identification of the MAIN TECHNICAL PROCESSES: 2.1.1 Connector design — This is a MAIN TECHNICAL PROCESS 2.1.2 Tooling manufacture 2.1.3 Piece part manufacture — These are MAIN TECHNICAL PROCESSES 2.1.4 Assembly — This is a MAIN TECHNICAL PROCESS 2.1.5 Test and release 2.1.6 Marking 2.1.7 Packaging and shipping NOTE The control site (see CECC 00114-VI: clause C) shall perform connector assembly (2.1.4 above) as one of the main technical processes 2.2 Description of activities and flow charts The manufacturer shall identify all the processes used in his application of electrical connector technology and include relevant flow charts This paragraph may include different processes for different types of components but covered by the same technology The procedures documenting each process and its process control shall be referenced Examples are: a) connector design, generic types; b) tooling design; c) tooling manufacturer; d) surface finishing/treatment; e) piece-part manufacturer, generic types; f) assembly; g) test; h) marking; i) packaging and shipment © BSI 04-2000 The manufacturer shall prepare an Abstract of the technology for inclusion in CECC 00200 For an example Abstract see Annex A Component design 3.1 Scope The manufacturer seeking technology approval shall include design information relevant to the technology for which approval is sought e.g setting target figures for the following connector parameters and any other special parameters where applicable: — radio frequency characteristics; — electrical ratings; — rated temperature; — shell or body material/plating; — insert material; — terminations, type, material/plating, size and number; — coupling method; — climatic category; — vibration severity; — bump and/or shock severity; — solvent resistance; — endurance test performance; — other parameters (specify) 3.2 Description of activities and flow charts The manufacturer shall provide documentation and flow charts describing each of the stages in the design process, how it is validated and controlled An example of a typical design flow chart is shown at Figure 3.3 Interrelationships 3.3.1 Design/manufacture The connector design activity cannot proceed without the production of prototype batches of connectors on production equipment, close co-operation is necessary between connector design and manufacturing The responsibilities of each department shall be carefully defined to facilitate this co-operation in the design stage CECC 299001:1999 Figure — Example flow chart — Design/manufacture/test © BSI 04-2000 CECC 299001:1999 Figure — Example flow chart — Design © BSI 04-2000 CECC 299001:1999 3.3.2 Customer/user When the manufacturer is designing a connector for a specific customer requirement, the manufacturer shall have a systematic method (e.g a questionnaire) to unambiguously ascertain the needs of the customer Where particular aspects of the connector not need to be precisely defined, the manufacturer shall advise the customer of those that are preferred See also subclause 6.5.2 of this TAS and subclause 4.3 of ISO 9001 After discussions with the customer are complete, the manufacturer shall have a documented system of confirming the design agreement which has been made, and for registration of detail specifications and other documentation as required by clause of CECC 00114-VI 3.3.3 Subcontractors, vendors and internal suppliers Design of connectors may not be sub-contracted if it is the only Main Technical Process apart from connector assembly which is carried out at the Control Site Where specialist contractor design is required for product, material or process/manufacturing equipment as part of the main connector design process, this shall be carried out in conjunction with the Control Site Where design is to be subcontracted the manufacturer shall specify the following: — Reason for sub-contracting; — Name and address of the subcontractor; — Name of company contact; — Documentation; — Interrelationship documentation Piece part manufacture 4.1 Scope The manufacturer seeking technology approval shall include piece-part manufacturing information relevant to the technology for which approval is sought 4.2 Description of activities and flow charts The critical operations to be monitored are determined by the manufacturer based on experience and knowledge of the processes The data coming from the process lines is analyzed using accepted process control methods (e.g SPC) to determine their effectiveness to control the process The manufacturer shall describe the activities of the various manufacturing processes for piece-parts, including flow charts showing all activities, critical process steps, process check points and quality indicators, used for the validation and control of the processes and sub-contractors Examples of Critical Operations are: a) Casting, forming; b) Stamping; c) Moulding; d) Machining; e) Plating; f) Sub-assembly; g) Process monitors and acceptance An example of a typical flow chart is shown at Figure 4.3 Materials, inspection and handling The manufacturer shall reference his procedures for inspection of materials used for piece-part manufacture Reference shall be made to the procedures giving inspection methods and limits and the lot-release criteria Details of any process control programmes operated in co-operation with suppliers shall also be given Requirements for the processing and handling of the materials shall be given 4.4 Equipment The manufacturer shall list the equipment and indicate its intended purpose in the manufacturing chain He shall describe, or refer to, documentation describing its operation and the methods used to monitor and control its performance, including regular maintenance programmes If any equipment requires special calibration or adjustment other than routine calibration of measuring equipment the manufacturer shall describe this fully 4.5 Rework Rework shall only be permitted where the manufacturer can and has demonstrated that it does not influence the quality and reliability of the product The manufacturer’s documentation shall specify all permitted rework processes/stages together with the criteria for their use, performance, and satisfactory completion The criteria for permitting rework shall be fully documented in the manufacturer’s TADD © BSI 04-2000 CECC 299001:1999 Figure — Example flow chart — Piece-part manufacture © BSI 04-2000 CECC 299001:1999 4.6 Validation methods and control of the process(es) An example of a typical flow chart is shown at Figure The manufacturer shall describe his procedures used for validation and control of the process(es) Validation will show that the process control in operation is adequate to control connector piece-parts performance on parameters which can be affected within the limits which the manufacturer has declared for those parameters The process control methods shall, wherever possible, be statistical controls applied in accordance with CECC 00016 5.3 Materials inspection and handling 4.7 Subcontracting Manufacture of piece-parts may not be sub-contracted if it is the only Main Technical Process apart from connector assembly which is carried out at the Control Site Where piece-part manufacture is to be subcontracted the manufacturer shall specify the following: — Reason for sub-contracting; — Name and address; — Name of company contact; — Documentation; — Interrelationship documentation Assembly of connectors 5.1 Scope The manufacturer seeking Technology Approval shall describe the activities, equipment and rework rules for the assembly of connectors, and give requirements for the validation of control processes and subcontractors 5.2 Description of activities and flow charts The manufacturer shall describe the activities of the assembly of connectors, including flow charts showing all activities, critical steps, check points and quality indicators Examples of the activities are: a) insertion/fixing of insert/insulator in shell/body/housing; b) insertion/fixing of contacts and contact retention mechanism in insert/insulator, if applicable; c) insertion of keyways, if applicable; d) housing (shell) polarising; e) attachment of coupling ring, if applicable; f) coupling/locking mechanism; g) marking 10 The manufacturer shall reference his procedures for inspection of materials and piece-parts used for assembly Reference shall be made to the procedures giving inspection methods and limits and lot-release criteria Details of any process control programmes operated in co-operation with suppliers shall also be given Requirements for the processing and handling of the piece-parts and materials shall be given 5.4 Equipment The manufacturer shall list the equipment and indicate its intended purpose in the manufacturing chain He shall describe, or refer to, documentation describing its operation and the methods used to monitor and control its performance, including regular maintenance programmes If any equipment requires special calibration or adjustment other than routine calibration of measuring equipment the manufacturer shall describe this fully 5.5 Rework Rework shall only be permitted where the manufacturer can and has demonstrated that it does not influence the quality and reliability of the product The manufacturer’s documentation shall specify all permitted rework processes/stages together with the criteria for their use, performance, and satisfactory completion 5.6 Validation and control of the process(es) The manufacturer shall describe his procedures used for validation and control of the process(es) Validation will show that the process control in operation is adequate to control connector performance on parameters which can be affected within the limits which the manufacturer has declared for those parameters The process control methods shall, wherever possible, be statistical controls applied in accordance with CECC 00016 5.7 Subcontracting Assembly of connectors may not be sub-contracted © BSI 04-2000 CECC 299001:1999 Figure — Example flow chart — Connector assembly © BSI 04-2000 11 CECC 299001:1999 Testing of connectors 6.1 Scope The manufacturer seeking technology approval shall describe the procedures involved in testing design validation, process control, 100 % in-line testing, lot-by-lot conformance testing, testing to verify that the inspection requirements of a Product Detail Specification (PDS) have been met, and testing involved in process boundary verification and product verification 6.2 Description of activities and flow charts The manufacturer shall describe the activities of the testing of connectors, including flow charts containing information on quality indicators and the procedures for qualification, acceptance, monitoring and release Examples of activities are: — atmosphere and cleanliness control; — test programme methodology; — test specifications; — test programme verification procedure; — maintenance and control of test programmes; — acceptance and release procedures; — recording and traceability procedures Lot-by-lot testing shall be carried out in accordance to the manufacturer’s specification or according to a PDS on the sampling basis described in the specification To support the performance claims made for his connectors and to validate his processes, the manufacturer shall periodically test samples from production to tests selected from the relevant generic/sectional/detail specifications for the technology or as defined by the manufacturer The manufacturer shall produce a schedule showing his programme of periodic testing, and detailing the type of test, its periodicity, the sampling scheme and the main test parameters An example of a typical flow chart is shown at Figure c) types of measurements (electrical, mechanical, environmental, climatic, electromagnetic); d) environmental test equipment; e) registration and control of type specific jigs, tools and fixtures 6.4 Test procedures The preferred test methods are those described in the relevant generic/sectional specifications for the technology Other test procedures shall be fully described 6.5 Interrelationships 6.5.1 Subcontracting Testing for process control and 100 % in-line inspection at the manufacturing location shall not be sub-contracted Initial boundary verification tests and periodic tests, as described in 6.2 above, may be subcontracted to a CECC approved test laboratory accredited for the relevant tests Where testing is to be subcontracted the manufacturer shall specify the following: — Reason for sub-contracting; — Name and address of sub-contractor; — Name of company contact; — Documentation; — Interrelationship documentation 6.5.2 Verification of customer specification The manufacturer shall have documented procedures for handling customer specifications and implementing special test procedures or other requirements which may be specified in them Following the guidelines in Annex D of CECC 210000, the manufacturer shall provide an outline for a customer to write a Customer Detail Specification (CDS) The manufacturer shall have a formal procedure for reviewing each CDS with the customer 6.3 Equipment The manufacturer shall describe the type and performance of the test equipment used, and the intended range Maintenance and calibration programmes for the equipment shall be included The information should cover: a) test equipment verification; b) connector function; 12 © BSI 04-2000 CECC 299001:1999 Figure — Example flow chart — Testing of connectors © BSI 04-2000 13 CECC 299001:1999 Verification and test vehicles 7.1 Process boundary verification The manufacturer, in his TADD, shall define the methods for verification of the component technology including: a) Rationale for the selection of the evaluation method; b) Test procedures or measurement system description; c) Description of tools and techniques used for qualification; d) Description of test vehicles and their relationship to end products; e) Periodic testing Test vehicles may be complete connectors, piece-parts or material samples Examples of boundaries these are used to assess are: — minimum/maximum sizes of housing/material/plating; — contact size/type/material/plating/termination method; — insert material/no and density of contacts; — dimensions; — coupling mechanisms; — terminal security system(s) 7.2 Product verification Product verification shall be in accordance with customer requirements or National or International Standards The manufacturer shall reference test plans in his TADD which demonstrate his ability to meet the design limits which are claimed in the Abstract of Technology Approval for all design features listed in 3.1 of this TAS Process characterisation NOTE Process characterisation may be achieved by reference to the existing system documentation e.g systems prepared in accordance with ISO 9000 or laboratory certification requirements 8.1 Identification of process characteristics The manufacturer shall give details of the methods used for the determining of relationships between process parameters and process outputs or product characteristics required for the characterisation of: — current processes; — newly introduced processes 14 This shall include the following key elements of process characterisation: a) Measurement system evaluation for ensuring data integrity; b) Identification of a standard of measurement for capability and continuous improvement assessments; c) Application of statistical methods for determining parameter relationship, performing diagnostics, assessing potential capability using experimentation and stimulating continuous improvement 8.2 Description of activities and flow charts The manufacturer shall give a complete description of his process characterisation activities, with particular attention to the following: a) Measurement parameter, e.g electrical, mechanical or physical and the measurement system evaluation to ensure data integrity; b) The stage(s) at which the measurement(s) should be made and the relationship with the product parameters; c) Rationale for: — description of critical parameters, — parameter selection, — measurement system selection Flow charts may be used to present or supplement this information Primary packaging and shipping NOTE These systems may be described by reference to existing internal &/or external standards complied with 9.1 Description of activities and flow charts The manufacturer shall identify and document packaging and shipping activities, supported by any relevant flow charts This is to ensure that the correct quantity of the correct product is delivered on time to the correct customer Examples of activities are as follows: — atmosphere and cleanliness of the area; — storage conditions; — storage life; — ensuring compliance with customer order; — protection against environmental change; — protection against mechanical damage; — protection against electrical damage; — documentation/labelling © BSI 04-2000 CECC 299001:1999 9.2 Interrelationships These may be described by reference to existing contract review procedures 9.2.1 Verification of customer requirements The manufacturer shall describe his procedures for checking and validating his customer’s requirements 9.2.2 Subcontracting Where packaging and shipping are to be sub-contracted the manufacturer shall specify the following: — Reason for sub-contracting; — Name and address of sub-contractor; — Name of company contact; — Documentation; — Interrelationship documentation 10 Withdrawal of Technology Approval In accordance with subclause 7.7 of CECC 00114-VI Technology Approval may be withdrawn only by the body which granted it if one or more of the following conditions apply: — The manufacturer fails to meet the requirements of CECC 00114-I or CECC 00114-VI; — At the request of the manufacturer; — Production of connectors within the scope of the TADD is terminated or suspended for a period of six months; — The manufacturer’s approval to CECC 00114-I is withdrawn 9.3 Validity of release Connectors shall be released for delivery in accordance with subclause 7.4 of CECC 00114-VI after any Quality Conformance inspection prescribed in the relevant detail specification have been carried out In accordance with CECC 00114-II, connectors held for a period exceeding five years following the release of the lot shall, before delivery, be re-examined to the relevant tests as specified in the detail specification Once a lot has been satisfactorily re-inspected, its quality is re-assured for a further five years, unless a shorter period is specified in the TADD or detail specification © BSI 04-2000 15 CECC 299001:1999 Annex A Example layout of an abstract of Technology Approval for inclusion in CECC 00200 Certificate Number Issue Date XXXX connectors according to Technology Approval Schedule CECC 299001 Manufacturer Technology Approval Declaration Document Reference Date Limits of approval to be stated separately for each of the following technologies: DC/LF connectors RF connectors Hybrid connectors This list is for example only: the actual list shall include all the major performance claims made in the TADD Frequency range Contact sizes Housing material/plating Contact material/plating Working voltage Contact current Insert/insulator materials Climatic category Vibration severity Bump or shock severity Rapid change of temperature Damp heat steady state Low air pressure Endurance test performance (temperature/electrical/mechanical) Salt mist Mould growth Solvents resistance NOTE It may not be possible to achieve the limits of performance listed above simultaneously Refer to the manufacturer for information 16 © BSI 04-2000