Connector Selection Checklist
Based on Section 10 — Practical Selection Checklist.
Interface definition
- What subsystem boundary is this?
- Internal or external?
- Technician-serviceable or factory-only?
- Must it be disconnected under power?
- How often mated/unmated over service life?
- Is wrong mating dangerous?
Electrical
- Voltage rating + transients/peak checked
- Current per contact at temperature checked
- Bundle/thermal derating applied
- Rating source (document + revision) recorded for the voltage/current values used
- Loaded-contact count, ambient temperature, termination type, allowable temperature rise, and margin rationale documented
- Wire gauge compatible with contact barrel
- Signal type identified; high-speed/RF flagged
- Shield strategy documented — type, termination points, rationale (one-end vs. both-ends vs. 360° is system/frequency-dependent, not a universal rule)
- Power and signal segregation considered
- Load-break / hot-plug / mate-under-power status recorded from the datasheet (yes / no / explicitly prohibited / not specified)
- For power interfaces: touch safety when unmated, fuse/overcurrent protection, available fault current, and inrush/precharge documented
- Spare positions added where feasible and justified
Mechanical / environmental
- IP rating verified for the complete assembly
- Mated and unmated (capped) sealing considered
- Vibration/shock requirement and locking matched
- Cable strain relief defined; backshell selected
- Cable jacket OD compatible with gland/clamp
- Wire seal range matches wire OD
- Bend radius and cable exit angle checked
- Panel thickness/cutout checked
- Mating sequence considered for hybrids where available
- Torque specs identified
- Dust caps / dummy plugs on BOM
Manufacturing
- Crimp contacts and correct crimp tool identified
- Positioner/die and insert/extract tools identified
- Assembly instructions and inspection criteria defined (acceptance per IPC/WHMA-A-620 or the program/customer equivalent)
- Pull-test / continuity test plan defined
- Supplier availability and lead time checked
- Second source / QPL considered
Documentation / configuration control
- Connector, mate, contact, backshell, cap, gasket part numbers
- Pinout table + cable drawing + harness drawing
- ICD entry written
- Key position unique across differing pinouts
- Rev-controlled BOM + labeling scheme
Source / evidence tracking
Make the selection reviewable: every rating or requirement above should be traceable to a document, and assumptions should be visibly different from verified facts.
- Datasheet revision/date:
- Manufacturer drawing revision/date:
- Application specification revision/date:
- Qualified listing checked: yes / no / not applicable
- QPD/QPL reference (if applicable):
- Program/customer requirement reference:
- Derating curve checked: yes / no / not applicable
- Tooling/application spec checked: yes / no / not applicable
| Claim / value relied on | Source document | Rev / date | Requirement type | Verification status | Verified by / date | Open questions / risk if wrong |
|---|---|---|---|---|---|---|
| TBD | TBD | TBD | customer / standard / manufacturer / internal / assumption | verified / assumed / example / TBD | TBD | TBD |