NUMBER
BUS-12-070
TYPE
PRODUCT SPECIFICATION
TITLE PAGE REVISION
1 of 15 F
AUTHORIZED BY DATE
Low Profile Jumper – Tin/Lead Plated
A.LUGO 28 Oct 08
CLASSIFICATION
UNRESTRICTED
Copyright FCI
Form E-3334
Rev F
GS-01-001
1.0 GENERAL
Scope - This specification covers tin-lead plated low profile jumper connectors designed for low power
interconnection of two adjacent 0.025 inch square pins, free standing or in headers, on 0.100 inch centers.
This specification is composed of the following sections. This product meets the requirements of the
European Union Directive of Restrictions for Hazardous Substances (Directive 2002/95/EC). The
specification is composed of the following sections.
Paragraph Title Page
1.0 GENERAL 1
2.0 APPLICABLE DOCUMENTS 1
3.0 REQUIREMENTS 2
3.1 Qualification 2
3.2 Material 2
3.3 Finish 2
3.4 Design and Construction 3
3.5 Electrical Characteristics 3
3.6 Mechanical Characteristics 6
3.7 Environmental Conditions 7
4.0 QUALITY ASSURANCE PROVISIONS 11
4.1 Equipment Calibration 11
4.2 Inspection Conditions 12
4.3 Qualification Inspections 12
4.4 Requalification Testing 13
5.0 NOTES AND DEFINITIONS 16
2.0 APPLICABLE DOCUMENTS
The following documents, of the issue in effect on the date of the latest revision of this specification, shall
form a part of this specification to the extent specified herein.
Military Specifications
MIL-M-24519 Molding Plastics, Polyester, Thermoplastics
MIL-C-45662 Calibration System Requirements
MIL-P-55110 Printed Wiring Boards
MIL-T-10727 Tin Plating, Electrodeposited or Hot-Dipped, for Ferrous and Non-Ferrous Metals
MIL-STD-202 Test Methods for Electronic and Electrical Component Parts
MIL-STD-275 Printed Wiring for Electronic Equipment
MIL-STD-1344 Test Methods for Electrical Connectors
Federal Specifications
QQ-S-571 Solder Lead Alloy, Tin Lead Alloy, and Tin Alloy: Flux Cored Ribbon and Wire, and Solid
Form
QQ-N-290 Nickel Plating (Electrodeposited)
QQ-B-750 Phosphor Bronze
PDM: Rev:F Released .STATUS: Printed: Nov 28, 2010
NUMBER
BUS-12-070
TYPE
PRODUCT SPECIFICATION
TITLE PAGE REVISION
2 of 15 F
AUTHORIZED BY DATE
Low Profile Jumper – Tin/Lead Plated
A.LUGO 28 Oct 08
CLASSIFICATION
UNRESTRICTED
Copyright FCI
Form E-3334
Rev F
GS-01-001
Industry Specifications/Standards
ASTM B-103 Phosphor Bronze Plate, Sheet, Strip and Rolled Bar, Spec. for DOD ADOPTED
UL-94 Tests for Flammability of Plastic Materials
3.0 REQUIREMENTS
3.1 Qualification
Connectors furnished under this specification shall be products capable of meeting the qualification
test requirements specified herein.
3.2 Material
The material for each part shall be as specified herein, or equivalent. Substitute material shall meet
the performance requirements of this specification.
3.2.1 Terminal. The body shall be 1/2 hard phosphor bronze strip C51000 in accordance with
QQ-B-750 and CA-510 specification.
3.2.2 Insulator Housing. The housing material shall be unfilled Polyester in accordance with
BUS-16-028. The material shall be rated flame retardant 94 V-O in accordance with UL-
94.
or
3.2.3 Insulator Housing. The housing material shall be 17-20% glass filled Polyester in
accordance with BUS-16-025. The material shall be rated flame retardant 94 V-0 in
accordance with UL-94.
3.3 Finish
3.3.1 The terminal shall be plated with 100 to 300 microinches of tin-lead per MIL-T-10727,
Type 1 or will plated with 100 to 160 microinches of pure tin.
PDM: Rev:F Released .STATUS: Printed: Nov 28, 2010
NUMBER
BUS-12-070
TYPE
PRODUCT SPECIFICATION
TITLE PAGE REVISION
3 of 15 F
AUTHORIZED BY DATE
Low Profile Jumper – Tin/Lead Plated
A.LUGO 28 Oct 08
CLASSIFICATION
UNRESTRICTED
Copyright FCI
Form E-3334
Rev F
GS-01-001
3.4 Design and Construction
The connector typically shall be a two piece assembly comprising two interconnected contacts
retained in a plastic housing. The female (disconnect) end of the contact shall interface with 0.025
inch square (or round) pins on 0.100 inch centers.
3.4.1 Mating. The connector shall be capable of being mated or unmated by hand without the
use of special tools within the specified temperature range.
3.4.2 Workmanship. Connectors shall be uniform in quality and shall be free from burrs,
scratches, cracks, voids, chips, blisters, pin holes, sharp edges, and other defects that
will adversely affect life or serviceability.
3.4.3 Interchangeability. The connector shall be capable of mating with any appropriately
constituted male connector of the same population without degradation in performance.
3.5 Electrical Characteristics
3.5.1 Current Rating. The maximum current rating of the connector shall be 3.0 amperes DC
(2.5 amperes for multi-position assembly).
3.5.2 Contact Resistance. (see 5.1) The contact resistance shall not exceed the value
specified in Table 1, when measured in accordance with MIL-STD-202, Method 307. The
following details shall apply:
(a) Method of Connection - Attach current and voltage leads as shown in Figure 1.
(b) Test Current - 1 ampere DC
FIGURE 1 - CONTACT RESISTANCE
PDM: Rev:F Released .STATUS: Printed: Nov 28, 2010
NUMBER
BUS-12-070
TYPE
PRODUCT SPECIFICATION
TITLE PAGE REVISION
4 of 15 F
AUTHORIZED BY DATE
Low Profile Jumper – Tin/Lead Plated
A.LUGO 28 Oct 08
CLASSIFICATION
UNRESTRICTED
Copyright FCI
Form E-3334
Rev F
GS-01-001
TABLE 1 - CONTACT RESISTANCE
Maximum Resistance Milliohms
Initial After Test
11 15
3.5.3 Low Level Circuit Resistance. (See 5.1) The low level circuit (contact) resistance shall
not exceed the value specified in Table 1, when measured in accordance with MIL-STD-
1344, Method 3002. The following details shall apply:
(a) Method of Connection - See Figure 1
(b) Test Current - 1 milliampere DC
(c) Maximum Open Circuit Voltage - 20 millivolts DC
3.5.4 Capacitance. (See 5.3) The capacitance between adjacent positions of the unmated
connector shall not exceed 2.0 pf, when measured in accordance with MIL-STD-202,
Method 305. The following details shall apply:
(a) Points of Measurement - Between adjacent contact positions
(b) Test Frequency - 1 megahertz
3.5.5 Insulation Resistance. (See 5.3) The insulation resistance between adjacent positions of
the unmated connector shall be not less than 50,000 megohms (20,000 megohms after
exposure to the humidity environment specified in paragraph 3.7.2), when tested in
accordance with MIL-STD-202, Method 302. The following details shall apply:
(a) Points of Measurement - Between adjacent contact positions
(b) Test Potential - B (500 volts)
(c) Time of Application - 60 seconds
3.5.6 Dielectric Withstanding Voltage. (See 5.3) There shall be no evidence of insulation
breakdown, arc-over, or excessive (>1 milliampere) leakage current when the unmated
connector is tested in accordance with MIL-STD-202, Method 301. The following details
shall apply:
(a) Test Potential - 1500 volts RMS, 60 Hz at sea-level
(b) Test Duration - 60 seconds
(c) Points of Measurement - Between adjacent contact positions
PDM: Rev:F Released .STATUS: Printed: Nov 28, 2010
NUMBER
BUS-12-070
TYPE
PRODUCT SPECIFICATION
TITLE PAGE REVISION
5 of 15 F
AUTHORIZED BY DATE
Low Profile Jumper – Tin/Lead Plated
A.LUGO 28 Oct 08
CLASSIFICATION
UNRESTRICTED
Copyright FCI
Form E-3334
Rev F
GS-01-001
3.6 Mechanical Characteristics
3.6.1 Contact Retention. (See 5.2) The contact pair shall not be dislodged from the housing
when an axial force of 3.0 pounds (1.5 pounds per contact) is applied in the direction of
insertion. The force shall be applied at a crosshead speed of 1 inch per minute using
fixture # MF 407.1. (See Figure 6)
3.6.2 Total Mating Force. The total force to mate the connector with an appropriate header
having properly configured (see Figure 2) 0.025 inch square pins shall not exceed the
value shown in Table II.
TABLE II - INSERTION/WITHDRAWAL FORCE
Individual Contact Force-Grams
Insert (Max.) Withdraw (Min.)
Total Mating Force for 2
Contacts ( Grams-Avg.)
Total Withdrawal Force for 2
Contacts ( Grams Avg.)
.026” Gage Pin .024 Gage Pin .025” Gold Pin .025” Gold Pin
450* 40* 400 150
* Multiply by number of positions for multi-position assembly.
3.6.3 Individual Contact Insertion Force. When measured using a maximum gage configured
as shown in Figure 3, the individual contact insertion force shall not exceed the value
shown in Table II.
3.6.4 Individual Contact Withdrawal Force. After three insertions of a maximum gage, the force
required to withdraw a minimum gage, configured as shown in figure 3, shall be not less
than the value shown in Table II.
3.6.5 Durability. After the number of mating cycles specified in Table III, the individual contact
withdrawal force shall be not less than the value shown in Table II (see 3.6.4) and the
contact resistance shall not exceed the value specified in Table I (see 3.5.2).
TABLE III - DURABILITY
Tin lead Plating Thickness Mating Cycles
100-300u” 25
PDM: Rev:F Released .STATUS: Printed: Nov 28, 2010
NUMBER
BUS-12-070
TYPE
PRODUCT SPECIFICATION
TITLE PAGE REVISION
6 of 15 F
AUTHORIZED BY DATE
Low Profile Jumper – Tin/Lead Plated
A.LUGO 28 Oct 08
CLASSIFICATION
UNRESTRICTED
Copyright FCI
Form E-3334
Rev F
GS-01-001
3.7 Environmental Conditions
3.7.1 Thermal Shock. After exposure of the mated connector to alternate periods of extreme
high and low temperature, there shall be no evidence of cracking or crazing of the
insulator housing or other physical damage to the connector; the dielectric withstanding
voltage of the unmated connector shall be not less than 2500 volts RMS (see 3.5.6). The
test shall be in accordance with MIL-STD-202, Method 107. The following details and
exceptions shall apply:
(a) Test Condition - A (5, 1-hour cycles)
(b) Temperature Range - +120oC to -55oC
(c) Exposure time at each temperature - 30 minutes, minimum
(d) Transfer time - 30 seconds maximum
3.7.2 Humidity. After exposure of the mated connector to a high humidity environment, the
contact resistance shall not exceed the value specified in Table I (see 3.5.2). The
insulation resistance of the unmated connector shall be not less than 20,000 megohms
(see paragraph 3.5.5). The test shall be in accordance with MIL-STD-202, Method 106
(excluding steps 7a and 7b). The following details shall apply:
(a) Test Duration - 10 days (240 hours)
3.7.3 High Temperature Life. After exposure of the mated connector to a high temperature
operating environment, the contact resistance shall not exceed the value specified in
Table I (see 3.5.2). The insulation resistance of the unmated connector shall be not less
than 50,000 megohms (see 3.5.5). The test shall be in accordance with MIL-STD-202,
Method 108. The following details shall apply:
(a) Chamber Temperature - Adjusted to achieve +120oC temperature of contact
under load.
(b) Test Condition - B (250 hours)
(c) Operating Conditions - Rated current (see 3.5.1) through both contacts; duty cycle:
45 minutes ON and 15 minutes OFF.
PDM: Rev:F Released .STATUS: Printed: Nov 28, 2010
NUMBER
BUS-12-070
TYPE
PRODUCT SPECIFICATION
TITLE PAGE REVISION
7 of 15 F
AUTHORIZED BY DATE
Low Profile Jumper – Tin/Lead Plated
A.LUGO 28 Oct 08
CLASSIFICATION
UNRESTRICTED
Copyright FCI
Form E-3334
Rev F
GS-01-001
FIGURE 2 - MATING HEADER
PDM: Rev:F Released .STATUS: Printed: Nov 28, 2010
NUMBER
BUS-12-070
TYPE
PRODUCT SPECIFICATION
TITLE PAGE REVISION
8 of 15 F
AUTHORIZED BY DATE
Low Profile Jumper – Tin/Lead Plated
A.LUGO 28 Oct 08
CLASSIFICATION
UNRESTRICTED
Copyright FCI
Form E-3334
Rev F
GS-01-001
FIGURE 3 - INSERTION/WITHDRAWAL FORCE GAGE
PDM: Rev:F Released .STATUS: Printed: Nov 28, 2010
NUMBER
BUS-12-070
TYPE
PRODUCT SPECIFICATION
TITLE PAGE REVISION
9 of 15 F
AUTHORIZED BY DATE
Low Profile Jumper – Tin/Lead Plated
A.LUGO 28 Oct 08
CLASSIFICATION
UNRESTRICTED
Copyright FCI
Form E-3334
Rev F
GS-01-001
FIGURE 4 - MOUNTING FOR STOCK/VIBRATION
PDM: Rev:F Released .STATUS: Printed: Nov 28, 2010
NUMBER
BUS-12-070
TYPE
PRODUCT SPECIFICATION
TITLE PAGE REVISION
10 of 15 F
AUTHORIZED BY DATE
Low Profile Jumper – Tin/Lead Plated
A.LUGO 28 Oct 08
CLASSIFICATION
UNRESTRICTED
Copyright FCI
Form E-3334
Rev F
GS-01-001
3.7.4 Shock. There shall be no evidence of physical or mechanical damage when the mated
connector is subjected to transient accelerations. During and after each shock, the
contacts shall evidence no discontinuity greater than 1 microsecond. The test shall be in
accordance with MIL-STD-202, Method 213. The following details shall apply:
(a) Test Condition - 1 (100G, 6 ms sawtooth).
(b) Number of Shocks - 3 shocks in each direction along three orthogonal axes (18
total).
(c) Mounting - See Figure 4
(d) Restraining Method - None
3.7.5 Vibration. There shall be no evidence of physical or mechanical damage when the mated
connector is subjected to prolonged mechanical vibration; and the individual contact
withdrawal force shall be not less than the value specified in Table II (see 3.6.4). During
the vibration along each axis, the contacts shall evidence no discontinuity greater than 1
microsecond. At the completion of the test, the contact resistance shall not exceed the
value specified in Table I (see 3.5.2). The test shall be in accordance with MIL-STD-202,
Method 204. The following details shall apply:
(a) Test Condition - B (15G, 10 to 2000 Hz)
(b) Test Duration - 4 hours along each of three orthogonal axes (12 hours total)
(c) Mounting - see Figure 4
(d) Restraining Method - None
3.7.6 Hydrogen Sulfide (H2S) Atmosphere. After exposure of the mated connector to moist
contaminated environment, the low level circuit resistance shall not exceed the value
specified in Table I (see 3.5.3). The following details shall apply:
(a) Test Medium - 3 ppm H2S in air
(b) Test Temperature - +40oC
(c) Test Duration - 48 hours
4.0 QUALITY ASSURANCE
4.1 Equipment Calibration
All test equipment and facilities used in the performance of any test shall be maintained in a
calibration system in accordance with MIL-C-45662.
PDM: Rev:F Released .STATUS: Printed: Nov 28, 2010
NUMBER
BUS-12-070
TYPE
PRODUCT SPECIFICATION
TITLE PAGE REVISION
11 of 15 F
AUTHORIZED BY DATE
Low Profile Jumper – Tin/Lead Plated
A.LUGO 28 Oct 08
CLASSIFICATION
UNRESTRICTED
Copyright FCI
Form E-3334
Rev F
GS-01-001
4.2 Inspection Conditions
Unless otherwise specified herein, all inspections shall be performed under the following ambient
conditions:
(a) Temperature - 25oC + 5oC
(b) Relative Humidity - 30% to 80%
(c) Barometric Pressure - Local ambient
4.3 Qualification Inspection
Qualification inspection shall be performed on sample units produced with equipment normally used
in production.
4.3.1 Sample. Qualification Inspection shall be performed on five (5) groups of connectors;
each group shall comprise five (5) connectors of each type for which qualification under
this specification is desired. For multi-position connectors, a sixth sample (one
connector) shall be required for Group 3 tests.
4.3.2 Preparation of Samples
4.3.2.1 Printed Wiring Test Boards - Five (5) test boards conforming to the
applicable requirements of MIL-P-55110 and MIL-STD-275 shall be
prepared as shown in Figure 5.
4.3.2.2 Mating Headers - Five (5) mating headers of the appropriate population
and configuration and conforming to the requirements of Figure 2 shall be
prepared.
4.3.2.3 Header Mounting - The headers shall be installed on, and hand soldered
to, the test boards; an appropriately active flux shall be used to ensure that
the connection does not contribute any degradation.
4.3.2.4 Sample Configuration - When mated with the headers, the connectors
shall form a series connected circuit.
4.3.3 Test Sequence. The connectors shall be subjected to the inspections specified in Table
IV, in the order shown.
PDM: Rev:F Released .STATUS: Printed: Nov 28, 2010
NUMBER
BUS-12-070
TYPE
PRODUCT SPECIFICATION
TITLE PAGE REVISION
12 of 15 F
AUTHORIZED BY DATE
Low Profile Jumper – Tin/Lead Plated
A.LUGO 28 Oct 08
CLASSIFICATION
UNRESTRICTED
Copyright FCI
Form E-3334
Rev F
GS-01-001
4.4 Requalification Testing
If either of the following conditions occurs, the product responsible engineer shall initiate
requalification testing.
4.4.1 A significant design change is made to an existing product previously qualified under this
specification. A significant design change shall be defined to include, but not be limited
to, changes in contact material composition, contact material thickness, contact force,
contact surface geometry, underlying material composition, underlying material thickness,
insulator design, contact base material, or contact lubrication requirements.
4.4.2 A product failure occurs during production or end use requiring corrective action to be
taken relative to the product design or manufacturing process.
Requalification testing shall consist of all or applicable parts of the Qualification Test Matrix as
determined by development/product, quality, test, and reliability engineering.
PDM: Rev:F Released .STATUS: Printed: Nov 28, 2010
NUMBER
BUS-12-070
TYPE
PRODUCT SPECIFICATION
TITLE PAGE REVISION
13 of 15 F
AUTHORIZED BY DATE
Low Profile Jumper – Tin/Lead Plated
A.LUGO 28 Oct 08
CLASSIFICATION
UNRESTRICTED
Copyright FCI
Form E-3334
Rev F
GS-01-001
TABLE IV - QUALIFICATION INSPECTION
Sample Group
Examination or Test Paragraph 1 2 3 4 5 6
Total Mating Force 3.6.2 - - - X X X
Individual Contact Withdrawal Force 3.6.4 - - - X X X
Contact Resistance 3.5.2 X X - X X X
Capacitance 3.5.4 - - X - - -
Insulation Resistance 3.5.5 - - X - - -
Dielectric Withstanding Voltage 3.5.6 - - X - - -
Contact Retention 3.6.1 X X - X X X
Thermal Shock 3.7.1 X X X - - -
Dielectric Withstanding Voltage 3.5.6 - - X - - -
Humidity 3.7.2 X X X - - -
Contact Resistance 3.5.2 X X - - - -
Insulation Resistance 3.5.5 - - X - - -
High Temperature Life 3.7.3 X - X - - -
Contact Resistance 3.5.2 X X - - - -
Insulation Resistance 3.5.5 - - X - - -
Shock 3.7.4 - - - X X -
Vibration 3.7.5 - - - X X -
Contact Resistance 3.5.2 - - - X X -
Individual Contact 3.6.4 - - - X X -
Durability 3.6.5 - - - X - X
Contact Resistance 3.5.2 - - - X- - X
Individual Contact Withdrawal Force 3.6.4 - - - X - X
Hydrogen Sulfide Atmosphere 3.7.6 - - - X X X
Low level Circuit Resistance 3.5.3 - - - X X X
Contact Retention 3.6.1 X - - X - -
PDM: Rev:F Released .STATUS: Printed: Nov 28, 2010
NUMBER
BUS-12-070
TYPE
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TITLE PAGE REVISION
14 of 15 F
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A.LUGO 28 Oct 08
CLASSIFICATION
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Form E-3334
Rev F
GS-01-001
5.0 NOTES AND DEFINITIONS
5.1 Contact Resistance
Differences in contact resistance between various terminal configurations represent changes in bulk
resistance due to longer lengths of current path.
5.2 Contact Retention
Only terminals employing an integral latching mechanism (e.g. barbs, dimples, etc.) for rigid
retention within the housing are subject to this requirement. Terminals which "free-float" within a
housing and are retained by the closure of some form of hinged cover are not included.
5.3 Multi-Position Connector
Assemblies containing more than one jumper shall be subjected to the Group 3 tests; these tests do
not apply to single position devices.
FIXTURE # 407.1 FIGURE 6
REVISION RECORD
PDM: Rev:F Released .STATUS: Printed: Nov 28, 2010
NUMBER
BUS-12-070
TYPE
PRODUCT SPECIFICATION
TITLE PAGE REVISION
15 of 15 F
AUTHORIZED BY DATE
Low Profile Jumper – Tin/Lead Plated
A.LUGO 28 Oct 08
CLASSIFICATION
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Copyright FCI
Form E-3334
Rev F
GS-01-001
REV PAGE DESCRIPTION EC# DATE
A ALL Change from preliminary to released V10415 02/26/91
B 5 V12241 08/06/91
C 6 Delete max load for 10 seconds. Add use fixture # 407.1,
Figure 6. Add Figure 6
V80421 12/10/98
D ALL Revised format to be consistent with GS-01-001, and
change BERG, Dupont, etc. references to FCI.
V01904 08/01/00
E 1-2 Add lead free information M06-0228 6/12/06
F ALL Change to 17-20% glass fiber polyester page 2 M08-0312 10/28/08
PDM: Rev:F Released .STATUS: Printed: Nov 28, 2010
