ALL INTERNATIONAL RIGHTS RESERVED. BY AMP INCORPORATED COPYRIGHT 1988 AMP QUALIFICATION TEST REPORT AMP* Aerial Mini-Drop Wire Splice 501-76 Rev. 0 Product Specification: 108-6018, Rev. B. CTL No.: CTL1242-005-001 Date: 7/8/88 Classification: Unrestricted Prepared By: Daniel E. McClure Tests Performed by: Laonard Smith *Trademark of AMP Incorporated Corporate Test Laboratory Harrisburg, PennsylvaniaRoe es BS * tt . i OO Go Ou te to tw Oo non & Ww Pk POP POR? Me PD RS BS Oho Rw Om auf wre 501-76, Rev. 9 Table of Contents INtroduction. ... ccc cca eww ene ee an es eee eeereeeaee Page PULPOSB.. ccc eee crete tee ete eee rennet ete Page SCOPE. oe ee eects Page CONCTUSION. ccc cece cee ee eee eet eet eee Page Product Description. ...... cee eee eee eee ete ee Page Test Connectors... ccc cece eee eee rete e tenn eeeee Page Qualification Test Sequence....... cee eee cee eee ees Page Summary Of Testing......c.-cce sees ceeerereceveenes Page Examination of Product. ... 0... ccs eee eee eee eee ee Page Termination Resistance, Dry Circuit............... Page Insulation Resistance... .... ccc cee eee ee eee Page Vibration, oo. cee eee ete a eee Page TANSi le. cece cc cee ce eee eet teeter eae Page Temperature Cycling w/High Humidity............--- Page Temperature CYCTING. .... cee eee renee eee teen eerie Page Immersion/IR.... 0... ee eee eee eee eee eee race Page Test Methods. .... ccc cece cece este werent eet eeneenees Page Examination of Product... 2.0.0... ccc eee een ee ens Page Termination Resistance, Dry Circuit..........-e0 es Page Insulation Resistance... . cee eee eee eee eens Page Vibration... cece eee eet ee eee Page TONStlG. ccc ccc ee ee eee teen ene Page Temperature Cycling w/High Humidity............05. Page Temperature CYCIING. ... 0... cece cee eee ere teens Page Immersion/ IR... .. ccc ee cee ce eee eee e ete teenee Page Validation... 0... cece cence c cers eee e tase eresneres Page R1242DM ud MM Poy eRe OHO & Wo a ~~ a HH501-76, Rev. OC. AMP AMP INCORPORATED HARRISBURG, PENNSYLVANIA 17105 PHONE: 717-564-0100 TWX: 510-657-4116 CORPORATE TEST LABORATORY Qualification Test Report AMP Mini-Drop Wire Splice Part Number: 552759-1 1. Introduction ].1 Purpose 1 1 Testing was conducted to measure product performance of the AMP Aerial Mini-Drop Wire Splice when tested to the requirements of AMP Product Specification 108-6018, Rev. B. +2 Scope This report covers electrical and mechanical performance of the AMP Aerial Mini-Drop Wire Splice made by the Communication Products Division of the Signal Transmission Products Group. They were submitted to the Corporate Test Laboratory on December 23, 1987. Testing was performed between March 22, 1988 and May 9, 1988. 3 Conclusion AMP Aerial Mini-Drop Wire Splice conforms to the performance requirements of product specification 108-6018, Rev. B.501-76 Page 2 1.4 1.5 1.6 Product Description The AMP Mini-Drop Wire Splice is used to join aerial telephone drop wire. The splice consists of insulation displacement terminals mounted in a plastic housing. It is designed for mid-span or pole mounted application. A gasket and sealant prevent moisture from entering the splice. Test Connectors Test group 1 consisted of 6 splices with approximately 5 feet of wire extending from each end. Test group 2 consisted of 6 splices with approximately 30 inches of wire extending from each end. Test groups 3,4, and 5 consisted of 6 splices each with approximately | foot of wire extending from each end. All splices were applied to aerial drop wire, meeting the requirements of AMP Commercial Specification 26291 in accordance with AMP Specification 114-6019, Qualification Test Sequence Test Group Test or Examination 1 2 3 4 5 Test Sequence (a) Examination of Product ] 1 1 ] ] Term. Resistance, Bry Circuit 2,4 2,4 Insulation Resistance 5 Vibration 2 Tensile Temperature Cycling w/High Humid. 3 Temperature Cycling 3 Immersion/iR 2 (a) Number indicates sequence in which tests were performed.2.1 Z.2 501-76 Page 3 Summary of Testing Examination of Product - Groups ] to 5 All connectors submitted for testing were selected from production lots that were subjected to inspection and found to be acceptable by the Product Assurance Department of the Communication Products Division. Termination Resistance, Dry Circuit - Groups 3 & 4 All connectors of groups 3 & 4 met the requirement for initial and final termination resistance, dry circuit testing. All calculated AR values were Tess than the 2.0 milliohms maximum requirement. Group 3 Sample Initial Resistance aft. Change in Number Resistance *Temp. Cycling Resistance Al 7.74 7.76 0.02 Az 7.90 7.92 0.02 B3 8.00 8.04 0.04 B4 7.86 7.94 0.08 c5 7.96 7.96 0.00 C6 8.02 8.02 0.00 D7 8.00 8.10 0.10 bg 8.16 8.18 0.02 E9 7.98 7.98 0.00 E10 8.02 7.98 -0.04 Fil 7.70 7.70 0.60 Fi2 7.82 7.80 -0.02 * Temperature Cycling with High Humidity was performed on group 3. All values are in milliohms.501-76 Page 4 2.3 2.4 2.5 Group 4 Sample Initial Resistance aft. Change in Number Resistance Temp. Cycling Resistance Al 7.56 7.60 0.04 A2 7.62 7.64 -0.06 B3 8.20 8.12 -0.16 B4 8.16 8.16 -0.08 c5 8.28 8.22 -0.16 C6 8.32 8.24 0.06 D7 7.86 7.90 -0.06 D8 7.90 7.80 -0.06 a) 7.50 7.42 -0.14 E10 7.50 7.44 -0.10 Fll 8.64 8.52 -0.06 Fl2 8.70 8.54 -0.10 All values are in milliohms. Insulation Resistance - Group 3 All connectors met the insulation resistance requirement with all measured values being above the 20.0 X 106% megohms minimum. The minimum measured value was 1.8 X 10 megohms. Sample Resistance Number (megohms } 3A 1.8 X 10 3B 1.9 X 105 3C 2.4 % 105 3D 2.4 X 10 3E 1.9 X 105 3F 2,0 X% 10 Vibration During vibration testing there were no discontinuities greater than one microsecond. Following vibration, there were no cracks, breaks or loose parts. Tensile - Group 2 All connectors of group 2 met the tensile strength requirement of 60% minimum and 70% average. These values were calculated from the average sample tensile strength and the average conductor tensile strength.2.6 2.7 2.8 501-76 Page 5 Tensile - Group 2 (contd) Ts/Cs X 100 = % Average conductor tensile = 485 lbs. Sample Tensile % Breaking Number (pounds ) Strength 2A 465 95.9 2B 430 88.7 2C 460 94.9 20 440 90.7 2E 432 89.1 2F 452 93.2 Avg. 447 92.2 Temperature Cycling w/High Humidity - Group 3 Ail connectors met the requirements for temperature cycling w/high humidity testing with no evidence of cracking, crazing, or other physical damage. In addition al] connectors met the termination resistance and insulation resistance requirements. See paragraphs 2.2 and 2.3 for those test results. Temperature Cycling - Group 4 All connectors met the termination resistance requirement after temperature cycling testing with changes of less then 2.0 milliohms occurring. See termination resistance results for measured values. Immersion/I.R. - Group 5 All connectors met the insulation resistance requirement of 1.2 X 10% megohms following immersion testing. The minimum measured insulation resistance was 1.5 X 10% megohms. Sample Resistance Resistance Resistance Number after 2 hrs. after 72 hrs. after 168 hrs. 5A 1.5 X 10 2.1 X 10% 2.2 X 10 5B 1.0 X 108 1.9 X 10% 1.5 X 108 5C 0.9 X 10 2.0 X 10 2.1 X 10 5D 0.9 X 10 1.9 X 10 2.9 X 10 5E 1.2 X 10 1.9 X 10% 2.2 X 108 5F 0.9 X 10 1.9 X 10 2.2 X 10501-76 Page 6 3.1 3.2 3.3 3.4 Examination of Product - Groups 1 to 5 The product drawing and inspection plan were used to examine the connectors. They were examined visually, dimensionally and functionally. Termination Resistance, Dry Circuit Termination resistance was measured on all contacts in each test group. A four-terminal resistance measuring station was used. Current during the test was maintained at 50 milliamperes with 50 millivolts dc maximum open circuit voltage. Insulation Resistance - Group 3 Insulation resistance was measured between the adjacent contacts of the connectors. A voltage of 1,000 volts dc was applied for two minutes or until connector readings stabilized and the insulation resistance was measured. Vibration - Group 1 Wired drop splices were subjected to 10 X 10 cycles of aeolian vibration at a frequency between 20-25 Hz and an amplitude of .38 to .50 inches. (See figure 1). <\_ 8 to 9Ft. F = 20 lbs. | 50" 38" Frequency acjusted between 20 and 25 Hz. Fig. 1 - Aeolian Vibration3.5 3.6 3.7 3.8 501-76 Page 7 Tensile - Group 2 Wired drop splices of group 2 were subjected to tensile strength testing. A gradually increasing axial load was applied to the conductors of each splice at a rate of 5.0 inches per minute until wire breakage or pullout. Four equal wire lengths were pulled to determine the average conductor tensile strength. Humidity-Temperature Cycling - Group 3 Wired splices were exposed to 10 days of humidity-temperature cycling. The Tength of each cycle was 24 hours, and consisted of cycling the temperature between +77F and +149F twice. The relative humidity was held at 95%. During five of the first nine cycles, connectors were exposed te a cold shock at +14F for 3 hours with humidity uncontrolled. Temperature Cycling - Group 4 Wired splices were subjected to 128 cycles between -40F and +140F. The length of each cycle was 8 hours and consisted of cycling between the temperatures once. Test connectors were held at each temperature extreme for 1 hour. Immersion/IR - Group 5 Wired splices were subjected to 168 hours of immersion in tap water. While splices were immersed, insulation resistance measurements were made after 2 hours, 72 hours, and at the end of the 168th hour. A test voltage of 1,000 vde was applied between the splice conductors to measure insulation resistance.501-76 Page 8 Validation Prepared by: LE MU hue. 8) 2184 Daniel E. McCLure Engineering Assistant Corporate Test Laboratory Reviewed by: a SO S Ve teed / 2s &F Jatk Edwards Supervisor, Design Assurance Testing Corporate Test Laboratory Approved by: E. Ralston Manager, Product Assurance Communication Products Division