PRODUCT SFECIFICATION 1. SCOPE 1.1. Gontent This specification covers the performance, tests and quality requirements for the AMP, crimp type I1I,, stamped and formed contacts. These contacts are for use in connectors and other electronic components. The contacts are primarily intended for use where coupling means is provided separately from individual contact. 1.2. Qualification When tests are performed on the subject product line, the procedures specified in AMP 109 series specifications shall be used. All inspections shall be performed using the applicable inspection plan and product drawing. 2. APPLICABLE DOCUMENTS The following documents form a part of this specification to the extent specified herein. In the event of conflict between the requirements of this specification and the product drawing, the product drawing shall take precedence. In the event of conflict between the requirements of this specification and the referenced documents, this specification shall take precedence. 2.1. AMP Documents A. 109-1: General Requirements for Test Specifications B. 109 Series: Test Specifications as indicated in Figure 1. (Comply with MIL-STD-202, MIL-STD-1344 and EIA RS-364) Cc. Corporate Bulletin 401-76: Cross-reference between AMP Test Specifications and Military or Commercial Documents BD, 114-10004 : Application Specification E. 501-66 : Test Report 2.2. Military Specification MIL-W-16878/1 & 4: Wire, Electrical, Insulated, High Temperature 3. REQUIREMENTS 3.1. Design and Construction Product shall be of the design, construction and physical dimensions specified on the applicable product drawing. xTrademark of AMP Incorporated Product Code: 5022 DR F.Rinehardt 5/6/88 ALL INTERNATIONAL RIGHTS RESERVED. COPYRIGHT 15 83 88, 90 BY AMP INCORPORATED AMP Incorporated AP Harrisburg, PA 17105-3608 CHK J.Stine 5/9/88 APP NO REV Loc D.Summers 5/11/88 108-10042 B |B B Revise per Hl /tt TITLE CONTACT, STAMPED AND ECN BD 4089 $e PAGE FORMED. TYPE IIT, LTR REVISIONRECORD | APP | DATE 10F 8 AMP 1250-16 REV 7-873.2. Material A. Body: Brass, gold or tin plated BE. Retention hood: Stainless steel 3.3. Rating A. Current/Voltage: See Para 3.5. (a) B, Operating temperature: (1) -55 to 150C for gold plated contacts (2) -55 to 90C for tin plated contacts 3.4. Performance and Test Description Contacts shall be designed to meet the electrical, mechanical and environmental performance requirements specified in Figure 1. 3.5. Test Requirements and Procedures Summary Test Description Requirements Procedure Examination of Product Meet requirements of product drawing and AMP Spec 1114-10004. Visual, dimensional and functional per applicable inspection plan. ELECTRICAL Termination Resistance, Specified Current See Figure 4. Measure potential drop of mated contacts after stabilizing, see Figure 3: AMP Spec 109-25, calculate resistance. Termination Resistance, Dry Circuit See Figure 4. Subject mated contact pair to 50 mv open circuit at 100 ma naximum, see Figure 3; AMP Spec 109-6-1. Current Cycling Termination resistance, specified current. Subject mated contacts to 500 cycles at 125% specified current for 30 minutes "ON" - 15 minutes "OFF"; AMP Spec 109-51, cond B, test method 3. Figure 1 (cont) AMP 1251-13 REV 10-65 AIM? AMP Incorporated Harrisburg, PA 17105-3608 2 108-10042Test Description Requirement Procedure MECHANICAL Contact Engaging Force See Figure 5 for maximum force per contact. Measure force to engage using gage 2 as indicated in Figure 6; AMP Spec 109-35, engagement depth 230 * 010. Contact Separating Force See Figure 5 for minimum force per contact. Size 3 times using gage 2 as indicated in Figure 6, insert gage 1 and measure force to separate; AMP Spec 109-35, separation depth .230 +.010. Crimp Tensile Crimp Tensile Wire Size, pounds AWG ninimum 14 50 16 40 18 25 20 1? 22 10 24 ? 26 4 28 2.5 30 1.5 Determine crimp tensile at a rate of 1 inch/ minute; AMP Spec 109-16. Durability Show no evidence of damage; contact engaging force and separating force. Contacts shall be installed in a suitable fixture and subject to 500 cycles for gold and 50 cycles for tin contacts; AMP Spec 109-27 except cycle rate shall not exceed 300 cycles/ hour. The applicable counterpart connector inserts may be used for fixture. ENVIRONMENTAL Thermal Shock Shall show no evidence no damage, meet termination resistance, dry circuit and specified current; engaging and separating force. Subject mated contacts to 10 cycles between -55 and 90C for tin and -55 and 150C for gold; AMP Spec 109-22. Figure 1 (cont) AMP AMP 1251-13 REV 10-85 AMP incorporated Harrisburg, PA 17105-3608 3 1108-10042Humidity~-Temperature Cycling Termination resistance, dry circuit; engaging and separating force. Subject mated connectors to 10 humidity- temperature cycles between 25 and 65C at 95% RH; AMP Spec 109-23, method III, cond B, with cold shock at -10C less step 7b. Industrial Mixed Flowing Gas Show no evidence of damage Meet termination resistance dry cireuit and specified current. Subject mated contacts to environmental class IT for 10 days; AMP Spec 109-85-2 Temperature Life Shew no evidence of damage Meet termination resistance dry circuit and specified eurrent; engaging and separating force. Subject mated connectors to temperature life, AMP Spec 109-43, except 240 hours at 150C for gold and 90C for tin. (a) The continuous current physical properties transient conditions. rating the material. System de Figure 1 (end) for individual contacts directly to the number of contacts as they are dependent on the thermal and of continuous current rating does not create internal hot spots that exceed the temperature designated by the connector specification, during steady state or cannot be applied sign shall assure that 3.6 Connector Tests and Sequences Test Group (a) Test or Examination 1 2 Test Sequence (b} 4 Examination of Product 1,10 1 Termination Resistance, Specified Current 2,4 Termination Resistance, Dry Cire." 2,7 Current Cycling 3 Contact Engaging Force 8 Contact Separating Force 9 Crimp Tensile 5 Durability 3 Thermal Shock a Humidity-Temperature Cycling (d) 6 Industrial Mixed Flowing Gas (c) 6 Temperature Life 3 (a) See Para 4.1.A (b) Numbers indicate sequence in which tests are performed (c) Gold plated samples only. {a4) Tin plated samples only. Figure 2 PAGE [NO REV | LOC AKRAF AMP Incorporated Harrisburg, PA 17105-3608 4 108- 10042 5B | 8 AMP 1251-13 REV 10-854. QUALITY ASSURANCE PROVISIONS 4.1. Qualification Testing A. Sample Selection Contacts shall be prepared in accordance with applicable Instruction Sheets, They shall be selected at random from current production. All test groups shall consist of 10 samples of each part number (pin and socket). One-half of the samples shall be crimped to maximum gauge wire and the other half crimped to minimum gauge wire, All wire lengths shall be a minimum of 12 inches. (1) Gold plated contacts shall be crimped to wire conforming to i MIL-W-16878/4, Type E. (2) Tin plated contacts shall be crimped to wire conforming to MIL-W-16878/1, Type B. B. Test Sequence Qualification inspection shall be verified by testing samples as specified in Figure 2. C. Acceptance (1) All samples tested in accordance with this specification shall meet the stated tolerance limit. (2) Failures attributed to equipment, test setup, or operator deficiencies shall not disqualify the product. When product failure occurs, corrective action shall be taken and samples resubmitted for qualification. 4.2. Quality Conformance Inspection The applicable AMP inspecrion plan will specify the sampling acceptable quality level to be used, Dimensional and functional requirements shall be in accordance with the applicable product drawing and this specification. PAGE | NO Loc ARAF | AMP Incorporated Harrisburg, PA 17105-3608 5 |. 108 -10042 B AMP 1251-13 REV 10-85a tia LO Ld _ rt Termination Resistance Measurement Points fr Power NOTE: Termination resistance equals millivolts divided by test resistance of 4.5 inches of wire Figure 3 Termination Resistance Measurement Test Circuit current less PAGE |NO ARAF? AMP Incorporated Harrisburg, PA 17105-3608 6 108 -40042 AMP 1251-13 REV 10-85 REV Loc: Resistance, Mating End Test Current milliohms Size amperes (a) maximum 16 13 .50 18 10 20 7. 00 22 5 9.50 24 3 14.5 26 2 0 30.0 30 1.2 43.0 (a) Single contact free air test currents only, not to be construed as connector rating currents, used only for testing. Figure 4 Termination Resistance Minimum Maximum Mating End Pin Diameter, Separation Engagement, Size inches ounces ounces 16 .0625 1.5 36.0 Figure 5 Contact Engagement and Separation Force IMI AMP Incorporated A P Harrisburg, PA 17105-3608 ? 1086-10042 AMP 1251-13 REV 10-851.000 Min Gage Contact A B Number Size Maximum Flat l 16 06157 0001 ~.0000 015 +,0000 . 2 16 9635 on01 Figure 6 Engaging and Separating Gages AMP | AMP 1251-13 REV 10-85 AMP INCORPORATED Harrisburg,Pa. 17105 PAGE | NO 8 108-10042 REV | Loc