ocorvriant 19 79,80, 86 TERNATIONAL PRODUCT SPECIFICATION 1, SCOPE L.L. Content This specification covers the performance, tests and quality requirements for the AMP* Tin Plated Non-Bifurcated crimp twin leaf connector assemblies, used to provide a connection method between discrete wiring and printed circuit boards. Contacts are crimp type, snap-in design. These multi-contact connectors have .100, .125 and .156 inch centerline spacing between adjacent contacts. 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 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 Specifications A. LO9-1: 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) C. Corporate Bulletin 76: Cross-reference between AMP Test Specifications and Military or Commercial Documents 2.2. Military Standard RIGHTS RESERVED. AMP PRODUCTS MAY BE COVERED BY U.S. AND z 4 28 Soe = z E MIL-STD-275: Printed Wiring for Electronic Equipment ree a,2 he? 33 z *Trademark of AMP Incorporated. Otte _ zus DR a ro . aaa F. Rinehardt 6-20-80 nm AMP INCORPORATED > z CHK ~ P | Harrisburg, Pa. 17105 ane H.J. Hagan 6-23-80 APP Loc | NO REV R, Johnston 6-23-80 | B lIO8-S9O05I A J TITLE } Z SHEET CONNECTOR, CRIMP pist 9A Revised per. SY , 1 OF 10 TWIN LEAF, NON-BIFURCATED, 14_ fire REVISION RECORD APP | DATE TIN PLATED AMP 1250-16 REV 4-823. REQUIREMENTS 3.1. Connectors shall be of the design, Design and Gonstruction construction specified on the applicable product drawing. 3.2.6 Materials A. Contact: 3.3, Ratings A. Current: B. Operating Temperature: 3.4, Connectors shall be 3.5. designed to environmental performance requirements specified in Figure 1. Phosphor bronze, tin plated B. Housing Material: Polyester, black 5 amperes maximum per contact -40 to 85C Performance and Test Description meet the Test Requirements and Procedures Summary electrical, and physical dimensions mechanical, and Test Description Requiremerit Procedure Examination of Product Meets requirements of product drawing. Visual, dimensional, and functional per applicable inspection plan. ELECTRICAL Termination Resistance, Dry Circuit (Low Level) 10 millichms maximum. Subject mated contacts assembled in housing to 50 mv open circuit at 100 ma maximum, see Figure 3; AMP Spec 109-6-1. Dielectric Withstanding Voltage Altitude, Test Voltage, rms feet .100cI .125cl .156cl Sea i000 1500 1800 Level 50,000 400 525 675 70,000 280 375 450 5 ma leakage maximum. Test between adjacent contacts of unmated connector assemblies, and contacts to mounting hardware; AMP Spee 109-29-1. Figure 1 (cont) AMP | AMP INCORPORATED Harrisburg, Pa. 17105 B toc} SHEET 2 OF 10 NO REV 108-9051 A AMP 1251-13 REV 4-62Test Description = Requirement Procedure Insulation Resistance 5,000 megohms minimum initial, Test between adjacent contacts of unmated connector assembly; AMP Spec 109-28-4 {500 vdc). Current Cycling Termination resistance, 5 milliiohms maximum. Subject mated contacts to 50 cycles at 125% rated current for 30 minutes "ON" - 15 minutes "OFF"; AMP. Spec 109-51, cond B, test method 5. Crimp Resistance Resistance, Measure potential drop Wire Test milliohms across crimped contact Size, Current maximum between wire as it AWG amperes Initial Final | enters the wire barre] 28 1.0 3.0 5.0 and the end of the 26 1,0 2.5 4.0 wire barrel nearest 24 3,0 2.0 3.3 the contact transition, 22 5.0 1.2 2.0 Figure 6. 20 7.5 0.7 1.2 18 10.0 0.5 0.8 fi 16 12,5 0.4 O,7 MECHANICAL Vibration (a) No discontinuities greater than 1 microsecond; no physical damage. Subject connectors mated with P.C. Board to 10-55-10 Hz traversed in 1 minute at .06 inches total. excursion; 2 hours in each of 3 mutually perpendicular planes; AMP Spec 109-21-1. Physical Shock (a) No discontinuities greater than 1 microsecond; no physical damage. Subject mated connector with P.C. Board to 100 G's sawtooth in 6 milliseconds; 3 shocks in each direction applied along the 3 mutually perpendicular planes total 18 shocks; AMP Spec 109-26-9. Figure 1 (cont) AMP AMP INCORPORATED Harrisburg, Pa. 17105 Loc NO SHEET 3 OF 10 REV 108-9051 rien AMP 1251-13 REV 4-62 , - Test Description Requirement Procedure Connector Mating Force 20 ounces maximum per Measure force necessary contact pair. to mate connector assembly from point in initial contact, with Maximum thickness gage .O70 (Figure 5) incorporating free floating fixtures at a rate of 0.5 inch/minute; AMP Spec 109-42, cond A calculate force per i contact. Contact Retention Contacts shall not Apply axial load of 8 (Crimped Contacts) dislodge from its normal pounds to contacts locking position. lead; AMP Spec 109-30. 7 Contact Engaging Force 20 ounces maximum per Measure force to contact pair. enpage using gage l, as indicated in Figure 5; AMP Spec 109-35, Contact Separating ? ounces minimum per Size 3 times using Force contact pair. gage 1, as indicated in Figure 5, insert gage 2 and measure force to separate; AMP Spec 109-35. Crimp Tensile Wire Tensile Determine crimp tensile Size, Strength, at a rate of 1 inch/ AWG pounds minimum minute; AMP Spec 28 3.0 109-16. 26 5.9 Z24 8.0 22 12.9 20 20,0 ig 30.0 16 42.0 Durability No physical damage. Mate and unmate connector assemblies for 15 cycles with gage 1, Figure 5; AMP Spec 109-27. Figure 1 (cont) LOG SHEET NO REV RATED | anae|rmmcrrorne [el eorw| vom || AMP 1251~13 REV 4-82a ARNON Test Description Requirement Procedure avers et EN VIRONMENT AL Humidity-Temperature Cycling (a) No physical damage. 1000 megohms final insulation resistance, Subject mated connectors to 10 humidity-temperature cycles between 25 and 65C at 95% RH; AMP Spec 109-23, method III, cond B, and cold shock at -10C. Thermal Shock (a) No physical damage. Subject mated connectors to 5 cycles -40C to 85C; AMP Spec 109-22, (a) Shall show no evidence of damage, cracking or chipping. Figure 1 (end) 3.6, Connector Qualification and Requalification Tests and Sequences Test Group (a) Test or Examination 1 j 2 | 3 Test Sequence (b) Examination of Product 1 1 1 Termination Resistance, Dry Circuit 3,12 2,1) Dielectric Withstanding Voltage 5,11 4 Insulation Resistance 4,10 3 Crimp Resistance 2,4 Current Cycling ~ 3 Vibration 9 Physical Shock 10 Mating Force 2 Contact Retention 13 12 Contact Engaging Force 5 Contact Separating Force 8 6,8 Crimp Tensile 5 Durability 7 7 Humidity-Temperature Cycling 9 Thermal Shock 6 (a} See Para 4.1.A. (b) Numbers indicate sequence in which tests are performed. Figure 2 coc! SHEET | NO REV ARAP AMP INCORPORATED A Harrisburg, Pa. 17105 Bl 5 OF 10 108-9051 es ad AMP 1251-13 REV 4-82ma = QUALITY ASSURANCE PROVISIONS Qualification Testing A. Sample Selection Connector housings and contacts shall be prepared in accordance with applicable Instruction Sheets. They shall be selected at random from current preduction. Test group 1 and 2 shall consist of three samples of the greatest number of positions of each connector type offered. Two additional specimens shall be selected from the least number of positions offered and tested to Test Group 2. Test group 3 shall consist of 30 contacts of each style and desired wire size. When connectors are required to be mated, mating boards shall conform to Figure 4, B. Test Sequence Qualification inspection shall be verified by testing samples as specified in Figure 1. C. Acceptance (lL) Test results from development on pre-qualification samples will be used to determine upper and lower one-sided statistical tolerance limits for 99% reliability at 95% confidence, as follows. Let X bar and s denote the sample average and standard deviation, respectively, of the test data, Let k denote the normal distribution one-sided tolerance factor for 95% confidence and 99% reliability. The value of k varies with sample size. Values of k are given in various tables, for example, NBS Handbook 91, Factors for QOne-Sided Tolerance Limits for Normal Distribution. Suitability of the normal distribution for representing the data shall be verified with normal probability plots, goodness of fit tests, etc. Then the upper one-sided tolerance limit for 99% reliability at 95% confidence is given by X bar + ks. The interpretation of this tolerance limit is as follows: based on the test data, and assuming a normal distribution for the test data, we can be 95% confident that 99% of the population of values represented by the sample data will not exceed X bar + ks. For any test parameter for which there is specified an upper requirement which is not to be exceeded, satisfactory performance of the product is achieved when the value of X bar + ks does not exceed the requirement value. The lower one-sided tolerance limit for 95% confidence and 99% reliability is given by X bar - ks. This has a similar interpretation and corresponding application to lower requirement values. al coc] SHEET | NO REV AAP AMP INCORPORATED A Harrisburg, Pa. 17105 Bi 6 OF 10 108-9051 i AMP 1251-83 REV 4-682(2) Failures attributed to equipment, test setup, of operator deficiencies shall not disqualify the product. When product failure occurs, corrective action shall be taken and samples resubmitted for qualification. 4.2, Requalification Testing Requalification shall be established by the cognizant divisional engineering function and may consist of all or any part of the overall qualification program provided that it is conducted within the required time period. 4.3. Quality Conformance Inspection The applicable AMP inspection 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. thy - Power SY Supply Printed Circuit Test Board Termination Resistance | Measurement Points fae eri pe- 4. 00 3 ft. min, length of continuous lead for Connector heat dissipation Figure 3 Termination Resistance Loc SH EET NO AAP AMP INCORPORATED Harrisburg, Pa. 17105 B | 7 OF 10 108-9051 A io AMP 1251-13 REV 4-62| -005 _ Be 000 Typ {| .003 Total A BSC Typ-} a - * . (See Note 3) Of 015 ,. oT | { NN i Section D-D peed C+ .005 - = (See Note 6) }A!,.004 Total Notes: 1, Dimensions are in inches. a. Unless otherwise specified, tolerance is +.005. 3. The test card shall extend 4.00 +t .02 from the receptacle after insertion. 4, Number of contacts shall be the same as on the corresponding printed wiring connector. 5. Printed circuit test board shall be 2 oz copper and tin/lead over nickel plated per MIL-STD-275. 6. This dimension shall be the minimum connector card slot length minus .005. 7. Conductor configuration optional beyond card slot depth. 8. Printed wiring shall be identical on both sides. Connector A Contact BSC B Spacing - 100 .100 2052 125 1125 ,078 +156 .156 094 Figure 4 Mating Card Loc] SHEET | NO REV AMP INCORPORATED AMP | Harrisburg, Pa. 17105 Bis oF 10 108-9051 A AMP 1251-13 REV 4-82=a am leg_-1. 250+. 016 w] . 3254. 005 x, 7125 on _ . 015+. 005 | 031 R Max i 13 (4 Sides) 4/ (4 Sides) Notes: 1. Tolerance: +.005 or +-2 as applicable, unless otherwise specified, 2. Material: Tool steel, AISI type 02 per AMP Specification 100-15. 3. Heat treat: Rockwell 50-55. 4, Gage Surface shall be clean of contaminants or lubricants. Gage A 1 .G70 inches 2 .054 inches Figure 5 Force and Durability Gages Loc HEET NO REV AMP AMP INCORPORATED s Harriaburg, Pa. 17105 B | 9 OF 10 108-9051 A AMP 1251-13 REV 4-82L fay Power wy Supply Crimp Resistance Measurement Points ee- 3.00 Note: The resistance of 3 inches of wire shall be measured and that amount deducted from the total value so as to show only the crimp resistance, Figure 6 Crimp Resistance Test Circuit ARAP | AMP INCORPORATED SHEET Harrisburg, Pa. 17105 B | 100F 10 108-9051 REV = AMP 1251-13 REV 4~82 iat