85 COPYRIGHT 19 83 BY AMP INCORPORATED ALC INTERNATIONAL RIGHTS RESERVED. D PRODUCT SPECIFICATION l. SCOPE l,l. Content This specification covers the performance, tests and quality requirements for the AMP* SDL system. The system consists of a printed circuit board mounted shielded receptacle, shielded plug connector and shielded cable. Receptacle housings are preloaded with contacts and a shield for direct receptacle assembly to a printed circuit board and the mounting panel. Plug housings are preloaded with contacts for mass termination of the plug to the shielded cable. The system ts designed to be used in class 2 circuits at voltages as defined by the National Electrical Code Table 725-31 (a) and (b). l.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 Specifications 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) C. 114-2081: SDL Top Entry and Side Entry Receptacle D. 114-2086: Flat Cable SDL Plug, 50 and 36 Series E. 114-2090: Round Cable SDL Plug, 50 and 36 Series F. 501-34: Test Report *Trademark of AMP Incorporated. F. Rinehardt 6-3-86 AMP INCORPORATED D [Revised SARAP | parisburg, Pa. 17105 e per ue CHK M 6-5-86 ECN BD-4874 #2 R. Myers - APP NO . REV | Loc [Revise per | if . Rohde 6-5-86 108-2047 | * [8 B Revise per 0. 5/293 TITLE ECN SP-124 SY PAGE CONNECTOR, SDL SYSTEM LTR REVISION RECORD APP DATE 1 OF ll AMP 1250.16 REV 7-872.2. Commercial Specifications A. UL 498: Attachment Plugs and Receptacles B. UL Subject 758: Appliance Wire Material 3. REQUIREMENTS 3.1, Design and Construction Connectors and cables shall be of the design, construction and physical dimensions specified on the applicable product drawing. Printed circuit board and mounting panel dimensions shall be on appropriate Application Specification. 3.2, Materials A. Contacts: (1} Receptacle: Phosphor bronze, selective gold over nickel in contact area and bright tin-lead over nickel on P.C, tails (2) Plug: Phosphor bronze, gold over nickel, selective in contact area B. Shield: Brass, bright tin lead over nickel] or copper C. Housings: {1) Receptacle: Polyester, UL 94V-0, 120C, modified polysulfone, UL 94V-0, 160C (2) Plug: Polycarbonate, UL 94V-2, 125C D. Cable: (1) Jacket: Polyvinylchloride, UL VW-1, 80C (2) Shield: Aluminum polyester with #28 AWG drain wire(s) (3) Conductor: (a) Insulation: Polyvinylchloride, UL VW-1 (b) Conductor: 7 strand tinned copper #28 or 24 AWG 3.3. Ratings A. Voltage/Current: 30 vac 42.4 vde at 1.5 amperes maximum, see 3.5. (a) B. Operating Temperature: -20 to 80C C. Shielding Effectiveness: *20 dB minimum reduction from 70 M Hz to 500 M Hz 10 dB minimum reduction from 500 M Hz to 1G Hz *Applies to 8 position plug on flat cable with aluminum mylar shield. Loc} SHEET NO REV AMP INCORPORATED AMP | harrisburg, Pa. 17105 Bj} 2 0F11 108-2047 D AAAD (75 1, 923 BPEL A-A23.4. Performance and Test Description Connectors 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 Requirement Procedure | Examination of Product Meets requirements of product drawing and appropriate Application Visual, dimensional and functional per applicable inspection Specification. plan. ELECTRICAL System Resistance, Wire Test Millivolt Measure potential drop Specified Current Size, Current, drop, of mated plug and AWG ampere maximum receptacle assembly, 28 1.5 45 see Figure 5; AMP 24 1.5 35 Spec 109-25. System Resistance, Wire Resistance Subject mated plug and Dry Circuit Size, milliohms maximum, receptacle assembly to AWG Initial Final 50 mv open circuit at 28 25 30 100 ma maximum, see 24 20 25 Figure 5; AMP Spec 109-6-1. Dielectric Withstanding Voltage 1000 vac (rms) dielectric withstanding voltage, one minute hold. Test between adjacent circuits of mated plugs and receptacles (unmounted); AMP Spec 109-29-1, Insulation Resistance 500 megohms minimum. Test between adjacent circuits of mated plugs and receptacles (unmounted); AMP Spec 109-28-4, Temperature Rise vs Current (a) 30C maximum temperature rise at 1.5 amperes. T~rise at rated current; AMP Spec 109-45-1. Current Cycling Wire millivelt drop, size, maximum AWG individual 28 50 24 40 Subject mated plug and receptacle to 500 cycles at 125% rated current (1.88A) for 15 minutes "ON" - 15 minutes "OFF"; AMP Spec 109-51, cond B, test method 2. Figure 1 (cont) AMP AMP INCORPORATED Harrisburg, Pa. 17105 B Loc SHEET 3 OF 11 NO REV 108-2047 D AMP 1251-13 REV 4-82Test Description Requirement Procedure Surge Test Meet insulation resistance: dielectric withstanding voltage. Subject mated plug and receptacle assembly using adjacent circuits, to 5 surges of each polarity at 1 minute intervals; a pulse width of 2 x 10* microseconds and a peak amplitude of 1000 volts. Shielding Effectiveness Effectiveness Frequency dB minimum 70 M Hz to 500 M Hz 20 500 M Hz to 1G Hz 10 Note: Results on 8 position flat cable with aluminum/mylar shield. (AMP Part No 520475-1) Measure radiated response from an unshielded reference (consisting of mated receptacle and plugs with cable, all unshielded) with circuit conductors excited between 70 M Hz and 1 G Hz; repeat procedure using shielded system (consisting of mated receptacle and plugs with cable, all shielded) the difference in response will give effective shielding in dB; AMP Spec 109-90, MECHANICAL Vibration No discontinuities Subject mated plug and greater than 1 receptacle mounted on microsecond. printed circuit board System resistance, to random vibration dry circuit; along each of 3 shielding effectiveness. mutually perpendicular axes: each axis shall be subjected to 15 minute duration according to AMP Spec 109-21-5, cond G, Test A. Connector wired in series with 100 ma de current applied. Figure 1 (cont) r RATED toc} SHEET NO REV AMP | Hariburg Pa t7i0s =| B | 4 oF 1 108-2047 D AMP 1251-13 REV 4-82Test Description Requirement Procedure _ Mating Force Mating force values must be noted as "maximum, initial values." 4 position 7.5 Ibs 6 position 8.0 lbs 8 position 8.5 Ibs 16 position 15.0 Ibs Measure force necessary to mate plug and receptacle connectors; AMP Spec 109-42, cond A. Unmating Force Unmating force values must be noted as "maximum; initial values." 4 position 6.0 Ibs 6 position 6.5 lbs 8 position 7.0 lbs 16 position 8.0 Ibs Measure force necessary to unmate plug and receptacle connector with locking latches disengaged; AMP Spec 109-42, cond A. Plug to Receptacle Retention 20 pounds minimum retention. Apply axial load (at a rate of 2 inches per minute} to plug with latches engaged and mated to appropriate receptacle; AMP Spec 169-30. Receptacle Retention, to Printed Circuit Board (Without Mounting Screws) Receptacles shall not dislodge from printed circuit board: before flow solder, 1 pound minimum: after flow solder, 5.5 pounds minimum axially with mounting posts. Apply a perpendicular load at a rate of 2 inches per minute to the receptacle mated to a .062 or.093 inch thick printed circuit board. Cable to Plug Tensile 20 pounds minimum with no discontinuities Determine tensile at a rate of 2 inches per minute with connector wired in series and 100 ma de current applied; AMP Spec 109-16, record maximum force before discontinuity. Figure 1 (cont) Loc] SHEET REV AMP INCORPORATED AMP Harrisburg, Pa. 17105 Bis ofll 108-2047 D AMP 1251-13 REV 4-82Test Description Requirement Procedure Durability System resistance, dry circuit; shielding effectiveness. Mate and unmate plug ~| and receptacle assembly to 3000 cycles at a rate of 20 cycles/ minute maximum; AMP Spec 109-27. Resistance to Soldering Heat No physical damage. 109-63-3. ENVIRONMENTAL Thermal Shock System resistance, dry circuit; insulation resistance; dielectric withstand; shielding effectiveness. Subject mated connectors to 25 cycles between -55 and 85C; AMP Spec 109-22, Humidity-~Temperature Check insulation Subject mated plug and i system resistance, dry circuit, see Figure 5. Cycling resistance within 30 receptacle assembly minutes of test to 10 humidity- completion ; temperature cycles system resistance, between 5 to 30C dry circuit; dielectric and 95 (+0, -5%} RH; withstand; shielding see Figure 2, effectiveness. Heat Age Shielding effectiveness; 80C for 1000 hours. (a) Maximum rated current that can be carried by this product is limited by maximum operating temperature of cable, which is 80C, and temperature rise of contacts, which is 30C. Variables which shall be considered for each application are: wire size, number of circuits, and ambient temperature. Figure 1 (end) l toc! SHEET | NO REV AMP INCORPORATED AMP | harrisburg, Pa. 17105 Bil 4 OF 11 108-2047 D AMP 1251-13 REV 4-82State Te rature C Time for of Test To Hold Changes 30 2 hours 4h 3 hours 3 hours The assembled hardware shall be placed at 95 (+0, -5) percent relative humidity at room temperature. Then, while the relative humidity is held at or returned to 95 percent, the temperature shall be reduced to 5C (41F) a maximum rate of 15C (59F) per hour, The temperature shall then be cycled linearly for ten cycles as specified above with a relative humidity of 95 percent. Figure 2 Humidity-Temperature Cycling Chart REV Loc | SHEET | NO AMP INCORPORATED AEAMP? | harrisburg, Pa. 17105 Bi? oOFll 108-2047 AMP 1251-13 REV 4-823.6. Connector Tests and Sequences Test Grou a} Test or Examination 4|5| 6 7 8 9 710 ],11 [12 |13 |14 115]t6 417 Test Sequence (b) Examination of Product System Resistance, Specified Current System Resistance, Dry Circuit Dielectric Withstanding Voltage Insulation Resistance Temperature Rise vs Current Current Cyclin Surge Test Shielding Effectiveness Vibration Mating Force Unmating Force Plug to Receptacle Retention Receptacle Retention, to P.C.B. Cable to Plug Tensile Durabilit Resistance to Soldering Heat Thermal Shock Humidity~Temperature Cyclin Heat Age (a) See Para 4.1.A. (b) Numbers indicate sequence in which tests are performed. Figure 3 Loc | )~=SHEET NO AMP INCORPORATED PARA | varrisburg, Pa. 17105 Bi 38 OF 11 108-2047 BMP 175113 REV d=_a?eee 4. 4.1. Note: QUALITY ASSURANCE PROVISIONS Qualification Testing A. Sample Selection Connector housings and contacts shall be prepared in accordance with Application Specification and applicable Instruction Sheets. They shali be selected at random from current production. Test Terminated Receptacles Receptacle Group (a) Plugs On Board Off Board = } 3,4,6,7,8,9,10, 11,12,13,14,15,17 tO 10 1,2,5 10 10 16 10 (a) Test groups 3, 7, 8, 9, 12 and 15 each require submittal of a 16 inch wire sample for equivalent wire length readings. Figure 4 Test Samples Per Group B. Test Sequence Qualification inspection shall be verified by testing samples as specified in Figure 3. C. Acceptance (1) The plug housings may exhibit crazing in the contact area. (2) 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 One-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. L- AMP | AMP INCORPORATED Lvoc| SHEET | NO REV Harrisburg, Pa. 17105 Bl 9 OF 11 108-2047 D AMP 175 14 REV 4-a2Then 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. {3} 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 Dimensional and functional requirements shall be in accordance with the applicable product drawing and this specification. fn Loc SHEET NO REV AMP INCORPORATED AMP | Harrisburg, Pa. 17105 B/10 OF 11 108-2047 D CS a AMP 12725 113 REV 4{R2System Resistance 3, 00 __ Power (a> Temperature Probe Voltage drop due to the 3" equivalent wire length is to be removed from all readings, Figure 5 System Resistance and Temperature Measurement Points Een _ LOC SHEET NO REV ANMAP AMP INCORPORATED Harrisburg, Pa. 17105 Bjil OF 11 108-2047 D REE AMP 1251-13 REV 4-82