Product Specification: Classification: Prepared By: ALL INTERNATIONAL RIGHTS RESERVED. COPYRIGHT 1961, 1994 8 AMP INCORPORATED AMPTP QUALIFICATION TEST REPORT CONTACT, TYPE VI _hea-i7s Rev. A May 13, 1992 Unrestricted Terrance M. Shingara 9990 -0062-94 CONTROLLED DOCUMENT This report ie 2 controlled document AMP" Specification 102-21. It is subject to Pe change and Corporate Standards should be contacted for latest ravision. Corporate Test Laboratory Harrisburg, Pennsylvania Th fink yor fr Ao ging Theet ee ee + # 8 @ wo Aon wae mH 00 COO OF OB eo me 8 COI OF On mm Wp > te) OD GO Go OW) OY Oo BPR PO D0 PO PO RO Po PO BO Se ew la al BO ba 501-175, Rev. A Table of Contents Introduction 1... ccc cece cece re ee eee eee eee e eens Page PUYPOSO 2... ccc a scence cece e sentence enue vee ence eee eens Page SCOPE coc cca ec cee eee e cece tener er eet seen eeenaneeeene Page CONCTUSION ... cece cece reece ee ttre setae nceteenees Page Product Description 1.0... . ccc cece eee eee eee cern enee Page TeSt Samples .. cece cece renee ete rset tener et einen cee Page Qualification Test Sequence 12... ccc cee eae ee ee eae Page Summary of Testing .. ccc cece eect a twee eee e eta e en enes Page Examination of Product .......... cc eee e cece ence teens Page Termination Resistance, Dry Circuit .....-.cce eee e eee Page Temperature Rise vs. Current ....... cer eee eect eer eceee Page Current Cycling ......cc cece cece eee eee ener ee tenons Page Contact Engaging Force ...... cca cee cece eee ee eee Page Contact Separating Force 2.0... cece ccc ee eee ees Page Crimp TONSil@ . oc. ccc cee tect e een ee tee ree sa pe eeeenees Page Thermal Shock 1... .05 cece see e ee ce eee eee eee ene eens Page Humidity-Temperature Cycling ........... cece cece eee eee Page Mixed Flowing GaS 1.0.2.2... ccc cece cece ence nee Page Temperature Life ..... cee ccc ete eee eee aeee Page Test Methods ......c. cece eer eee e nee e tere eet e eee nees Page Examination of Product ......... cee cea e eee nee e er aeeeeeee Page Termination Resistance, Dry Circuit ...............224. Page Temperature Rise VS CUrrant wo... cece eee een nee eens Page Current Cycling 2.0... cc. eee eee cece ee eee ee eee enes Page Contact Engaging Force ..... Lene eet a eae neat ener eeeee Page Contact Separating Force 0.0... cece cee e eee eee Page Crimp Tensile .... ces scece ven rereces seve eevee ener aeane Page Thermal Shock ............. eee een e een a nese nano aees Page Humidity-Temperature Cycling .........c cee peer eee ener Page Mixed Flowing Gas ........ 0. cc ccc cece cence ees aceeuee Page Temperature Life 2... .c eee ce eee eee eee eee ees Page Validation .... ccc cece cect eee n ese ceeveretaeneennneeunes Page (R5056TS1) eh om OO Po Ba RO Rs et ee SOMA A AS oo ein ao501-175, Rev. A AMP AMP INCORPORATED HARRISBURG, PENNSYLVANIA 17105 PHONE: 717-564-0100 TWX: 510-657-4110 CORPORATE TEST LABORATORY Qualification Test Report Type VI Contact 1.1 1.2 1.3 Introduction Purpose Testing was performed on amp Type VI Contact to determine its conformance to the requirements of AMP Product Specification 108-10038 Rev.0. Scope This report covers the electrical, mechanical, and environmental performance of the Type VI Contact manufactured by the Interconnection Components & Assemblies Products Division of the Capital Goods Business Unit. The testing was performed between December 11, 1990 and February 26,1992. Conclusion The Type VI Contact meets the electrical, mechanical, and environmental performance requirements of AMP Product Specification 108-10038 Rev. 0. * Trademark501-175, Rev. A Page 2 1.4 1.5 1.6 Product Description The Type VI contact is a .062 diameter size 16 contact. The contact base material is a copper alloy with either tin or goid over nickel plating. Contacts are designed to accept wire sizes AWG 14 thru AWG 28. Test Samples The test samples were randomly selected from normal current production lots, and the following part numbers were used for test: All samples were loaded in CPC Series 1 Connectors using the 23-37 arrangement. Test Group Quantity Part Number Description 1,2,4,5,6 402 66585-2 Sn Pin AWG 28 1,2,4,5,6 402 66586-2 Sn Socket AWG 28 4,5 222 66581-2 Sn Pin AWG 20 4,5 222 66582 -2 Sn Socket AWG 20 2,4,5,6 312 66577 -2 Sn Pin AWG 14 2,4,5,6 312 66578-2 Sn Socket AWG 14 2,3,4,5 312 66585-4 Au Pin AWG 28 2,3,4,5 312 66586-4 Au Socket AWG 28 4,5 222 66581 -4 Au Pin AWG 20 4,5 222 66582-4 Au Socket AWG 20 1,2,3,4,5 582 66577-4 Au Pin AWG 14 1,2,3,4,5 582 66578-4 Au Socket AWG 14 Qualification Test Sequence Test or Examination Examination of Product Termination Resistance T-Rise vs. Current Current Cycling Contact Engaging force Contact Separating Force Crimp Tensile Durability Thermal Shock Humidity-Temperature Cycling Mixed Flowing Gas Temperature Life any] ho os Test Groups 2 3 4 5 6 3 The numbers indicate sequence in which tests were performed.501-175, Rev. A Page 3 2.1 2.2 2.3 Summary of Testing Examination of Product - All Groups All samples submitted for testing were selected from normal current production lots. the Product Assurance Depa Unit Group. They were inspected and accepted by rtment of the Capital Goods Business Termination Resistance, Dry Circuit - Groups 1,2,3,4,5,6 All termination resistance measurements, taken at 100 milliamperes dc. and 50 mill Tess than 32 milliohms. ivolts open circuit voltage, were Test No. of Group Samples Condition Min Max Mean 1 30 Initial AWG 14 1.83 2.13 1.96 30 Initial AWG 28 3.49 5.29 4.24 30 Final AWG 14 2.13 3.03 2.48 30 Final AWG 28 5.09 8.29 6.80 2 60 Initial AWG 14 1.83 3.03 2.25 60 Initial AWG 28 2.29 5.79 4.0] 60 Final AWG 14 1.93 10.43 3.70 60 Final AWG 28 2.29 10.19 5.72 3 45 Initial AWG 14 1.91 2.17 1.98 45 Initial AWG 28 2.40 3.93 3.03 45 Final AWG 14 1.95 2.45 2.10 45 Final AWG 28 2.56 3.75 3.06 4 30 Initial AWG 14 2.03 2.83 2.42 30 Initial AWG 28 2.89 6.29 4,00 30 Final AWG 14 2.33 26.73 7.43 30 Final AWG 28 3.69 7.29 5.04 5 20 Initial AWG 14 1.83 2.43 2.01 30 Initial AWG 20 1.52 2.22 1.77 30 Initial AWG 28 2.39 5.39 3.75 20 Final AWG 14 1.86 2.68 2.23 30 Final AWG 20 0.74 1.89 1.25 30 Final AWG 28 2.78 20.63 5.09 6 30 Initial AWG 14 1.53 2.23 1.99 30 Initial AWG 20 1.32 2.12 1.64 30 Initial AWG 28 1,99 3.79 2.99 30 Final AWG 14 1.84 2.88 2.18 30 Final AWG 20 0.84 1.83 1.27 30 Final AWG 28 1.29 6.19 4.35 Temperature Rise vs. Current - Group 6 All samples had a temperature rise of ambient when a specified current of 1. All values in milliohms less than 30C above & amperes dc was applied.501-175, Rev. A Page 4 z.4 2.5 2.6 2.7 2.8 2.9 2.10 current Cycling - Group _5 No evidence of physical damage was visible to the test samples, after 500 cycles of cycling the current on and off at a minimum of 125% of specified current. Contact Engaging Force - Group 1 All contact engaging forces were less than 22 ounces for gold plated contacts and 27 ounces for tin plated contacts. Contact Separating Force - Group \ All contact separating forces were greater than 1.5 ounces per contact. Crimp Tensile - Group 5 All tensile values were greater than specification limits. Wire Size # of Samples Limit Min Ave AWG 14 40 50.0 52.4 67.7 AWG 20 60 17.9 28.4 32.3 AWG 28 60 2.5 4.3 6.8 all values in pounds Durability - Group ] No physical damage occurred to the samples aS a result of mating and unmating the connector 500 times for gold plated samples and 25 cycles for tin plated samples. Thermal Shock - Group 1 No evidence of physical damage to the contacts was visible as a result of thermal shock. Humidity-Temperature Cycling - Group 4 No evidence of physical damage to the contacts was visible as 4 result of exposure to humidity-temperature cycling. Mixed Flowing Gas - Group 3 No evidence of physical damage to the contacts was visible as a result of exposure to the pollutants of mixed flowing gas. Temperature Life - Group 2 No evidence of physical damage to the contacts was visible as a result of exposure to an elevated temperature.501-175, Rev. A Page 3.1 3.2 Test Methods Examination of Product Product drawings and inspection plans were used to examine the samples. They were examined visually and functionally. Termination Resistance, Low Level Termination resistance measurements at low level current were made, using a four terminal measuring technique (Figure 1). The test current was maintained at 100 milliamperes dc, with an open circuit voltaga of 50 millivelts dc. Lge 2 Fermination Resistance Measurement Points ny Power VY Supply Note: Termination resistance equals millivolts divided. by tesc current less 3.3 resistence of 4.5 inches of wire. Figure 1 Typical Termination Resistance Measurement Points Temperature Rise vs Specified Current Contact temperature was measured, while energized at the specified current. Thermocouples were attached to the contacts to measure their temperatures. This temperature was then subtracted from the ambient temperature to find the temperature rise. When three readings at five minute intervals were the same, the readings were recorded.501-175, Rev. A Page 6 3.4 3.5 3.6 3.7 3.8 3.9 3.11 Current Cycling The contacts were cycled on and off at 125% of the specified current. Testing consisted of 500 cycles, with each cycle having current on for 30 minutes and current off for 15 minutes. Contact Engaging Force Engaging forces were acquired by inserting a 0.0635 inch gage into the socket. Contact Separating Force After insertion a 0.0635 inch gage, Separating forces were acquired by withdrawing a 0.0615 inch gage from the socket. Crimp Tensile An axial load was applied to each sample at 4 crosshead rate of 1.0 inch per minute. Durability Contacts were mated and unmated the appropriate number of times at a rate not exceeding 300 per hour. Thermal Shock Mated contacts were subjected to 10 cycles of temperature extremes, with each cycle consisting of 30 minutes at each temperature. The temperature extremes were -55C and 105C for gold plated contacts and -55C and 90C for tin plated contacts. the transition between temperatures was less than one minute. Humidity-Temperature Cycling After preconditioning the gold piated samples with 50 cycles of durability and the tin plated samples with 5 cycles of durability, mated contacts were exposed to 10 cycles of humidity- temperature cycling. Fach cycle lasted 24 hours and consisted of cycling the temperature between 25C and 65C twice, while the relative humidity was held at 95%. Mixed Flowing Gas, Class II After preconditioning the gold plated samples with 50 cycles of durability and the tin plated samples with 5 cycles of durability, mated contacts were exposed for 7 days to an mixed flowing gas Class i] exposure. Class II exposure is defined as a temperature of 30C and a relative humidity of 70%, with the pollutants of Cls at 10 ppb, NO: at 200 ppb, and H:S at 10 ppb.501-175, Rev. A Page 7 3.12 Temperature Life After precanditioning durability and the ti durability, mated con the gold plated samples with 50 cycles of n plated samples with 5 cycles of tacts were exposed to a temperature of 105C for 315 hours for gald plated contacts and 90C for 1300 hours for tin plated contacts.501-175, Rev. A Page & Validation Prepared by: _ Ehe/22- * Test Engineer Design Assurance Testing Corporate Test Laboratory Reviewed by: Q. ENE 1 . brott | Supervisor Design Assurance Testing Corporate Test Laboratory Approved by: Br? S119) ward Gi Manager Engineering & Design Assurance Capital Goods Business Unit