between 1. SCOPE l.1l. Content 1.2, Qualification 2. APPLICABLE DOCUMENTS 2.1. AMP Documents PRODUCT SPECIFICATION TENTATIVE This specification covers performance, AMPMODU" Mod IV 1/2 interconnection system. intermediate pressure receptacle contacts crimped onto either solid or stranded wire and then inserted into a Mod IV housing. It is designed to mate with AMPMODU Mod II .025 inch square posts or headers. JUL 2 4 1989 AUG 2 3 1989 MAR 13 1992 tests and quality requirements This miniature system consists of specification and referenced documents, 109-1: General Requirements for Test Specifications 109 Series: Test Specifications as indicated in Figure 1. (Comply with MIL-STD-202, MIL-STD-1344 and EIA RS-364) Corporate Builetin 401-76: 3. REQUIREMENTS Product shall be of design, applicable product drawing. 3.1, Design and Construction Cross-reference between AMP Test for When tests are performed on subject product line, procedures specified in AMP 109 series specifications shall be used. All inspections shall be performed using applicable inspection plan and product drawing. 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 product drawing, product drawing shall take precedence. In the event of conflict requirements of this specification shall take precedence. this Specifications and Military or Commercial Documents 114-25003: Application Specification 501- > Test Report construction and physical dimensions specified on NOV 09 1981 a @ a & ~ a 2 of <i =9 Product Code: 5207,5208,5210, 283 Trademark of AMP Incorporated 5456 5677, 5912 28 35 sou TENTATIVE DR got < This specification is based on design objectives and ia AMP Incorporated Sad | ERimai Aitaepeiiariencame, [oH AAIMAIP farrsburg, PA 17105-2600 results of additional testing and evaluation. Accordingly, AMP Incorporated makes no representation or wi reseed or im, uct de- APP NO REV Lo Erne Peeee asa mri teat te Reeser 108-2502 0 IB TITLE INTERCONNECTION SYSTEM, PAGE AMPMODU MOD IV 1/2, WIRE TO BOARD REVISION REGORD | APP | DATE 1OF 12 STANDARD PRESSURE CONTACT AMP 1250-19 REV 12-873.2. Materials A. Contact: (1) Beryllium copper (2) Copper-tin-phosphor-bronze B. Housing: Flame retardant thermoplastic, UL 94-0 rated. 3.3. Ratings A. Voltage: 250 vac B. Current: See Figure 2 for applicable current carrying capability Cc. Temperature; -65 to 105C 3.4. Performance and Test Description Product is designed to meet electrical, mechanical and environmental performance requirements specified in Figure 1. All tests are performed at ambient temperature unless otherwise specified. 3.5. Test Requirements and Procedures Summary Test Description Requirement Procedure Examination of product. Meets requirements of Visual, dimensional and product drawing and AMP functional per applicable Spec 114-25003, quality inspection plan. ELECTRICAL Termination resistance, 12 millichms maximum for Subject mated contacts dry circuit. beryllium copper. assembled in housing to 20 milliohms maximum for 50 my open circuit at copper-tin-phosphor. 100 ma maximum. See Figure 5. AMP Spec 109-6-1. Dielectric withstanding | Test Voltage (rms) Test between adjacent voltage. Centerline contacts of unmated . 100 Altitude | connector assemblies. & . 150 Feet AMP Spec 109-29-1. 125 750 1000 Sea Level 300 400 50000 275 275 70000 No breakdown or flashover. Insulation resistance. 5000 megohms minimum Test between adjacent initial. contacts of unmated connector assemblies. AMP Spec 109-28-4. Figure 1 (cont) PAGE | NO REV | Loc ARAF = AMP Incorporated Harrisburg, PA 17105-3608 2 1908-25021 AMP 1251-13 REV 16-85Test Description Requirement Procedure Current cycling. Termination resistance, dry circuit. Crimp resistance shall not exceed final requirement Subject mated contacts to 50 cycles at 125% rated current for 30 minutes "ON" and 15 minutes "OFF". AMP Spec 109-51. Temperature rise vs current. 30C maximum temperature rise at specified current. See Figure 2. Measure temperature rise vs current, AMP Spec 109-45-1, Crimp resistance. Wire Test Resistance | Measure potential drop Size Current milliohms of mated contacts after AWG amperes maximum temperature of wire has Int Final | stabilized. Calculate 20 3.0 2.0 3.0 | crimp resistance. 22 3.0 3.0 5.0 | See Figure 5. 24 3.0 4.0 6.0 26 2.0 4.5 6.5 28 1.5 5.0 7.0 30 1.0 11.0 13,0 32 1.0 13.0 15.0 MECHANICAL Vibration, sinusoidal, high frequency. No discontinuities greater than 1 microsecond. See Note (a). Subject mated connectors to 20 G's, between 10-2000 Hz traversed in 20 minutes. 4 hours in each of 3 mutually perpendicular planes. see Figure 7. AMP Spec 109-21-4, Physical shock. No discontinuities greater than 1 microsecond. See Note (a). Subject mated connector to 100 G's sawtooth shock pulses of 6 milliseconds duration. 3 shocks in each direction applied along 3 mutually perpendicular planes, 18 shocks total. AMP Spec 109-26-9. Mating force. 16 ounces maximum per contact, Measure force necessary to mate connector assembly a distance of .230 inch from point of initial contact with housing face using free floating fixtures at rate of 1 inch per minute. Calculate force per contact, AMP Spec 109-42, Condition A, ANP AMP 1251-13 REV 10-85 AMP Incorporated Harrisburg, PA 17105-3608 Figure 1 (cont) 108-25021Test Description Requirement Procedure Unmating force. 2 ounces minimum per Measure force necessary to contact, unmate connector assembly at rate of 1 inch per minute. Calculate force i per contact. AMP Spec 109-42, Condition A. Contact retention. Contacts shall not Apply axial load of 5 dislodge from normal pounds to each contact locking position. wire at a rate of 1 inch per minute. AMP Spec 109-30. Contact engaging force. 13 ounces maximum per Measure force using gage contact. 1 at rate of 1 inch per minute. Engagement depth shall be .230 + .005. See Figure 6. AMP Spec 109-35, Contact separating 1.5 ounces minimum per Size 3 times using gage 1, force. contact, insert gage 2 and measure force to separate at rate of 1 inch per minute. Separation depth shall be .230 + .005. See Figure 6. AMP Spec 109-35. Crimp tensile. Wire Crimp Tensile Determine crimp tensile at Size pounds rate of 1 inch per minute. AWG minimum AMP Spec 109-16. 20 17.5 22 11.0 24 7.0 26 4.0 28 2.7 30 1.2 32 1.0 Durability. Mating/unmating force; Mate and unmate connector termination resistance, assemblies for 150 cycles dry circuit. for 30 win gold plating, 75 cycles for 15 win gold plating and 75 cycles for 100 Win tin plating at maximum rate of 150 cycles per hour. AMP Spee 109-27. Figure 1 (cont) PAGE [NO Rev [Loc ARKRAP Qs AMP Incorporated Harrisburg, PA 17165-3608 4 10608-25021 0 B AMP 1251-13 REV 10-85Test Description Requirement Procedure ENVIRONMENTAL Thermal shock. 750 vae dielectric withstanding voltage; termination resistance, dry circuit. See Note (a). Subject mated connectors to 5 cycles between -65 and 105C. AMP Spec 109-22, Humidity-temperature cycling. 1000 megohms final minimum insulation resistance; termination resistance, dry circuit. Subject mated connectors 10 humidity-temperature cycles between 25 and 65C at 95% RH. AMP Spec 109-23-3 except with cold shock at -10C. Mixed flowing gas. Termination resistance, dry circuit. Subject mated connectors with 15 win gold plating to environmental class II for 10 days. AMP Spec 109-85-2, Subject mated connectors with 30 Win gold plating to environmental class III for 10 days. AMP Spec 109-85-3. Temperature life. Termination resistance, dry circuit. Subject mated connectors to temperature life. AMP Spec 109-43, Test level 9, Duration I. (a) Shall remain mated and show no evidence of damage, cracking or chipping. Figure 1 (end) PAGE | NO AAIMAEF An? incorporated Harrisburg, PA 17105-3608 5 ns AMP 1251-13 REV 10-85 108-25021Figure 2A Current Carrying Capability Note: To determine acceptable current carrying capacity for the percentage connector loading and wire gage indicated, use Multiplication Factor (F) from above chart and multiply it times Base Rated Current for a single circuit at maximum ambient operating temperature as shown on Figure 2A. Figure 2B Current Rating PAGE INO REV | Loc AARAF AMP incorporated Harrisburg, PA 17105-3608 108-25021 AMP 1251-13 REV 10-853.6. Product Qualification and Requalification Tests Test Group (a)(e) Test or Examination 1 | 27 3 [4m 5 7 6 | 7 [ 8 | 9 T 10 Test Sequence (c) Examination of product 1,9 1,10) 1,5/1,8731,5 1,8 Termination resistance, dry circuit 2,8) 2,4 2,4 {2,5 Dielectric withstanding voltage 3,7 Insulation resistance 2,6 Temperature rise vs current 3,9 Current cycling Crimp resistance 3,6 Vibration Physical shock Mating force So] Bol ONE ny Unmating force Contact retention Contact engaging force Contact separating force 4.8 Crimp tensile Durability 4 Thermal shock Thermal shock 500 cycle minimum Humidity- temperature cycling Mixed flowing gas 3() Temperature life See Para 4.1.4, BDiscontinuities shall not be Numbers indicate sequence in Does not apply to tin plated Test groups 9 and 10 are for Precondition samples with 10 (a) (b) (c) (d) (e) (f) measured for this test group. which tests are performed. contacts. retention of Qualification only. cycles durability. Figure 3 ARAL = AMP Incorporated Harrisburg, PA 17105-3608 7 PAGE [NO 108-25021 AMP 1251-13 REV 10-85Legend: Plating in contact area/under plate/ plating in crimp area Test Group | Plating Configuration Base Material (Thickness in Win) 100Sn/30Ni/100Sn BeCu 30Au/50Ni/1005n CuSn- PhBz 1,2,4,7 15Au/50Ni/100Sn CuSn-PhBz 15Au/50Ni /AuFlash BeCu 30Au/50Ni /AuFlash BeCu 15Au/50Ni /AuFlash BeCu 3,8(a) 100Sn/30Ni/100Sn BeCu 15Au/50Ni/1005n CGuSn-PhBz 30Au/S5ONi /AuFlash BeCu 15Au/50Ni/100Sn CuSn-PhBz 5 15Au/50Ni/AuFlash BeCu & CuSn-PhBz 15Au/50Ni/50Ni BeCu 30Au/50Ni/AuFlash BeCu 6 Optional Optional (a) For test group 8 crimp resistance and tensile use only the following plating types. Plating Configuration (Thickness in Win) Base Material 1005n/30N1/100Sn BeCu & CuSn-PhBz L5Au/S50Ni/50Ni BeCu ' 15Au/50Ni/AuFlash BeCu & CuSn-PhBz Figure 4 4. QUALITY ASSURANCE PROVISIONS 4.1. Qualification Testing A. Sample Selection Connector housings and contacts shall be prepared in accordance with applicable instruction sheets and shall be selected at random from current production. Test groups 1 through 4, and 7 shall consist of minimum of 2 connector assemblies loaded with minimum of 40 receptacles for each plating type and base material as indicated in Figure 4. Test proup 5 shall consist of minimum of 2 connector assemblies loaded with minimum of 40 receptacles for each plating type and base material, except full tin plated receptacles. Test group 6 shall consist of 5 housings each fully loaded with receptacles. Test group 8 shall consist of 30 receptacles of each plating type, base material and wire size (AWG 20, 22, 24, 26, 28, 30, and 32). All contacts shall be crimped in accordance with AMP Specification 11214-25003. Test measurements shall be performed on all receptacles. B. Test Sequence Qualification inspection shall be verified by testing samples as specified in Figure 3. REV | toc RAF = AMP incorporated Harrisburg, PA 17105-3608 8 108-25021 AMP 1251-13 REV 10-854.2. Retention of Qualification If, in a 3 year period, no changes to product or process occur, product shall be subjected to test groups 9 and 10 of testing described in test sequence, see Figure 3. Justification for exceeding this time limit must be documented and approved by division manager. 4.3. Requalification Testing If changes significantly affecting form, fit or function are made to product or manufacturing process, product assurance shall coordinate requalification testing, consisting of all or part of original testing sequence as determined by development/product, quality and reliability engineering. 4.4, Acceptance Acceptance is based on verification that product meets requirements of Figure 1. Failures attributed to equipment, test setup or operator deficiencies shall not disqualify product. When product failure occurs, corrective action shall be taken and samples resubmitted for qualification, Testing to confirm corrective action is required before resubmittal. 4.5. Quality Conformance Inspection Applicable AMP quality inspection plan will specify sampling acceptable quality level to be used. Dimensional and functional requirements shall be in accordance with applicable product drawing and this specification. PAGE | NO ARKRAF AMP Incorporated Harrisburg, PA 17105-3608 9 108-25021 AMP 1251-13 REV 10-85Termination Resistance Measurement Points Crimp Resistance Measurement Points aut l . rT d y ire / A Panel Wire . Post (See Note) far. Power A / Supply Note: Post plating shall be identical to receptacle plating when conducting tests, see Figure 4. Thermocouple 3 Places 1 Side aa A gan (| itt UTUUUUT TUTTI of Thermocouple Place Thru Hole Drilled in Housing Figure 5 Resistance and Temperature Measurement Points REV | LOC AMP Incorporated Harrisburg, PA 17105-3608 10 108-25021 AMP 1251-13 REV 10-85To be ground in lengthwise direction only .62 L .010 *.005 Blend R Typ 15 41 Typ Note: 1. Tolerances shall be + .005 or 2 as applicable, unless otherwise specified. 2. Material shall be tool steel, AISI type 01 per AMP Specification 100-3. 3. Heat treat to Rockwell C60-62. 4. Gage surface shall be clean of contaminate or lubricants. Gage Number! A Dimension +.0000 1 .0260 - O00L +.0001 2 -9240 | g990 Figure 6 teow Melle Econ oo Flat Typ va 4 Sides Engaging and Separating Gages AAKRAF = AMP Incorporated Harrisburg, PA 17105-3608 PAGE |NO 11 AMP 1251-13 REV 10-85 l Rev 108-25021 0 LocWire Bundle Receptacle Clamp P.C. Board Moot Til > CO) cng ee LLL L TL TTI AGA T ITZ LITT) Header Figure 7 Mounting and Clamping Location for Vibration and Physical Shock A = PAGE | NO REV | Loc vi AMP Incorporated Harrisburg, PA 17105-3608 12 108-25021 o |B AMP 1251-13 REV 10-85