Ow o So 2S a 2 1. SCOPE PRODUCT SPECIFICATION CONNECTORS, SERIES "G" This specification establishes the physical and performance requirements for the modular Series "G" Connectors. provisions applicable to product manufactured to this specification. I,1, Product Configuration It also describes the testing and quality assurance This specification covers inultiple position module housings (cially) phthalate or phenolic) installed in various shells which will accommodate from one to three niudules, All modules have the same facial envelope dimensions and vary only in the type and number of contacts each will accommodate. No, of Contacts Module Will Accommodate These Variations of Contacts 4 Type XIf 4 Miniature COAXICON Contacts or Type [, Size 12 Miniature COAXICON Contacts or 4 - Miniature COAXICON and 4 - Type I Size 12 Contacts li 6 - Miniature COAXICON or Type I, Size 12 and 5 - Type II, Size 16 (Long), Type III (+) Size 16 or Subminiature COAXICON (Long Pin) Contacts 14 2 - Type XII and 12 - Type II, Size 16 (Long), Type III 4) Size 16 or Subminiature COAXICON (Long Pin) Contacts 23 Type Il, Size 16 (Long), Type IIT (+) Size 16 or Subminiature COAXICON (Long Pin) Contacts FIG. i Mcdules L A~9-79 AMP INCORPORATED Harrisburg, Pa. A Rev per EFCN C131 DLT EE] Rud Schehadd 212-73) 2 [A] !08-l0002 REV PRINT DIST and released SHEET |"*"* LTR REVISION RECORD DR cHK [PATE 1 OF 1L Connectors, Series "G" 1250-13 REV 2/72 xWN o S 2. REFERENCE DOCUMENTS The following documents form a part of this specification to the extent referenced herein, 2.1. Military and Federal Specifications MIL-M-14 Molding Plastic and Molded Plastic Parts; Thermosetting MIL -S-7947 Steel (#1095) MIL -W-16878 Wire, Electrical Insulated, Copper MIL -[-45208 Inspection System Requirements QQ-A-591 Aluminum Alloy Die Castings QQ -P-416 Cadmium Plating (Electrodeposited) QQ-N-290 Nickel Plating (Electrodeposited) 0-5-6640 Stecl, Curbon QQ-S-763 Stecl, Corrosion Resistant 2.2, AMP Specifications LOY-1 Definitions of Terms and Methods used in AMP Test Specifications 108-10101 Product Specification for Type I] and Type I+ Contacts 108 -10102 Type XII Contacts 108-10108 Type I Contacts GPS-501-1 Miniature Coaxicon Contacts GPS-501-6 Sub-Miniature Coaxicon Contacts 112-230 Passivation of Stainless Steel 2.3. Military Standards MIL-STD-1!05 Sampling Procedures and Tables for Inspection by Attributes ly MIL-STD-202 Test Methods for Electronic and Electrical Components Parts 2.4, Other Documents Powder Metallurgy Parts Manufacturers Association - BZN-1818-U Nickel Silver Powered Metal 3. DESIGN REQUIREMENTS 3.1. Intended Use The Series "G" Connector hus becn designed to provide a multiple position connector which combines signal, power, and coaxial circuits in one basic connector style. The connector provides easy assembly and maintenance, ready circuit identification, case of circuit change, and repeated connect-disconnect capabilities, r T | AMP INCORPORATED 2_OF 1 mR A NO. iO8- ljooo02 "AL Connectors, Series "G" MAME 2783-2 REV 2/72 aNUMBER 108-10002 3,2, Physical Characteristics The dimensions of all components and assemblies which constituted the Series "G" connector system shall meet the requirements contained on applicable drawings. The materials and finishes used shal] be as specified in the following parapraphs. Substitute materials and finishes may be authorized only after the performance and life equivalency of the substitute has been demonstrated. 1251-13 REV 2/72 A. Connector Assembly A connector assembly consists of a mated plug assembly and receptacle assembly wired with a full complement of contacts which have been crimped to wire. The assembly also includes accessory hardware. B. Plug Assembly A plug assembly consists of a shell sub-assembly which will accommodate from one to three pin or socket modules. C. Receptacle Assembly A receptacle assembly consists of a shell sub-assembly which will accommodate from one to three pin or socket modules. D. Shell Sub-Asscembly The shell sub-assembly consists of a die cast shell and retainer conforming to QQ-A-591 aici cadmium plated per QQ-P-416, E. Pin and Socket Module The wedules arc molded plastic blocks categorized! by the number of contacts, the type of contacts, and the type of plastic material, The plastic molding material shall conform to MIL=M-14, Type SDG-F (Diallyl Phthalate) or Type CFG (Phenolic). F. Shields and Cable Clamps The shields and cable clamps shall be die cast from material conforming to QQ-A-591 and cadmium plated per QQ-P-416. G. Locking Latch Assembly Tne assembly consists of a spring catch made from nickel silver powdered metal conforming to PMPMA-RZN-1818-U and a spring caich plate conforming to Q-S-640, The spring catch plate shall be nickel plated per QQ-N-290. H. Locking Spring and Locking Spring Catch Both the locking spring and the locking spring catch shall be fabricated from stecl conforming to MIL-S-7947 and nickel plated per QQ-N-290. SOF Lt AMP INCORPORATED Ss HEET Harrisburg. Pa. oor A | 108-1002 REV NAME Connectors, Series "G" 7_-->I. Screws Al} screws which are component parts of the various assemblies shall be stainless steel conforming to QQ-S-763 and passivated per AMP Specification 112-230, 3.3. Performance and Environmental Requirements The Series "G" Connector has been designed to equal or exceed the tollowing rating for principal characteristics. A, Toiperature Ratio The upper temperature limit includes current heating effects associated with various contact current loads. Dielectric Material Operating Temperature Type CRG (Phenolic) ~55C to +125C Type SDG-T' (Diallyl) ~65C to +150C The temperature range of a particular connector assembly may be further reduced by including one or more of the following components; Miniature or Sub-Miniature Coaxicon Contact (-55C to +85C) Type X00 Contacts (-55C to +105C) Cable Bushing (-55C to +145C) B. Insulation Resistance - See Figure 2 C. Dielectric Strength - See Figure 3 D. Vibration - 10G @ 10 to 500 hertz E. Mechanical Sheck ~ 50G F. Durability - 500 cycles G. Contact Retention Type 1 & Hi: 10 pounds Type I: 15 pounds Type XII: 25 pounds SHEET AMP INCORPORATED | Harrisburg, Pa. 4 OF LL 3 TA] 108-10002 |< Connectors, Series "G" NAME 2763-2 REV 2/72v (08-10002 4. TEST REQUIREMENTS AND TEST METHODS 4.1, Test Environments and Conditions Unless specifically stated, tests and examinations required by this specification shall be conducted under any combination of conditions within the following ranges. Temperature: 20 to 30C Relative Humidity: 30 to 38U percent narometric Pressures: 24 to 31 inches of mercury 4.2, Test Measurements Whenever possible, all testing shall be conducted in a manner which yields variables data. Unless otherwise specified, a minimum of 15 random measurements shall be recorded, 4.0. Examination of Product Before, during, and after testing the test operator shall visually examine all hardware, to note and record original and changed characteristics with respect to; surface finish, texture, color, cracks, etc. Changes in physical characteristics beyond drawing and/or specification allowances shall be considered a test failure. 4.4. Insulation Resistance A, Requirements When tested in accordance with Para, 4.4.B., the insulation resistance shall not be less than the values specified in Figure 2. ; . Insulation Resistance, Megohms Type Material Initial Final CFG Phenolic 5,060 100 SDG-+F Diallyl 50, 000 5, 000 FIG. 2 5h. Test Method The insulation resistance of unmated connector assemblies shall be tested in accordance with MIL-STD-202, Method 302, Test Condition B. The following detuils shall apply: (1) Duration of applicatiou of test voltupe - 1 minute, (2) Points of application of test voltage - between contacts alternately connected and between contacts and shell (See Figure 6). AMP IncOoRPORATED SHEET Harrisburg, Pa. SOFU 3 LA 108-l0002 NAME Connectors, Series "C"' 1291-13 REV 2/72 4Ol 5 S i S 4.5. Dielectric Strength A. Requirement When tested in accordance with Para. 4.5.B., the connectors shall show no evidence of flashover or corona when the voltages specified in Pigure 3 are applicd. Dielectric Strength,] Voltage AC RMS Altitude Modules With Modules With Only Mixed Contacts Type XII Contacts Sea Level 900 1,500 25,000 Feet 600 1,000 30, 000 Feet 300 750 FIG. 3 B. Test Method The unmated connector assemblies shall be tested in accordance with MIL-STD-202, Method 301 at the voltages and simulated altitudes specified in Figure 3, The modules shall be wired as shown in Figure 6 and the voltage applied between all adjacent contacts and between the shell and closest contacts. The test voltage shall be applied at a rate not exceeding 500 volts per second until the applicable voltage of Figure 3 is reached. The specified voltage shall be maintained for one minute, 4.6. Durability 4.7, A. Requirement When tested in accordance with Para. 4.6.B., the connector assemblies shall show no evidence of mechanical damage. B. Test Methuxl The connector assemblies shall be subjected to 500 cycles of mating and unmating. The cycling shall be conducted in a manner which simulates service at a rate not exceeding 500 cycles per hour, Vibration A, Requirement When tested in accordance with Para. 4.7.8., the connector assemblies shall show no evidence of cracking, breaking, loosening of parts, nor loss of continuity of any contact circuit greater than one microsecond, AMP INCORPORATED SHEET Harrishurg, Pa. | OFU = TA] [08-0002 REY N&aME Connectors, Series "CG" 2763-2 REV 2/72B. Test Method The mated connector assemblies shall be vibrated in accordance with MIL-STD-202, Method 204, Condition A. The connector assemblies shall be tigicly attached to the vibration fixture. The wires shall be secured toa stable support external to the vibrating table at a distance of 8 inches. The wires between the assemblies and support shall approximate the neutral condition of either slack nor tension. All contacts shall be series wired and connected toa suitable testing circuit with 0.1 ampere flowing through the contacts, om 1908-10002 4.38. Physical Shock A. Requirement When tested in accordance with Para, 4.8.B., the conuector assemblies shall show no evidence of cracking, breaking, loosening of parts, nor loss of continuity of any contact circuit greater than one microsecond, B. Test Metho! The mated connector assemblies shall be subjected to a shock test in accordance with MIL-STD-202, Method 205, Condition C. All contacts shall be series wired and connected to a suitable testing circuit with 0.1 ampere flowing through the conlwets. The shock test shall be cepeated 3 times in both dircetions of tie referenced 90 axis planes (@ total of 18 drops). \ 4.9, Thermal Shock A. Requirement When tested in accordance with Para. 4.9.B., the connector assemblies shall show no evidence of inechauical damage, B. Test Methol The mated assemblies shall be subjected to temperature cycling in accordance with MIL-STD-202, Method 107, The minimum and maximum temperature shall be as specified tn Para. 3.3.A. 4.00. Moisture Resistance A, Requirement When tested in accordance with Para, 4.10.3., the assemblies shall show no evidence of corrosion. B. Test Method The unmated connector assemblies shall be tested in accordance with MIL-STD-202, Method 106, except that Step 7B is not required. _| . AMP INCORPORATED rer AT 108-l0002 |*. Connectors, Series "G"' on 1251-13 REV 2/724.11. Contact Retention A. Requirement When tested in accordance with Para, 4.11.B., the contact retention shall not be less than the applicable valucs specified below. Type I, & IH: 10 pounds Type I: [5 pounds Type X[I: 25 pounds Bh. Test Method The contacts shall be extracted and inserted 10 times using the applicable extraction tool, After the eleventh insertion, the connector shall be mounted to an appropriate fixture and the force to dislodge the contact from the cavity measured and recorded. The load shall be applied uniformly to the contacts from the mating: fuce at approximately 5 pounds per second, 3. QUALITY ASSURANCE PROVISIONS 9.1. General Requirements Connector assemblies furnished under this specification shall be a product which has been tested and has passed the test sequence specified in Figure 5. Qualification testing shall demonstrate the cffectiveness of the manufacturing processes and the quality processes on a product which has previously demonstrated its ability to meet the product design requirements of Para. 3. Qualification testing shall be conducted ona product which represents established materials, processes, and production tooling. Ff Re -qualification testing shall occur at 18 month intervals or subsequent to any material, process, or tooling change that can cffect the product performance, 3.2. Lot Acceptance Inspection Piece parts, sub-assemblies, and finished assemblies shall be subjected to inspection and tests to assure product conformance to Para. 3 of this specification. Dimensional and visual inspections shall be performed using both sampling and 100% inspection methods, The inspection system shall meet the requirements of MIL-STD-105 and MIL-[-45208. AMP as the responsible authority shall sclect the sampling: plan, the plan level, and the acceptance quality level in order to assure the quality of the tindshed assemblies. A 1.0% AQL is used for major defects and 4.0% is used for minor defects. A major defect is defined as one which can degrade the performance or reliability of the product to the point where it will not meet the requirements of Para. 3. A minor defect is defined as one which will not significantly degrade the performance or reliability of the product to the point where it will not meet the requirements of Para, 3. OF libs nO. % TAT 108-0002 |" Connectors, Series "G" NAME 2794-2 REV 2/72_["" 108-1002 5.3, Qualification Test Samples The connector asscmblies for test shall be wired with a full complement of contacts which have been crimped to wire, The wire used with Type I, U1, and [ft contacts shull meet the requirements of MIL-W-16878, Type E. The wire used with Type XII comacts shall mect the requiccments of MIL-W-16878, Type D. Each connector assembly shall utilize one of the available plug to receptacle fastening methods. All cotTnector hardware shall be represented in the test package. A. Individual Module Qualification if an individual pair of module part numbers are to be qualified, 6 module pairs shall be installed ina "G" 1, "G" 2, and "G" 3 shell sub-assemblies, The connector assemblies shal! be subjected to the test sequence of Figure 5, 8B, Connector Family Qualification If the family of Series "'G" connectors is to be qualified, a total of 12 connector assemblies shall be subjected to the test sequence of Figure 5. The 12 connector assemblies, as shown in Figure 4, shall] include 3 modules of cach part number. Co tor Famil Plug With Pin Modules Plug With Socket Modules mes y Diallyl Phenolic Diallyl Phenolic Shell "G" 1 | | Assy | Assy I Assy 1 Assy "Ga" 2 i Assy | Assy 1 Assy 1 Assy Sub-Assembly "G'3 | | Assy 1 Assy I Assy lt Assy FIG. 4 3.4. Test Documentation and Failures A formal report containing test data, analysis summarics, and product evaluation shall be issued at the completion of each qualification test program. Unless otherwise specified, all performance characteristics shall fall within established limits 99% of the time at a confidence level of 95%. Failures attributed to causes such as test set-up, equipment, or operator deficiencies will not disqualify the product; however, that portion of the test shall be re-run after correction of the cause. AMP INCORPORATED HEET 2 OFIL 31 A | 108-l0002 REY A NAME Connectors, Series "Gi" 1257-13 REV 2/72NUMBER 108-0002 2783-2 REV 2/72 Qualification Test Test Sequence Requirement Paragraph Examination of Products 4.3. Insulation Resistance (Initial) 4.4. Dielectric Strength 4.5, Thermal Shock 4.9, Durability 4,6, Vibration 4./, Physical Shock 4.8. Moisture Resistance 4,10, Insulation Resistance (Final) 4.4, Dielectric Strength 4.5. Contact Retention 4.11, FIG, 3 SHEET AVOF il Harrisburg, Pa. AMP INCORPORATED = TAI 108-l0002 REV MAME Connectors, Series "G"4 Position (Type XID """ 1908-10002 8 Pasition fo 14 Position QE 4 Position 4 Position (Type XII) 8 Position Ll Position 14 Position 23 Position FIG. 6 Wiring Diagram, Suggested Method for Insulation Resistance and Dielectric Strength Tests 4 Position ei Ll Position seh O-eF a4 23 Position 1 AMP INCORPORATED LLOF ili BLA 108-10002 REV A qNAME 1251-13 REV 2/72 z Comnectors, Series "G" _j