re PRODUCT SPECIFICATION l. SCOPE 1.1. Content This specification covers the performance, test and quality requirements for the AMPLIMITE HDP-22 subminiature D connectors with removable F crimp contacts for 22 thru 28 AWG. The assembly consists of a two piece plastic housing which has integral plastic retention tines and two metal shells which secure the housing components. 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 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 Documents 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) Cc. Corporate Bulletin 401-76: Cross-reference between AMP Test Specifications and Military or Commercial Documents D. 114-10001 : Application Specification E. 501-156 : Test Report F 27280: Gage Pin, Engagement Test, Socket Contact 3. REQUIREMENTS 3.1. Design and Construction Product shall be of the design, construction and physical dimensions specified on the applicable product drawing. ALL INTERNATIONAL RIGHTS RESERVED. COPYRIGHT 19 89 BY AMP INCOR! * Trademark of AMP Incorporated Preduct Code: 5889 ma _ bd ' ay AMP | CHK AMP Harrisburg, PA 17105-3608 Wlhax heperyroht Laud Af *n|" 108-1268 |" QO Release per LE 9/23 TITLE CONNECTOR, AMPLIMITE HDP-22, ECN BD-5403 GO PAGE SUBMINIATURE D CONNECTOR, WITH LTR REVISION RECORD APP |! DATE 10F 10 REMOVABLE F CRIMP CONTACTS 7a AMP 1250-16 REV 7-873.2. Material A. Contact: (1) Pin: Brass (2) Socket: Phosphor bronze B. Housing: 3.3. Ratings A. Voltage: 250 vac B. Current: (1) 22 AWG, 1.9 amperes (2) 26 AWG, 1.1 amperes (3) 28 AWG, .95 amperes Cc. Temperature: -55* to 105 3.4. Performance and Test Description Thermoplastic, glass filled, UL 94V-0 Fully loaded and energized connectors The product is designed to meet the electrical, mechanical and environmental performance requirements specified in Figure 1. ambient temperature unless otherwise specified. 3.5. Test Requirements and Procedures Summary All tests are performed at Test Description Requirement Procedure Examination of Product Meets requirements of product drawing and AMP Spec 114-10001. Visual, dimensional and functional per applicable quality inspection plan. | ELECTRICAL Termination Resistance, Wire Test Resistance Specified Current Size current maximum AWG ampere milliohms 22 1.9 15 26 1.1 15 28 95 15 Measure potential drop of mated contacts assembled in housing, see Figure 4; AMP Spec 109-25, calculate resistance. Termination Resistance, 15 milliohms maximum Bry Circuit Subject mated contacts assembled in housing to 50 mv open circuit at 100 ma maximum, see Figure 4; AMP Spec 109-6-1, Dielectric Withstanding Voltage 1.0 kvac dielectric withstanding voltage, one minute hold. 1.0 milliampere maximum leakage current, Test between adjacent contacts of unmated connector assemblies; AMP Spec 109-29-1. Insulation Resistance 5000 megohms minimum initial. 500 megohms minimum final. Test between adjacent contacts of unmated connector assembly; AMP Spec 109-28-4 Figure 1 (cont) ARAP _s AMP incorporated Harrisburg, PA 17105-3608 AMP 1251-13 REV 10-85 PAGE {NO Loc 2 108-1268 BTest Description Requirement Procedure Temperature Rise vs Current Maximum temperature rise at specified current, 30C. Reference Para 3.3.B at a max. ambient of 70C. Measure temperature rise vs current; AMP Spec 109-45-1. MECHANICAL Vibration Random No discontinuities greater than 1 microsecond. See note (a). Subject mated connectors to 20 G rms with 100 ma. current applied AMP Spec 109-21-5, test level F. See Figure 3, 20 minutes each axis Physical Shock No discontinuities greater than 1 microsecond. See note (a). Subject mated connector to 50 G's half-sine shock pulses of 11 milliseconds duration; 3 shocks in each direction applied along the 3 mutually perpendicular planes total 18 shocks, see Figure 3; AMP Spec 109-26-1. Mating Force See note (b), Measure force necessary Number of W/O With |to mate connector Size Positions Grd. Grd. |assembly incorporated Indents free floating fixtures at 1 15 5.6 33 a rate of 1 inch/minute; 2 26 9.8 38 AMP Spec 109-42, cond A. 3 44 16.5 46 4 62 23.3 52 5 78 29.3 58 pounds maximum. Unmating Force See note (b). Measure force necessary Number of W/O With |to ummate connector Size Positions Grd. Grd. jassembly at a rate of Indents 1 inch/minute; AMP Spec 1 15 5.6 33 109-42, cond A. 2 26 9.8 38 3 44 16.5 46 4 62 23.3 52 5 78 29.3 58 pounds maximum. Contact Insertion Force 3 pounds maximum per contact. Measure force to insert contact into housing; AMP Spee 109-41. ARAP _ AMP incorporated Harrisburg, PA 17105-3608 AMP 1251-13 REV 10-85 Figure 1 (cont) PAGE i NO Loc 3 108-1268 BTest Description Requirement Procedure Contact Retention Contacts shall not Apply axial load of dislodge from the 3 pounds to contacts, connector housing. AMP Spec 109-30. Contact Engaging Force 8 ounces maximum per Measure force using contact. gage A, as indicated in Figure 5; AMP Spec 109-35, engagement depth .200. Contact Separating 0.75 ounces minimum per Size 2 times using Force contact, gage A, as indicated in Figure 5, insert gage B and measure force to separate; AMP Spec 109-35, separation i depth .200. Crimp Tensile Wire Crimp Tensile Determine crimp tensile Size, pounds at a rate of 1 inch/ AWG minimum minute; AMP Spec 109-16. 22 12 24 8 26 4.5 28 2.7 Durability See note (a). Mate and unmate connector assemblies for number of cycles indicated at a maximum rate of 200 cycles/hour; AMP Spec 109-27, Plating microinches Cycles Gold Flash 100 30 Gold 500 ENVIRONMENTAL Thermal Shock See note (a). Subject unmated connectors to 5 cycles between -55 and 105C: AMP Spec 109-22 Figure 1 (cont) AIMEF AMP incorporated Harrisburg, PA 17105-3608 PAGE |NO Loc 4 108-1268 B AMP 1251-13 REV 10-85Test Description Requirement Procedure Humidity-Temperature See note (a). Subject unmated Cycling connectors to 10 humidity-temperature cycles between 25 and 65C at 95% RH; AMP Spec 109-23-4, cond. B. Industrial Mixed See note (a). Precondition connectors Flowing Gas to 10 durability cycles. Subject mated connectors to environmental class III for 20 days; AMP Spec 109-85-3. Temperature Life See note (a). Subject mated connectors to temperature life at 105C for 500 hours duration; AMP Spec 109-43. (a) Shall meet visual requirements, show no physical damage, and shall meet requirements of additional tests as specified in the Test Sequence in Figure 2 (b) Grounding indents are on plugs. Figure 1 (end) PAGE | NO Loc JARAF? ANP Incorporated B Harrisburg, PA 17105-3606 5 108-1268 AMP 1251-13 REV 10-853.6. Product Qualification and Requalification Tests and Sequence Test Groups (a) Test or Examination 1 [2]; 3] 4[s5s76f7T7 8 Test Sequence (b) Examination of Product 1,10/1,6| 1,6; 1,6 | 1,6] 1,10[/1,5] 1,7 Termination Resistance, Specified Current 8 3 3 Termination Resistance, Dry Circuit . 3,7 2,5 2,5 2,4 2,4 2,4 Dielectric Withstanding 4.8 Voltage , Insulation Resistance 3,7 Temperature Rise vs Current Vibration Physical Shock Mating Force SOP Roy ON PLA kad] Unmating Force Hyun Contact Insertion Force wits Contact Retention Contact Engaging Force 2 had Contact Separating Force Crimp Tensile 4 Durability 4 3 3 4 Thermal Shock 2 Humidity-Temperature Cycle 4 6 Industrial Mixed Flowing Gas 3 Temperature Life 4 (a) See Para 4.1.4 (b) Numbers indicate sequence in which tests are performed. Figure 2 PAGE | NO VEE ss AMP Incorporated ~ Harrisburg, PA 17105-3608 6 108-1268 AMP 1251-13 REV 10-85LOCATION OF MONITORS (CLOSEST TO SHELL AS POSSIBLE) _ Figure 4 Mounting and Clamping Locations for Vibration and Physical Shock a PAGE | NO AMP INCORPORATED AMP | Harrisburg,Pa. 17105 7 108-1268 AMP 1251-13 REV 10-854. QUALITY ASSURANCE PROVISIONS 4.1. 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 production. Test groups 1,2,3and 5 shall each consist of 3 mated pairs with contacts of gold flash and 30 microinch gold in the contact area, crimped to 26 AWG wire. Test group 4 shall consist of 3 mated pairs each of largest size plug/receptacle connectors with gold flash contacts crimped on 22, 26 and 28 AWG wire. Test group 6 shall consist of connectors with gold flash contacts crimped on 26 AWG wire (loaded during testing). Test group 7 shall consist of 25 pairs of contacts crimped to each of 22, 24, 26 and 28 AWG wire sizes,without housings. Test group 8 shall consist of 5 mated pairs of each housing size 26, 44, 62 and 78 positions, loaded with gold flash contacts crimped to 26 AWG wire. Hardware clamps shall be used for all group 1 connectors. Connectors for vibration and physical shock shall be secured using screwlocks and male screws. Test group 2 thru 6 shall use cable clamps on all connectors. No hardware will be required for group 7. Test group 8 cable clamps are optional. B. Test Sequence Qualification inspection shall be verified by testing samples as specified in Figure 2. 4.2. Requalification Testing If changes significantly affecting form, fit, or function are made to the product or to the manufacturing process, product assurance shall coordinate requalification testing, consisting of all or part of the original testing i sequence as determined by development/product, quality, and reliability engineering. 4.3. Acceptance Acceptance is based on verification that the product meets the requirements of Figure 1. Failures attributed to equipment, test setup, or operator deficiencies shail not disqualify the product. When product failure occurs, corrective action i shall be taken and samples resubmitted for qualification. Testing to confirm corrective action is required before resubmittal. 4.4. Quality Conformance Inspection The applicable AMP quality 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. ARAP _s AMP incorporated Harrisburg, PA 17105-3608 PAGE [NO Loc 8 108-1268 B AMP 1251-13 REV 10-85Termination Resistance Measurement Points .12 Max oe y " i y tL bh SAN >] | a ia, ee ee fa Power aad Supply Figure 5 Resistance Measurement Points AMP INCORPORATED PAGE )NO ree AMP | Harrisburg,Pa. 17105 9 108-1268 B AMP 1251-13 REV 10-85LY Gage AMP P/N R +.0000 ~ | A 27280-6 .0305 - .0001 +,0001 B 27280-5 -0295 - .0000 SPHERICAL RADII SHALL BE 1/72 THE PIN DIAMETER AND SMOOTHLY BLENDED INTO IT ) 4 .007 x bia CMAX FLAT) 1.00 MIN 1. Gage Material: 100-97 2. Heat Treat to RC 68-70 3. This gage is for contact size 22 4. Pin te comply with MS 3197 3. Finish: 6-10 microinches RMS Figure 6 AMP INCORPORATED AMP Harrisburg,Pa. 17105 0 108-1268 o | 8 AMP 1251-13 REV 10-854.4, Acceptance Acceptance is based on verification that the product meets the requirements of Figure 1. Failures attributed to equipment, test setup, or operator deficiencies shail not disqualify-the product. When product failure occurs, corrective action shall be taken and samples resubmitted for qualification. Testing to confirm corrective action is required before resubsittal. 4.5. Quality Conformance Inspection The applicable AMP quality 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. MP INCORPORATED PAGE |NO T Rev | Loc A amp | Harrisburg,Pa. 17105 11 108-1268 o |B AMP 1251-13 REV 10-85Termination Resistance Measurement Points .12 Max Pe Figure 5 Resistance Measurement Foints amp | AMP 1281-13 REV 10-85 AMP INCORPORATED Harrisburg,Pa. 17105 108-1268 REV Loc+,.0000 0305 - 9001 | | +.0001 27280-5 .0295 - ,0000 SPHERICAL RADI! SHALL BE 1/72 THE PIN DIAMETER AND SMOOTHLY BLENDED INTO IT tooo? x ora CMAX FLAT) MIN Gage Material: 100-97 Heat Treat to RC 68-70 This gage is for contact size 22 Pin to comply with MS 3197 Finish: 6-10-microinches RMS whe Figure 6 REV | iLoc AMP INCORPORATED AMP [ Hartisburg,Pa. 17105 108-1268 o |B AMP 1251-13 REV 10-85