PRODUCT SPECIFICATION os. SCOPE 1.1L. Content This specification covers the performance, tests and quality requirements for AMPLIMITE connectors with shielding hardware. 1.2. Qualification When tests are performed on the subject preduct 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 4 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 ETA RS-364) Cc. Corporate Bulletin 401-76: . Cross-reference between AMP Test Specifications and Military or Commercial Documents D. 114-40006 : Connectors, AMPLIMITE HDE-20 for Overmolding E. 114-40007 : Connectors, AMPLIMITE HDP-20 for Overmolding F 501-83 : Test Report 3. REQUIREMENTS 3,1. Design and Construction Product shall be of the design, construction and physical dimensions specified on the applicable preduct drawing. Trademark of AMP Incorperated ALL INTERNATIONAL RIGHTS RESERVED. copyacHT 1385, 88 BY AMP INCORPORATED 2, Lib ipofeh | AMP | AMP INCORPORATED | Go a. ao rf 3 Harrisburg, Pa. 17105 "Uy amar u/e/e@ NOy 08-40030 REV woe O Release per ~2.\f2 TITLE GONNEGTOR, AMPLIMITE, ECN BD-2598 PAGE SHIELDING HARDWARE LTR REVISION RECORD APP | DATE tor / AMP 1250-16 REV 7-873.2. Materials A, Commnector (1) Shields: Thermoplastic, UL 94V-0 (2) Shells: Steel B. Hardware (1) Shields: Steel (2) Ferrules; Copper 3.3. Ratings A. Current (1) AMPLIMITE HDP-20: 7.5 amperes per contact maximum (2) AMPLIMITE HDE-20;: 5.0 amperes per contact maximum, see Para.3.5. (a) B. Storage Temperature: -55 to 105C. While this is the operating temperature of the connector, the operating environment used must not exceed the Limits of either the connector or the cable 3.4. Performance and Test Description Connectors and hardware shall be designed to meet the electrical, mechanical and environmental performance requirements specified in Figure 1. Since the results of many of the tests are dependent not only on the hardware and the connectors, but also on the cable, the cable must be chosen to meet the electrical, mechanical and environmental performance requirements in Figure 1 or the stresses derated appropriately 3.5. Test Requirements and Procedures Summary Test Description Requirement Procedure Examination of Product Meet requirements of Visual, dimensional and product drawing and AMP functional per applicable Spec 114-40006 and inspection plan. 1414-40007 ELECTRICAL Dielectric Withstanding 1.0 kvac dielectric Test between contacts Voltage withstanding voltage, one and shield of mated minute hold. One milli- connector assemblies; ampere maximum leakage AMP Spec 109-29-1. current. Figure 1 (cont) Rev | Loc AMP INCORPORATED 108 -40030 o |B AMP | Harrisburg,Pa. 17105 AMP 1251-13 REV 10-85Test Description Requirement Procedure Shtelding Effectiveness ' Shielding shall decrease Measure shielding emissions by the following | effectiveness of double minimum levels: ended single braid cable; MHz Shielding AMP Spec 109-90, 30 to 216 35 dB L 216 te 1000 15 dB MECHANTCAL Vibration (b) No discontinuities greater | Subject mated connectors than 1 microsecond, to 10-55-10 Hz traversed | in 1 minute at .06 inches total excursion; 2 hours in each of 3 mutually perpendicular planes; AMP Spec 109-21-1. Physical Shock No discontinuities greater | Subject mated connectors than 1 microseconds. to 50 G's half-sine in 11 milliseconds; 3 shocks in each direction applied along the 3 mutually perpendicular planes; AMP Spec 109-26-1. Cable Pullout No discontinuities greater | Gradually apply 50 pounds than 1 microsecond for weigh to cable, gee shield circuit. Figure 3, maintain weight for 1 hour; AMP Spec 109-46, cond A. Circular Jacket Cable No evidence of damage, Subject cable to 100 Flexing eracking or chipping. cycles at a rate of 12 to 14 cycles per minute, see Figure 4; AMP Spec 109-20. ENVIRONMENTAL Thermal Shock (b) (c) Dielectric withstanding Subject mated connectors voltage; insulation to 5 cycles between -55" resistance. and 105C; AMP Spec 109-22. Industrial Mixed Flowing Shielding effectiveness Subject mated conmectors Gas final to environmental class III for 10 days; AMP Spec 109-85-3. (a) Maximum rated current that can be carried by this product is limited by maximum operating temperature of housings, which is 30C. Variables which shall be considered for each application are: wire size, connector size, contact material, and ambient temperature. Figure 1 (cont) Harrisburg,Pa. 17105 AMP INCORPORATED AMP | L08- 40030 AMP 1251-13 REV 70-85(b>) Shall remain mated and show no evidence of damage, cracking or chipping. (c) The temperature range of this test must be adjusted as necessary to assure that the temperatures of the cable assemblies are exposed to shall not exceed the temperature rating of either the cable or the connector. Figure 1 (end) 3.6, Connector and Hardware Qualification and Requalification Tests and Sequences Test Grow a Test or Examination est quence Examination of Froduct electric thst e ectiveness ration Sica e ou Yeular Jacket cable ex industrial Mixed Flowing Gas (a) See Para 4,1.A, (b} Numbers indicate sequence in which tests are performed. Figure 2 4. 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. All test groups shall consist of a minimum of 6 double ended cable assemblies of each type (HDE-20 and HDP-20) with shielding hardware crimped on but not overmolded. The cable shall be constructed as follows: CL) 0.032 inch maximum single jacket, 75 to 80 shore durometer (2) Overall tinned copper braid, 90% coverage. (3) Overall foil shield with drain wire (4) The above items constitute approximately 88% of the cross sectional area of the cable (5) All contacts terminated. Each cable assembly shall have a cable length of 6 feet * .5 inch between the connector back shells as specified in AMP Test Specification 109-90. B. Test Sequence Qualification inspection shall be verified by testing samples as specified in Figure 2. AMP INCORPORATED PAGE |NO REV | Loc AMP | Harrisburg,Pa. 17105 4 108-40030 o |B AMP 1251-13 AEV 10-85Cc. Acceptance (1) 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 Xbar and gs 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. Then the upper one-sided tolerance limit for 99% reliability at 95% confidence is given by Xbar + ks. The interpretation of this tolerance limit fs as follows: based on the test data, and assuming a normal distribution fer the test data, we can be 95% confident that 99% of the population of values represented by the sample data will not exceed Xbar + 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 Xbar + ks does not exceed the requirement value. The lower one-sided tolerance limit for 95% confidence and 99% reliability is given by Xbar -_ ks, This has a_e similar interpretation and corresponding application to lower requirement values, (2) Failures attributed to aquipment, test setup, or operator deficiencies shall not disqualify the product. When product failure oceurs, corrective action -shall be taken and samples resubmitted for qualification. 4,2. Requalification Testing Requalification shall be established by the cognizant divisional engineering function and may consist of all or any part of the overall qualification pregram provided that it is conducted within the required time period. 4.3. Quality Conformance Inspection The applicable AMP inspection plan will specify the sampling acceptable quality level to be used. Dimensional and functional requirements shall be in accordance with the applicable preduct drawing and this specification. AMP INCORPORATED PAGE | NO | Rev | Loc AMP | Harrisburg,Pa. 17105 5 108 -40030 > | 8 AMP 1251-13 REV 10-85UUL UU mn ry oy G? 7 3 co WwW LJ ef === nana AnANA Weight Figure 3 Cable Pullout REV | LOC AMP INCORPORATED Harrisburg,Pa. 17105 108-40030 amp | AMP 4251-13 REV 10-85St Connector mounted to rotating fixture using normal mounting hardware. (Connector not mated with its counterpart) No weight was applied Sf Cable clamped 14 inches below during flex testing crimp ferrule Figure 4 Circular Jacket Cable Flexing AMP INCORPORATED Harrisburg,Pa. 17105 ARAPFP | 108-40030 AMP 1257-13 REV 10-85