NUMBER TYPE BUS-12-071 PRODUCT SPECIFICATION TITLE PAGE Low Profile Jumper - Gold or GXT Plated REVISION 1 of 15 AUTHORIZED BY G DATE 05/15/12 J.ZHOU CLASSIFICATION UNRESTRICTED 1.0 GENERAL Scope - This specification covers gold or gold flash over palladium alloy plated low profile jumper connectors designed for low power interconnection of two adjacent 0.025 inch square pins, free standing or in headers, on 0.100 inch centers. This specification is composed of the following sections. This product meets the requirements of the European Union Directive of Restrictions for Hazardous Substances (Directive 2002/95/EC). The specification is composed of the following sections. Paragraph 1.0 2.0 3.0 3.1 3.2 3.3 3.4 3.5 3.6 3.7 4.0 4.1 4.2 4.3 4.4 5.0 2.0 Title Page GENERAL APPLICABLE DOCUMENTS REQUIREMENTS Qualification Material Finish Design and Construction Electrical Characteristics Mechanical Characteristics Environmental Conditions QUALITY ASSURANCE PROVISIONS Equipment Calibration Inspection Conditions Qualification Inspections Requalification Testing NOTES AND DEFINITIONS 1 1 2 2 2 2 3 3 6 7 11 11 12 12 13 16 APPLICABLE DOCUMENTS The following documents, of the issue in effect on the date of the latest revision of this specification, shall form a part of this specification to the extent specified herein. Military Specifications MIL-M-24519 MIL-C-45662 MIL-P-55110 MIL-G-45204 MIL-P-45209 MIL-STD-202 MIL-STD-275 MIL-STD-1344 Molding Plastics, Polyester, Thermoplastics Calibration System Requirements Printed Wiring Boards Gold Plating, Electrodeposited Palladium Plating, Electrodeposited Test Methods for Electronic and Electrical Component Parts Printed Wiring for Electronic Equipment Test Methods for Electrical Connectors Federal Specifications QQ-N-290 Nickel Plating (Electrodeposited) QQ-B-750 Phosphor Bronze PDS: Rev :G Copyright Form E-3334 Rev F STATUS:Released Printed: May 22, 2012 FCI GS-01-001 NUMBER TYPE BUS-12-071 PRODUCT SPECIFICATION TITLE PAGE Low Profile Jumper - Gold or GXT Plated REVISION 2 of 15 AUTHORIZED BY G DATE J.ZHOU 05/15/12 CLASSIFICATION UNRESTRICTED Industry Specifications/Standards 3.0 ASTM B-103 Phosphor Bronze Plate, Sheet, Strip and Rolled Bar, Spec. for DOD ADOPTED UL-94 Tests for Flammability of Plastic Materials REQUIREMENTS 3.1 Qualification Connectors furnished under this specification shall be products capable of meeting the qualification test requirements specified herein. 3.2 Material The material for each part shall be as specified herein, or equivalent. Substitute material shall meet the performance requirements of this specification. 3.3 3.2.1 Terminal. The body shall be 1/2 hard phosphor bronze strip C51000 in accordance with QQ-B-750 and CA-510 specification. 3.2.2 Insulator Housing. The housing material shall be unfilled Polyester in accordance with BUS-16-028. The material shall be rated flame retardant 94 V-O in accordance with UL94. or 3.2.3 Insulator Housing. The housing material shall be 17-20% glass filled Polyester in accordance with BUS-16-025. The material shall be rated flame retardant 94 V-0 in accordance with UL-94. Finish 3.3.1 PDS: Rev :G Copyright Form E-3334 Rev F Terminal. 3.3.1.1 The terminal shall be plated in the contact area with 15 microinches (minimum) gold per MIL-G-45204 or a thin gold flash over 15 microinches (minimum) palladium alloy per MIL-P-45209, Type II, Grade C over 50 microinches (minimum) nickel per QQ-N-290, Class 2 3.3.1.2 The terminal shall be plated in the contact area with 30 microinches (minimum) gold per MIL-G-45204 or a thin gold flash over 27 microinches (minimum) palladium alloy per MIL-P-45209, Type II, Grade C over 50 microinches (minimum) nickel per QQ-N-290, Class 2. STATUS:Released Printed: May 22, 2012 FCI GS-01-001 NUMBER TYPE BUS-12-071 PRODUCT SPECIFICATION TITLE PAGE Low Profile Jumper - Gold or GXT Plated REVISION 3 of 15 AUTHORIZED BY G DATE J.ZHOU 05/15/12 CLASSIFICATION UNRESTRICTED 3.4 Design and Construction The connector typically shall be a two piece assembly comprising two interconnected contacts retained in a plastic housing. The female (disconnect) end of the contact shall interface with 0.025 inch square (or round) pins on 0.100 inch centers. 3.5 3.4.1 Mating. The connector shall be capable of being mated or unmated by hand without the use of special tools within the specified temperature range. 3.4.2 Workmanship. Connectors shall be uniform in quality and shall be free from burrs, scratches, cracks, voids, chips, blisters, pin holes, sharp edges, and other defects that will adversely affect life or serviceability. 3.4.3 Interchangeability. The connector shall be capable of mating with any appropriately constituted male connector of the same population without degradation in performance. Electrical Characteristics 3.5.1 Current Rating. The maximum current rating of the connector shall be 3.0 amperes DC (2.5 amperes for multi-position assembly). 3.5.2 Contact Resistance. (see 5.1) The contact resistance shall not exceed the value specified in Table 1, when measured in accordance with MIL-STD-202, Method 307. The following details shall apply: (a) Method of Connection - Attach current and voltage leads as shown in Figure 1. (b) Test Current - 1 ampere DC FIGURE 1 - CONTACT RESISTANCE PDS: Rev :G Copyright Form E-3334 Rev F STATUS:Released Printed: May 22, 2012 FCI GS-01-001 NUMBER TYPE BUS-12-071 PRODUCT SPECIFICATION TITLE PAGE Low Profile Jumper - Gold or GXT Plated REVISION 4 of 15 AUTHORIZED BY G DATE J.ZHOU 05/15/12 CLASSIFICATION UNRESTRICTED TABLE 1 - CONTACT RESISTANCE Maximum Resistance - Milliohms Initial After Test 11 15 3.5.3 3.5.4 3.5.5 3.5.6 PDS: Rev :G Copyright Form E-3334 Rev F Low Level Circuit Resistance. (see 5.1) The low level circuit (contact) resistance shall not exceed the value specified in Table 1, when measured in accordance with MIL-STD1344, Method 3002. The following details shall apply: (a) Method of Connection - See Figure 1 (b) Test Current - 1 milliampere DC (c) Maximum Open Circuit Voltage - 20 millivolts DC Capacitance. (see 5.3) The capacitance between adjacent positions of the unmated connector shall not exceed 2.0 pf, when measured in accordance with MIL-STD-202, Method 305. The following details shall apply: (a) Points of Measurement - Between adjacent contact positions (b) Test Frequency - 1 megahertz Insulation Resistance. (see 5.3) The insulation resistance between adjacent positions of the unmated connector shall be not less than 50,000 megohms (20,000 megohms after exposure to the humidity environment specified in paragraph 3.7.2), when tested in accordance with MIL-STD-202, Method 302. The following details shall apply: (a) Points of Measurement - Between adjacent contact positions (b) Test Potential - B (500 volts) (c) Time of Application - 60 seconds Dielectric Withstanding Voltage. (see 5.3) There shall be no evidence of insulation breakdown, arc-over, or excessive (>1 milliampere) leakage current when the unmated connector is tested in accordance with MIL-STD-202, Method 301. The following details shall apply: (a) Test Potential - 1500 volts RMS, 60 Hz at sea-level (b) Test Duration - 60 seconds (c) Points of Measurement - Between adjacent contact positions STATUS:Released Printed: May 22, 2012 FCI GS-01-001 NUMBER TYPE BUS-12-071 PRODUCT SPECIFICATION TITLE PAGE Low Profile Jumper - Gold or GXT Plated REVISION 5 of 15 AUTHORIZED BY G DATE J.ZHOU 05/15/12 CLASSIFICATION UNRESTRICTED 3.6 Mechanical Characteristics 3.6.1 Contact Retention. (see 5.2) The contact pair shall not be dislodged from the housing when an axial force of 3.0 pounds (1.5 pounds per contact) is applied in the direction of insertion. The force shall be applied at a crosshead speed of 1 inch per minute using Fixture #MF 407.1. ( See Figure 6 ) 3.6.2 Total Mating Force. The total force to mate the connector with an appropriate header having properly configured (see Figure 2) 0.025 inch square pins shall not exceed the value shown in Table II. TABLE II - INSERTION/WITHDRAWAL FORCE Individual Contact Force-Grams Insert (Max.) Withdraw (Min.) .026" Gage Pin 450* Total Mating Force for 2 Contacts (Grams Avg.) .024" Gage Pin 30* .025" Gold Pin 350 Total Withdraw Force for 2 Contacts (Grams Avg.) .025" Gold Pin 150 * Multiply by number of positions for multi-position assembly. 3.6.3 Individual Contact Insertion Force. When measured using a maximum gage configured as shown in Figure 3, the individual contact insertion force shall not exceed the value shown in Table II. 3.6.4 Individual Contact Withdrawal Force. After three insertions of a maximum gage, the force required to withdraw a minimum gage, configured as shown in figure 3, shall be not less than the value shown in Table II. 3.6.5 Durability. After the number of mating cycles specified in Table III, the individual contact withdrawal force shall be not less than the value shown in Table II (see 3.6.4) and the contact resistance shall not exceed the value specified in Table I (See 3.5.2). TABLE III - DURABILITY Gold Plating Thickness 30 u" 15 u" PDS: Rev :G Copyright Form E-3334 Rev F Mating Cycles 50 50 STATUS:Released Printed: May 22, 2012 FCI GS-01-001 NUMBER TYPE BUS-12-071 PRODUCT SPECIFICATION TITLE PAGE Low Profile Jumper - Gold or GXT Plated REVISION 6 of 15 AUTHORIZED BY G DATE J.ZHOU 05/15/12 CLASSIFICATION UNRESTRICTED 3.7 Environmental Conditions 3.7.1 Thermal Shock. After exposure of the mated connector to alternate periods of extreme high and low temperature, there shall be no evidence of cracking or crazing of the insulator housing or other physical damage to the connector; the dielectric withstanding voltage of the unmated connector shall be not less than 2500 volts RMS (see 3.5.6). The test shall be in accordance with MIL-STD-202, Method 107. The following details and exceptions shall apply: (a) 3.7.2 (b) Test Condition - A (5, 1-hour cycles) Temperature Range - +120oC to -55oC (c) Exposure time at each temperature - 30 minutes, minimum (d) Transfer time - 30 seconds maximum Humidity. After exposure of the mated connector to a high humidity environment, the contact resistance shall not exceed the value specified in Table I (see 3.5.2). The insulation resistance of the unmated connector shall be not less than 20,000 megohms (see paragraph 3.5.5). The test shall be in accordance with MIL-STD-202, Method 106 (excluding steps 7a and 7b). The following details shall apply: (a) 3.7.3 PDS: Rev :G Copyright Form E-3334 Rev F Test Duration - 10 days (240 hours) High Temperature Life. After exposure of the mated connector to a high temperature operating environment, the contact resistance shall not exceed the value specified in Table I (see 3.5.2). The insulation resistance of the unmated connector shall be not less than 50,000 megohms (see 3.5.5). The test shall be in accordance with MIL-STD-202, Method 108. The following details shall apply: (a) Chamber Temperature - Adjusted to achieve +120oC temperature of contact under load. (b) Test Condition - B (250 hours) (c) Operating Conditions - Rated current (see 3.5.1) through both contacts; duty cycle: 45 minutes ON and 15 minutes OFF. STATUS:Released Printed: May 22, 2012 FCI GS-01-001 NUMBER TYPE BUS-12-071 PRODUCT SPECIFICATION TITLE PAGE Low Profile Jumper - Gold or GXT Plated REVISION 7 of 15 AUTHORIZED BY G DATE J.ZHOU 05/15/12 CLASSIFICATION UNRESTRICTED FIGURE 2 - MATING HEADER PDS: Rev :G Copyright Form E-3334 Rev F STATUS:Released Printed: May 22, 2012 FCI GS-01-001 NUMBER TYPE BUS-12-071 PRODUCT SPECIFICATION TITLE PAGE Low Profile Jumper - Gold or GXT Plated REVISION 8 of 15 AUTHORIZED BY G DATE J.ZHOU 05/15/12 CLASSIFICATION UNRESTRICTED FIGURE 3 - INSERTION/WITHDRAWAL FORCE GAGE PDS: Rev :G Copyright Form E-3334 Rev F STATUS:Released Printed: May 22, 2012 FCI GS-01-001 NUMBER TYPE BUS-12-071 PRODUCT SPECIFICATION TITLE PAGE Low Profile Jumper - Gold or GXT Plated REVISION 9 of 15 AUTHORIZED BY G DATE J.ZHOU 05/15/12 CLASSIFICATION UNRESTRICTED FIGURE 4 - MOUNTING FOR STOCK/VIBRATION PDS: Rev :G Copyright Form E-3334 Rev F STATUS:Released Printed: May 22, 2012 FCI GS-01-001 NUMBER TYPE BUS-12-071 PRODUCT SPECIFICATION TITLE PAGE Low Profile Jumper - Gold or GXT Plated REVISION 10 of 15 AUTHORIZED BY G DATE J.ZHOU 05/15/12 CLASSIFICATION UNRESTRICTED 3.7.4 3.7.5 3.7.6 Shock. There shall be no evidence of physical or mechanical damage when the mated connector is subjected to transient accelerations. During and after each shock, the contacts shall evidence no discontinuity greater than 1 microsecond. The test shall be in accordance with MIL-STD-202, Method 213. The following details shall apply: (a) Test Condition - 1 (100G, 6 ms sawtooth). (b) Number of Shocks - 3 shocks in each direction along three orthogonal axes (18 total). (c) Mounting - See Figure 4 (d) Restraining Method - None Vibration. There shall be no evidence of physical or mechanical damage when the mated connector is subjected to prolonged mechanical vibration; and the individual contact withdrawal force shall be not less than the value specified in Table II (see 3.6.4). During the vibration along each axis, the contacts shall evidence no discontinuity greater than 1 microsecond. At the completion of the test, the contact resistance shall not exceed the value specified in Table I (see 3.5.2). The test shall be in accordance with MIL-STD-202, Method 204. The following details shall apply: (a) Test Condition - B ( 15G, 10 to 2000 Hz) (b) Test Duration - 4 hours along each of three orthogonal axes (12 hours total) (c) Mounting - see Figure 4 (d) Restraining Method - None Hydrogen Sulfide (H2S) Atmosphere. After exposure of the mated connector to moist contaminated environment, the low level circuit resistance shall not exceed the value specified in Table I (see 3.5.3). The following details shall apply: 3.7.7 PDS: Rev :G Copyright Form E-3334 Rev F (a) Test Medium - 3 ppm H2S in air (b) Test Temperature - +40oC (c) Test Duration - 48 hours Salt Spray. After exposure of the mated connector to a salt fog atmosphere, the low level circuit resistance shall not exceed the value specified in Table I (see 3.5.3). The test shall be in accordance with MIL-STD-202, Method 101. The following details shall apply: (a) Salt Solution - 5 percent by weight (b) Test Condition - B (48 hours) STATUS:Released Printed: May 22, 2012 FCI GS-01-001 NUMBER TYPE BUS-12-071 PRODUCT SPECIFICATION TITLE PAGE Low Profile Jumper - Gold or GXT Plated REVISION 11 of 15 AUTHORIZED BY G DATE J.ZHOU 05/15/12 CLASSIFICATION UNRESTRICTED 4.0 QUALITY ASSURANCE 4.1 Equipment Calibration All test equipment and facilities used in the performance of any test shall be maintained in a calibration system in accordance with MIL-C-45662. 4.2 Inspection Conditions Unless otherwise specified herein, all inspections shall be performed under the following ambient conditions: (a) Temperature - 25oC + 5oC (b) Relative Humidity - 30% to 80% (c) Barometric Pressure - Local ambient 4.3 Qualification Inspection Qualification inspection shall be performed on sample units produced with equipment normally used in production. 4.3.1 Sample. Qualification Inspection shall be performed on five (5) groups of connectors; each group shall comprise five (5) connectors of each type for which qualification under this specification is desired. For multi-position connectors, a sixth sample (one connector) shall be required for Group 3 tests. 4.3.2 Preparation of Samples 4.3.3 PDS: Rev :G Copyright Form E-3334 Rev F 4.3.2.1 Printed Wiring Test Boards - Five (5) test boards conforming to the applicable requirements of MIL-P-55110 and MIL-STD-275 shall be prepared as shown in Figure 5. 4.3.2.2 Mating Headers - Five (5) mating headers of the appropriate population and configuration and conforming to the requirements of Figure 2 shall be prepared. 4.3.2.3 Header Mounting - The headers shall be installed on, and hand soldered to, the test boards; an appropriately active flux shall be used to ensure that the connection does not contribute any degradation. 4.3.2.4 Sample Configuration - When mated with the headers, the connectors shall form a series connected circuit. Test Sequence. The connectors shall be subjected to the inspections specified in Table IV, in the order shown. STATUS:Released Printed: May 22, 2012 FCI GS-01-001 NUMBER TYPE BUS-12-071 PRODUCT SPECIFICATION TITLE PAGE Low Profile Jumper - Gold or GXT Plated REVISION 12 of 15 AUTHORIZED BY G DATE J.ZHOU 05/15/12 CLASSIFICATION UNRESTRICTED 4.4 Requalification Testing If either of the following conditions occur, the product responsible engineer shall initiate requalification testing. 4.4.1 A significant design change is made to an existing product previously qualified under this specification. A significant design change shall be defined to include, but not be limited to, changes in contact material composition, contact material thickness, contact force, contact surface geometry, underlying material composition, underlying material thickness, insulator design, contact base material, or contact lubrication requirements. 4.4.2 A product failure occurs during production or end use requiring corrective action to be taken relative to the product design or manufacturing process. Requalification testing shall consist of all or applicable parts of the Qualification Test Matrix as determined by development/product, quality, test, and reliability engineering. PDS: Rev :G Copyright Form E-3334 Rev F STATUS:Released Printed: May 22, 2012 FCI GS-01-001 NUMBER TYPE BUS-12-071 PRODUCT SPECIFICATION TITLE PAGE Low Profile Jumper - Gold or GXT Plated REVISION 13 of 15 G AUTHORIZED BY DATE 05/15/12 J.ZHOU CLASSIFICATION UNRESTRICTED TABLE IV - QUALIFICATION INSPECTION PDS: Rev :G Copyright Form E-3334 Rev F Examination or Test Paragraph 1 2 Total Mating Force Individual Contact Withdrawal Force Contact Resistance Capacitance Insulation Resistance Dielectric Withstanding Voltage Contact Retention Thermal Shock Dielectric Withstanding Voltage Humidity Contact Resistance Insulation Resistance High Temperature Life Contact Resistance Insulation Resistance Shock Vibration Contact Resistance Individual Contact Durability Contact Resistance Individual Contact Withdrawal Force Hydrogen Sulfide Atmosphere Low level Circuit Resistance Salt Spray Low Level Circuit Resistance Contact Retention 3.6.2 3.6.4 3.5.2 3.5.4 3.5.5 3.5.6 3.6.1 3.7.1 3.5.6 3.7.2 3.5.2 3.5.5 3.7.3 3.5.2 3.5.5 3.7.4 3.7.5 3.5.2 3.6.4 3.6.5 3.5.2 3.6.4 3.7.6 3.5.3 3.7.7 3.5.3 3.6.1 X X X X X X X X X X X X X X - STATUS:Released Sample Group 3 4 5 X X X X X X X X X - X X X X X X X X X XX X X X X X X X X X X X X X X X X X - 6 X X X X X X X X X X X - Printed: May 22, 2012 FCI GS-01-001 NUMBER TYPE BUS-12-071 PRODUCT SPECIFICATION TITLE PAGE Low Profile Jumper - Gold or GXT Plated REVISION 14 of 15 AUTHORIZED BY G DATE J.ZHOU 05/15/12 CLASSIFICATION UNRESTRICTED 5.0 NOTES AND DEFINITIONS 5.1 Contact Resistance Differences in contact resistance between various terminal configurations represent changes in bulk resistance due to longer lengths of current path. 5.2 Contact Retention Only terminals employing an integral latching mechanism (e.g. barbs, dimples, etc.) for rigid retention within the housing are subject to this requirement. Terminals which "free-float" within a housing and are retained by the closure of some form of hinged cover are not included. 5.3 Multi-Position Connector Assemblies containing more than one jumper shall be subjected to the Group 3 tests; these tests do not apply to single position devices. FIXTURE # 407.1 FIGURE 6 PDS: Rev :G Copyright Form E-3334 Rev F STATUS:Released Printed: May 22, 2012 FCI GS-01-001 NUMBER TYPE BUS-12-071 PRODUCT SPECIFICATION TITLE PAGE Low Profile Jumper - Gold or GXT Plated REVISION 15 of 15 AUTHORIZED BY G DATE 05/15/12 J.ZHOU CLASSIFICATION UNRESTRICTED REVISION RECORD REV PAGE DESCRIPTION EC# DATE A ALL Change from preliminary to released V10415 02/26/91 B 5 V12241 08/06/91 C 6 V80421 12/10/98 D ALL V01904 08/01/00 E F G 1 2 1,2 M06-0228 M08-0312 06/12/06 10/28/08 05/15/12 PDS: Rev :G Copyright Form E-3334 Rev F Delete max. load for 10 seconds, add use Fixture #407.1 Figure 6, add Figure 6 page Revised format to be consistent with GS-01-001, and change BERG, Dupont, etc. references to FCI. Add lead free information Change to 17-20% glass fiber polyester page 2 Change plating from Au to Au or GXT STATUS:Released ELX-N-011639 Printed: May 22, 2012 FCI GS-01-001 Mouser Electronics Authorized Distributor Click to View Pricing, Inventory, Delivery & Lifecycle Information: FCI: 69146-210 71363-102LF 71363-202LF 68786-202LF 68786-102LF 69145-306LF 69145-220LF 69145-218 69146-212 71363-202 68786-102 71363-102 68786-202 69145-212 69145-208 69145-210 69145-210LF 69145212LF 69145-208LF 69145-214LF 69146-206LF 69145-206LF 69146-204LF 69144-204LF 69145-204LF 69146208LF 69145-216LF 69145-106LF 68786-203LF 69144-206LF 69144-208LF 69144-210LF 69144-212LF 69144214LF 69144-216LF 69144-218LF 69144-220LF 69145-104LF 69145-108LF 69145-110LF 69145-114LF 69145116LF 69145-120LF 69145-218LF 69145-304LF 69145-308LF 69145-310LF 69145-312LF 69145-314LF 69145316LF 69145-318LF 69145-320LF 69146-210LF 69146-212LF 69145-220 69144-204 69145-206 69145-216 69146-206 69145-204 69146-204 69145-214 68786-103LF 69145-112LF 69146-216 69146-214 69146-220 69146-218