ALL INTERNATIONAL RIGHTS RESERVED. BY AMP INCORPORATED COPYRIGHT 1991 ANE QUALIFICATION TEST REPORT Connector, AMPLIMITE HDP-22, Subminiature 7D Connector, with Removable F Crimp Contacts 501-156 Rev. 0 Product Specification: 108-1268 Rev. 0 CTL Na.: CTL5889-137-035 Date: August 7, 1991 Classification: Unrestricted Prepared By: Terrance M. Shingara *Trademark of AMP Incorporated Corporate Test Laboratory Harrisburg, Pennsylvania= mo oun Whe wooo Whe Mor PO Po Pom Po Bho ho ho RS Po ho RO PO PhO Po PO fo Bo PO beet 8 8 WwW Ww Ww Oo Ww oo oo We a Ga et NE 501-156, Rev. 0 Table of Contents INtroduction ... ccc e cece cece ee teen ene nee e een eenteae Page PUYPOSE Lee cece eee eee eee tee eee eee eee nantes Page SCOPE co eee c cere cece teeta eee cree ener t ean eee tees Page CONCTUSION wo. ccc cece ee eee eee een nee eee eeenaee Page Product Description .. 0... cece eee eee ee eect e ee nenee Page Test Samples 2... cece cece recente e eee eee e tener enaee Page Qualification Test Sequence ......... es eerste eee eee Page Summary Of Testing 0... ccc cece ere n eee cree tenet teense Page Examination Of Product ........ cee eee cee teen en eneee Page Termination Resistance, Specified Current ........-..46 Page Termination Resistance, Dry Circuit ...............-066 Page Dielectric Withstanding Voltage ....... ccs eet eee ees Page Insulation Resistance 2... cece eee eee ee rere eee eens Page Temperature Rise vs. Current ......-. ee cece reece re eeee Page Vibration co.cc cc cece eee ee eee eee eee ee tenes Page Physical SHOCK ...... ccc eee cece eee eee eee een eee teenies Page Mating Force ........ cece eee cece en eect eee teen ee taenees Page Unmating Force 2... cece cece cece ener een e erent ten nae Page Contact Insertion Force ....... eee cee cece eee eens Page Contact Retention 2. .... cece eee ee ene eee eee renee Page Contact Engaging Force 2... .. ccc eee eee een eens Page Contact Separating Force ....... cece ee eee ee tee tee eee Page Crimp TENSiTE 22... cece eee eee tee teen e eens Page Durability .. cc cece cece eee eee eee tee eterna Page Thermal SHOCK ...... cc cece eee eee eee renee e tee ete eee Page Humidity-Temperature Cycling ......0. eee cece eter eens Page Industrial Mixed Flowing GaS ......... eee cess eee eens Page Temperature Life 22... eee cece eee ee tence eens Page Test Methods 2... .. cece cece ee ee eee tte e renee Page Examination of Product .......:ee cece cece cece eee teens Page Termination Resistance, Specified Current ............- Page Termination Resistance, Dry Circuit ......... ccc cena Page Dielectric Withstanding Voltage ....... cc cee eee eee Page Insulation Resistance ...... ccc ce cece eee eee eee eas Page Temperature Rise vs. Current ......se cess cree eee renee Page Vibration 2... ccc ec cece eee tee tetera nent rere eas Page Physical Shock ...... cece eee ee cette ener eens Page Mating FOrce .. cece eee cece ce ee eee ete een eee eee Page Unmating Force wo cece eee cece eect een e teen eee es Page Contact Insertion Force ...... cece ee eee ee ete eens Page Contact Retention ....... cece cece eee eee eee Page Contact Engaging Force ...... ccc eee eee e eee cere enes Page Contact Separating Force 1.2... . cece eee ere eens Page Crimp TAnsile ccc cece eee eect eee eee eee teens Page Durability co cc cece cece cee eee eee tence eee teen enna Page Thermal Shock ..cccccc cree cere eee et teen erect eteeneeneee Page Humidity-Temperature CYCTING ...... cee eee eee eee eters Page Industrial Mixed Flowing Gas ..... ceca eee ee eee eee eee Page Temperature LifG 2... cece cece cette eee teen en eens Page VW ne 0 a 0) | Page (R5889TS) tJ RO RD RS ee et Rt AMNAAHAMA AAMT KTTKNRAHNUPHhHP PE Woo pM WW WN OOOO MM BAHAY Ham o501-156, Rev. 0 ANPr AMP INCORPORATED HARRISBURG, PENNSYLVANIA 17105 PHONE: 717-564-0100 TWX: 510-657-4110 CORPORATE TEST LABORATORY Qualification Test Report Connector, AMPLIMITE HDP-22 Subminiature D Connector with removable F Crimp Contacts 1.1 1.2 1.3 Introduction Purpose Testing was performed on AMPs AMPLIMITE HDP-22 Connectors to determine its conformance to the requirements of AMP Product Specification 108-1268 Rev.0. scope This report covers the electrical, mechanical, and environmenta! performance of the AMPLIMITE HDP-22 Connectors manufactured by the Interconnection Components & Assemblies Products Division of the Capital Goods Business Group. The testing was performed between April 17, 1991 and July 31, 1991. Conclusion The AMPLIMITE HDP-22 Connectors meets the electrical, mechanical, and environmental performance requirements of AMP Product Specification 108-1268 Rev. 0.501-156, Rev. 0 Page 2 1.4 Product Description AMPLIMITE HDP-22 Subminature D connectors with removable F crimp contacts are designed to accept wire sizes 22-28 AWG. The assembly consists of a twp piece plastic housing which has integral plastic retention tines and two metal shells which 1.5 secure the housing components. Test Samples The test samples we production lots, an re randomly selected from normal current d the following part numbers were used for test: Test Group Quantity Part Number Description 1,2,3,5,6,8 32 748364-1 i5 Pos. Plug 1,2,3,5,6,8 32 748565 -1 15 Pos. Receptacle 8 5 748365-1 26 Pos. Plug 8 5 748566 -1 26 Pos. Receptacle 8 5 748366-1 44 Pos. Plug 8 5 748567 -1 44 Pos. Receptacle 8 5 748367 -1 62 Pos. Plug 8 5 748568 -1 62 Pos. Receptacle 4,8 15 748368-1 78 Pos. Plug 4,8 15 748569-1 78 Pos. Receptacle 1,2,3,5,? 265 748333 -2 30 Gold Pin . 1,2,3,5,7 265 748610-2 30 Gold Socket All 1325 748333 -5 Gold Flash Pin All 1325 748610-5 Gold Flash Socket501-156, Rev. 0 Page 3 1.6 Qualification Test Sequence Test Groups Test or Examination 1 2 3 4 5 & 7 8 Examination of Product 1,10 1,6 1,6 1,6 1,6 1,10 1,5 1,7 Termination Resistance, Specified Current 8 5 5 Termination Resistance, Dry Circuit 3,7 2,5 2,5 2,4 2,4 Dielectric Withstanding Voltage Insulation Resistance T-Rise vs. Current 3 Vibration Physical Shock Mating Force Unmeting Force Contact Insertion Force 2 Contact Retention 9 Contact Engaging Force 2 Contact Separating Force 3 Crimp Tensile 4 Durability 4 3 3 4 Thermal Shock 5 Humidity-Temperature Cycling 4 Industrial Mixed Flowing Gas 3 Temperature Life 4 Ae be ~ [oe a [rm [& [we WW iN be Oi The numbers indicate sequence in which tests were performed.501-156, Rev. 0 Page 4 2. Summary of Testing 2.1 Examination of Product - All Groups All samples submitted for current production lots. testing were selected from normal They were inspected and accepted by the Product Assurance Department of the Capital Goods Business Sector. 2.2 Termination Resistance, Specified Current - Groups 1,4,5 All termination resistance measurements taken at the specified current were less than 15.0 millichms. Test No. of Test Group Samples Condition Current Min. Max. Mean 1 90 After Mechanica! 1.10 5.3 7.4 6.07 4 30 After T-rise 1.90 4.7 6.5 5.25 30 After T-rise 1.10 5.3 7.5 5.78 30 After T-rise 0.95 5.6 7.6 6.15 5 60 After IMFG 1.10 4.32 8.99 5.23 All values in milliohms 2.3 Termination Resistance, Dry Circuit - Groups 1,2,3,4,5 All termination resistance measurements, taken at 100 milliamperes dc. and 50 millivolts open circuit voltage, were less than 15.0 milliohms. Test No. Group Samples Condition Min. Max. Mean i 90 Initial 5.4 6.2 5.80 After Mechanical 5.3 6.7 5.95 2 90 Initial 5.3 6.0 5.63 After Temp. Life 5.3 7.5 5.92 3 90 Initial 54 6.2 5.73 After Humidity 5.4 6.2 5.78 4 90 Initial 4.8 8.4 5.52 After T-rise 4.7 8.0 5.61 5 60 Initial 4.1 5.6 4.82 After IMFG 4.3 9.0 5.23 All values in milliohms 2.4 Dielectric Withstanding Voltage - Group 6 No dielectric breakdown or flashover occurred when a test voltage was applied between adjacent contacts.501-156, Rev. 0 Page 5 2.5 2.6 2.7 2.8 2.9 2.11 insulation Resistance - Group 6 All insulation resistance measurements were greater than 5000 megohms initially and 500 megohms after test. Temperature Rise vs. Current - Group 4 All samples had a temperature rise of less than 30C above ambient when a specified current was applied, Wire Size Test Temperature Rise AWG Current Above Ambient (Max) 22 1.90 15.2 26 1.10 14.6 28 0,95 21.5 All Temperatures in Degrees Celsius Vibration - Group 1 No discontinuities of the contacts were detected during vibration. Following vibration, no cracks, breaks, or loose parts on the connector assemblies were visible. Physical Shock - Group 1 No discontinuities of the contacts were detected during physical shock, Following physical shock testing, no cracks, breaks, or loose parts on the connector assemblies were visible. Mating Force - Groups 1,8 All mating force measurements were less than the specification requirements Unmating Force - Groups 1,8 All unmating force measurements were greater than the specification requirements. Contact Insertion Force - Group 6 The force required to insert each contact into its housing cavity was less than 3.0 pounds. Contact Retention - Group 6 No physical damage occurred to either the contacts or the housing, and no contacts dislodged from the housings as a result of applying an axial load of 5.0 pounds to the contacts.501-156, Rev. 0 Page 6 3. 14 15 16 17 18 19 20 1 Contact Engaging Force - Group 7 All contact engaging forces were less than 8.0 ounces per contact. Contact Separating Force - Group 7 All contact separating forces were greater than 0.75 ounces per contact. Crimp Tensile - Group 7 All tensile values were greater than 12 lbs for AWG #22, 8 lbs for AWG #24, 4.5 lbs for AWG #26 and 2.7 lbs for AWG #28. Durability - Groups 1,2,3,8 No physical damage occurred to the samples as a result of mating and unmating the connector 100 times for gold flash or 500 times for 30 micro inch gold. Thermal Shock - Group 6 No evidence of physical damage to either the contacts or the connector was visible as a result of thermal shock. Humidity-Temperature Cycling - Groups 3,6 No evidence of physical damage to either the contacts or the connector was visible as a result of exposure to humidity- temperature cycling. Industrial Mixed Flowing Gas - Group 5 No evidence of physical damage to either the contacts or the connector was visible as a result of exposure to the pollutants of industrial mixed flowing gas. Temperature Life - Group 2 No evidence of physical damage to either the contacts or the connector was visible as a result of exposure to an elevated temperature. Test Methods Examination of Product Product drawings and inspection plans were used to examine the samples. They were examined visually and functionally.501-156, rev. 0 Page 7 3.2 Termination Resistance, Specified Current Termination resistance measurements taken at the specified current were made, using a four terminal measuring technique (Figure 1). 3.3 Termination Resistance, Low Level Termination resistance measurements at low level current were made, using a four terminal measuring technique (Figure 1). The test current was maintained at 100 milliamperes dc, with an open circuit voltage of 50 millivolts dc. ! Termination Resistance , | Measurement Poincs oo (ay | Power Ve | Suppty Figure 1 Typical Termination Resistance Measurement Points 3.4 Dielectric Withstanding Voltage A test potential of 1000 vac was applied between the adjacent contacts. This potential was applied for one minute and then returned to zero, 3.5 Insulation Resistance Insulation resistance was measured between adjacent contacts, using a test voltage of 500 volts dc. This voltage was applied for two minutes before the resistance was measured.501-156, Rev. 0 Page 8 3.6 3.7 3.8 3.9 Temperature Rise vs Specified Current Connector temperature was measured, while energized at the specified current. Thermocouples were attached to the connectors to measure their temperatures. This temperature was then subtracted from the ambient temperature to find the temperature rise. When three readings at five minute intervals were the same, the readings were recorded. Vibration, Random Mated connectors were subjected to a random vibration test, specified by a random vibration spectrum, with excitation frequency bounds of 50 and 2000 hertz. The power spectral density at 50 hz is 0.075 G /Hz. The spectrum slopes up at 6 dB per octave to a PSD of .3 G /Hz at 100 Hz. The spectrum is flat at .3 G /Hz from 100 to 1000 Hz. The spectrum slopes down at 6 dB per octave to the upper bound frequency of 2000 Hz, at which the PSD is 0.075 G /Hz. The root-mean square amplitude of the excitation was 20.71 GRMS. Physical Shock Mated connectors were subjected to a physical shock test, having a half-sine waveform of 50 gravity units (g peak) and a duration of il milliseconds. Three shocks in each direction were applied along the three mutually perpendicular planes, for a total of 18 shocks. The connectors were monitored for discontinuities greater than one microsecond, using a current of 100 milliamperes in the monitoring circuit. Mating Force The force required to mate individual connectors was measured, using a free floating fixture with the rate of travel at 1.0 inch/minute. Unmating Force The force required to unmate individual connectors was measured, using a free floating fixture with the rate of travel at 1.0 inch/minute. Contact Insertion The force required to insert the contact into the housing was measured. Contact Retention An axial load of 5 pounds was applied to each contact and held for 60 seconds. The force was applied in a direction opposite to contact insertion to cause removal of the contacts from the housing.501-156, Rev. 0 Page 9 3.13 Contact Engaging Force Engaging forces were acquired by inserting a 0.0305 inch gage into the socket. Contact Separating Force Separating forces were acquired by withdrawing a 0.0295 inch gage from the socket. Crimp Tensile An axial load was applied to each sample at a crosshead rate of 1.0 inch per minute. Durability Connectors were mated and unmated at a rate of 200 per hour. Thermal Shock Mated connectors were subjected to 5 cycles of temperature extremes, with each cycle consisting of 30 minutes at each temperature. The temperature extremes were -55C and 105C. The transition between temperatures was less than one minute. Humidity-Temperature Cycling Mated connectors were exposed to 10 cycles of humidity- temperature cycling. Each cycle lasted 24 hours and consisted of cycling the temperature between 25C and 65C twice, while the relative humidity was held at 95%. Industrial Mixed Flowing Gas, Class II! Mated connectors were exposed for 20 days to an industrial mixed flowing gas Class III exposure. Class III exposure is defined as a temperature of 30C and a relative humidity of 75%, with the pollutants of Clz at 20 ppb, NOz at 200 ppb, and HzS at 100 ppb. Temperature Life Mated samples were exposed to a temperature of 105C for 500 hours.501-156, Page 10 4, Rev. 0 Validation Prepared by: Terrance M. Shingara Test Engineer Design Assurance Testing Corporate Test Laboratory Reviewed by: Gol) G \s.4 Richard A. Groft Supervisor Design Assurance sean Corporate Test Laboratory Approved by: Leen A Bef Edward Gill Manager, Engineering & Design Assurance Capital Goods Business Sector VEL Y 5 /le/ a S/20/ I