> BY AMP INCORPORATED, 0 HARRIGBURS, Pa. ALL INTERNATIONAL RIGHTS Reseaven. AMP INCORPORATED PRODUCTS COVERED BY U.S. AND FOREIGN PATENTS AND/OR PATENTS PENDING, COPYRIGHT 18 PRODUCT SPECIFICATION 1, SCOPE Ll. Content This specification covers the performance, tests and quality requirements for the AMPMODU mass terminated interconnection system. This preloaded insulation displacement connector consists of AMPMODU receptacles crimped to wire and is intended to mate with .025 square posts. i.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 shail 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 Specifications A. 109-1: General Requirements for Test Specifications B. 109 Series: Test Specifications as indicated in Figure l, . (Comply with MIL-STD-202, MIL-STD-1344 and ELA RS- 364) . Cc. 1114-25015: Connector AMPMODU, Mass Terminated, Application of .2. Federal Specifications A. B. QO-N-290: QO-B-750: Nickel Platiny, Electrodeposited Phosphor Bronze .3. Military Standard MIL-STD-105: Sampling Procedures and Tables tor Inspection hy Attributes Trademark of AMP Incorporated. Do. oo hy xn Ag ji Y LEG PSE he LA Ze AMP | 4ve incorroraten CHK, : oD Pere Harrisburg, Pa. ae ne ee | APP i a. HPs fh pLoc NO REV Powe, .| 8 {A} 108-25015 [3 > SoFE NAME - 42 [Rev Figure 1 =e \s2 | SHEET CONNECTOR, AMPMODG o5 LA [Rev Figure | FE EZ" | 1 of 3 ( MASS TERMINATED LTR| REVISION RECORD APP | GATE STANDARD PRESSURE AMP 1250 REV 7-782.4. Military Specifications MIL-T-10727: Tin Plating, Electrodepusited MIL-M-29693: Malded Plastic, Polymide MIL-G-45204: Gold Plating, Electrodeposited MIL-I-45208: Inspection System Requirements OO WS 3, REQUIREMENTS 3.1. Design and Construction Connectors shail be of the design, construction and physical dimensions specified on the applicable product drawing. 3.2. Materials A. Terminal: Copper alloy B. Housing; Black, glass filled thermoplastic 94V-0 C. Cover: Black, glass filled thermoplastic 94V-0 3.3. Ratings A. Current: 3 amperes maximum B. Operating Temperature: -65 to 105C 3.4. Performance and Test Description Connector assemblies shall be designed to meet the electrical, mechanical and environmental performance requirements specified in Figure l. 3.5. Test Requirements and Procedures Summary __Test Description Requirement Procedure Examination of Product Meets requirements of Visual, dimensional and product drawing and functional per applicable AMP Spec 1114-25015. inspection plan, ELECTRICAL Termination Resistance, 12 milliohms maximum Measure potential drop of Rated Current initial, mated contacts assembled Wire Size, Test Current in hausing, see Figure 34; AWG ampere AMP Spec [0-25, 30 1.0 calculate resistance, 28 1.5 26 2.0 24 3.0 22. 3.0 20 3.9 AMP IN RP D AMP | CORPORATED | SHEET Figure | (cont) Harrisburg, Pa. Zor 2 ep |A/i08- 25015 |= CONNECTOR, AMPMODT MASS TERMINATED STANDARD PRESSURE AMP 2783-2 REV 7-78 >7 Test Description Requirement Procedure Termination Resistance, Dry Circuit (low level} 12 milliohn.s maximum initial. Subject mated contacts assembled in housing to 50 mv open circuit at 100 ma maximum, see Figure 3; AMP Spec 109-5, cond A. Dielectric Withstanding Voltage Test Voitage ac rms Altitude .100 & .125 CL Feet 750 Sea Level 300 50, 000 275 7O, 000 No breakdown or flashover. Test between adjacent contacts of mated connector assemblies; AMP Spec 109-29-1. Insulation Resistance 5000 megohms minimum initial. Test between adjacent contacts of mated connector assembly; AMP Spec 109-28-4. Current Cycling Crimp resistance, see Figure 3. AR = 2 milliohms maximum, Subject mated contacts ta 50 cycles at 125% rated current for 30 minutes TON - 15 minutes "OFF": AMP Spec 109-51, cond Bj test method 3, Crimp Resistance Resistance, Wire Test milliohms Size, Current, maximum AWG amperes _ initial 30 1.0 7,0 28 1.5 7.0 26 2.4 5.0 24 3,0 4.0 22 3.0 3,0 20 3.0 3.0 AR = 2 milliohms maxitmum. Measure potential drop or crimp as indicated in Figure 3, after temperature of wire has stabilized ts current indicated; AMP Spec 108-25, caleulabe orimp resistance. MECHANICAL Vibration {a} No discontinuities yreater than 1 microsecond. Subject mated codaectors to 15 G's, 10-2000 Ele with 100 me current applied: AM{P spec 109-21-3, cond . Figure Ll {cont} AMP INCORPORATED SHEET AMP Harrisburg, Pa. 3 s OF_ f[rse A NO REV B lIO8- 25015 | 5 NAME CONNEC POR, AMPMONDTtU MASS TERMINATED STANDARD PRESSURE AMP 1251-14 Rev 7-78_ Test Description Requirement Procedure Physical Shock (a) Wo discontinuities greater than 1 microsecond. Subject mated connector to 100 G's sawtooth in 6 milliseconds; 3 shocks in each direction applied along the 3 mutually perpendicular planes total 18 shocks; AMP Spec 109-26-9, cond l. Mating Force 9,0 ounces maximum initial. Measure force necessary to mate connector, a distance of .070 inch fram point of initial contact, incorporating free floating fixtures ata rate of 0.5 inch/minute; AMP Spec 109-42, cond A. Calculate force per contact, Measure force after third mating. Unmating Force 1.5 final. ounces minimum Measure force necessary to unmate connector assembly, ata rate of 0.5 inch/minute; AMP Spec 109-42, cond A, calculate force per contact. Contact Retention pounds minimum per contact. Apply axial load of 5 pounds to crimped contacts; AMP Spec 109-30, Contact Engaging Force 9.0 ounces maximum per contact. Measure force to envare using vave i, as indicated in Figure 4, AMP Spec 109-35, envavenent depth - O70 inch; after third mating. measure force Contact Separating 1.5 ounces minimum Size 3 times using wage l, Force per contact. as indicated in Figure 4, insert vage 2 and measure force to separate; AMP Spec 109-35, separation depth .070 inch. Figure 1] (cont) AMP | iguete | SHEET Loc NO REV ort p | A/108-25015 | 5 NAME CONNECTOR, AMPMODU MASS TERMINATED STANDARD PRESSURE AMP 2783-2 REV 7-78> Test Description Requirement Procedure Crimp Tensile (b) Slot Wire Tensile, Number & Size, pounds ColorlL BP. AWG minimum 30 2.0 1 28 3.0 Yellow 26 3.5 26 2.5 2 24 7.0 White 22 6.0 22 4.5 3 Green 20 9.5 Determine crimp tensile ata rate of l inch/minute; AMP Spec 109-19, Durability Mating-unmating; 12 milliohms maximum resistance, dry circuit. Mate and unmate connector assemblies for 200 cycies; AMP Spec 109-27, ENVIRONMENTAL Thermal Shock (a) Dielectric withstanding voltage; 12 milliohms maximum termination resistance, dry circuit. AR = 2 milliohms maximum. Subject mated connectors to S cycles between -05 and 105C; AMP Spec 109-22, Temperature-Humidity Cycling 1000 megohms final insulation resistance, 12 milliohms maximum termination resistance, dry circuit; diclectric withstanding voltage. Subject mated connectors to 10 temperature-humidity cycles between 25 and 65C at 95% RH: AMP Spec 109-23, method IIL, and cold shack at -10C, less step 7h. eand BR, Corrosion, Salt Spray Termination resistance, dry circuit and rated current, Subject mated connectors to 5% salt concentration for 48 hours; AMP Spec CONNISCTOR, 109-24, cond B. Corrosion, Industrial Gas Termination resistance, Subject mated connectors dry circuit and rated to 1% solution, 24+ hours: current. AMP Spec LOG-487, tnethuect 2. Fivure L (cont) AMP INCORPORATED SHEET AMP | Harrisburg, Pa. 2 OFS Loc A NO REY B IO8 25015] 2 NAME AM PMODTU MASS TERMINATED STANDARD PRESSURE AMP 1251-13 REv 7-76~~ Test Description Requirement Procedure Temperature Life (a) Meet termination Subject mated connectors resistance, dry circuit to temperature life, and rated current. AMP Spec 109-43, test 12 milliohms maximum. level 9, test duration I, (a) Shall remain mated and show no evidence of damage, cracking or chipping. (ob) Slot number is stamped on terminal. Figure 1 (end) 3.6. Connector Tests and Sequences Test Group (a) Test or Examination 1 I 2 {| 3 { 4 Test Sequence (b) Examination of Product 1 1 1 1 Termination Resistance,Rated Current(c) 4,13 5,12,17, 20 : wo 3 Termination Resistance, Dry Circuit (c) 3,8, 12 4,11,16,19 2; Dielectric Withstanding Voltage 7 7, t4 Insulation Resistance b, 3 Current Cycling 3 Crimp Resistance } 2,4 Vibration co Physical Shock 9 Mating Force 2,10 Unmating Force 3,11 Contact Retention 2] Contact Engaging Force 2 Contact Separating Force 3 Crimp Tensile 5 Durability Q Thermal Shock b Temperature-Humidity Cycling 1d Corrosion, Salt Spray 15 Corrosion, Industrial Gas 18 Temperature Life + (a) See Para 4, 1.4. (b) Numbers indicate sequence in which tests are performed, () Termination resistance equals millivolts divided by test current Jess resistance of |! inch of wire. Fieure 2 AMP INCORP AMP | ORPORATED SHEET Harrisburg, Pa. 2 oF_$ 8 |A jos-25015 | NAME CONNECTOR, AMPMODU MASS TERMINATED STANDARD PRESSURE AMP 2783-2 REV 7-78 a/_- 4. QUALITY ASSURANCE PROVISIONS 4.1. Qualification Testing A. Sample Section 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 and 3 shali consist of two 20 position connectors crimped to a nominal wire size. Test group 4 shall consist of a minimum of 30 contacts crimped to each AWG wire size, 20, 22, 24, 26, 28 and 30, All contacts shall be crimped in accordance with AMP Specification 1114-25015. B. Test Sequence Qualification inspection shall be verified by testing samples as specified in Figure 2. 4.2. Quality Conformance Inspection The applicable AMP inspection plan will specify the sampling acceptable quality level to he used. Dimensional and functional requirements shall be in accordance with the applicable product drawing and this specification, 4.3. Quality Assurance Requirements Product manufacture shall be controlled by an inspection system at least equivalent to the requirements of MIL-I-45208 to assure the delivered product to be within 1.0 AQL when inspected in accordance with MIL-STD-1L05, Normal Sampling, Inspection Level I. AMP INCORPORATED Harrisburg, Pa. SHEET | IMrF 7 8 OFS Free REV 8 |A'108-25015|~ NAME CONNECTOR, AMPMOIDT MASS TERMINATED STANDARD PRESSURE AMP 1251-13 REV 7-78f. ;Crimp Resistance Measurement Points Termination Resistance Measurement Points a YY) Power Supply Figure 3 Resistance and Temperature Measurement Points . 1254. 016 4 Notes: petjaan 1. 259+, OEG gd wy . 325+. 005 { .031 R Max 4/ (A Sides) ete 1 5+, OOS > = 13 (4 Sides) . Tolerance: +.005 or #2 as applicable, unless otherwise specified, Material: Tool steel, AISI type 02 per AMP Specification 100-135. 1 2 3, Heat treat: Rockwell C 50-55, 4 Gage surface shall be clean of contaminants or lubricants. AMP INCORPOR AMP | Harrisburg Pe. SHEET . 8 Loc NO REV Sort B | A| 1108-25015 |z NAME CONNECTOR, AMPMODU MaSS TERMINATED STANDARD PRESSURE Uapre A B 1 O2t ot .O000 O2 ot BU00 . au veo 0001 "900k 2 p249 77 DOO! o24077 VOUS . .00g0 ce GOOD Figure + Envaping and Separating Giaves AMP 2793-2 REV 7-78