ED HARI COPYRIGHT 19 / + PRODUCT SPECIFICATION L. SCOPE LL. Content This specification covers the performance, tests and quality requirements for the AMP" Crimp Snap Twin Leaf Connector assemblics, used to provide a connection method between discrcte wiring and printed circuit boards. Contacts are crimp type, wrap in design. These multi-contact connectors have .100, 125 and .156 inch centerline spacing between adjacent contacts, 1,2. Qualification When tests are performed on the subject product line, the procedures specificd in AMP 109 serics 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 hercin. 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 Specifications RISBURG,PA. ALL INTERNATIONAL at BY AMP INGORPOR, A. 109-1: General Requirements for Test Specifications B. 109 Scrics: Test Specifications as indicated in Figure |. (Comply with MIL-STD-202, MIL-STD-1344 and EIA R5S-364) Cc. Corporate Bulletin 76: Cross-reference between AMP Test Specifications and Military or Commercial Documents D. Il4- E. 501- : Test Report o < 3.. REQUIREMENTS 2 3.1. Design and Construction Ry Connectors shall be of the design, construction and physical dimensions specified on the ue applicable product drawing. x Zs a 3.2. Ratings fi fe A. Current: 5 amperes maximum per contact 22 B. Opcrating Temperature: -55 to 105C ge ea Trademark of AMP Incorporated pe DR E C.E. Fritz 1-27-78 AMP INCORPORATED ae CHK AMP I Harrsburg, Pa. 17105 H, Hagan 1-27-78 APP NO REV | Loc John Kaufman 1-27-72 108 903! c |B C (Revise per Ye ef DIST 14 TITLE CONNECTOR, CRIMP SNAP JIECN AD-t054 PAGE TWIN LEAF LTR REVISION RECORD APP | DATE ror 10 AMP 1250-18 REV 10-853.4. Performance and Test Description Connectors shall be designed to meet the electrical, mechanical and environmental performance requirements specified in Figure 1. 3.5. Test Requirements and Procedures Summary Test Description Requirement Procedure Examination of Product Meets requirements of product | Visual, dimensional drawing. and funetional per applicable inspection plan. ELECTRICAL Termination Resistance, 10 milliohms maximum initial | Measure potential drop Specified Current of mated contacts at 1 ampere test current assembled in housing, see Figure 5; AMP Spec 109-25, calculate : resistance, Termination Resistance, 10 milliohms maximum Subject mated contacts Dry Circuit initial. assembled in housing to 50 my open circuit at 100 ma maximum, see Figure 23 AMP Spec 109-6-1. Dielectric Withstanding || See Figure 3. Test between adjacent Voltage contacts of ummated connector assemblies; and contacts to mounting , hardware; AMP Spec 109-29-1, Insulation Resistance 5000 megohms minimum Test between adjacent initial. | contacts of urnmated connector assembly; AMP Spec 109-28-4, 500 vdc. Current Cycling Crimp resistance not to Subject mated contacts exceed final value. to 50 cycles at 125 % rated current for 30 minutes "ON" - 15 minutes OFF"; AMP Spec 109-51, cond 8B, test method 3. Figure 1 (cont) REV }Loc AMP INCORPORATED Harrisburg,Pa, 17105 AMP 108-9031 AMP #251-13 REV 10-85Test Description Procedure Requirement Crimp Resistance Test Milliohms Measure potential drop AWG Current Init Final across crimped contacts 28 1.0 3,0 5.0 between wire as it 26 1,0 2.5 4.0 enters the wire barrel 24 3.0 2.0 3.3 and the end of the wire 22 5.0 1.2 2.0 barrel nearest the 20 7.5 0.7 1.2 the contact transition; 18 10.0 0.5 0.8 see Figure 6; AMP Spec 16 12.5 0.4 O.7 109-25. MECHANTCAL Vibration No discontinuities greater than 1 microsecond. No physical damage. Subject mated connectors te 10-55-10 Hz traversed in 1 minute at . 06 inches total excursion; ? hours in each of 3 mitually perpendicular planes; AMP Spec 109-21-1. Physical Shock Mating Force No discontinuities greater than 1 microsecond.No physical damage. 12 ounces maximum per contact pair. Subject mated commector 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. Measure force necessary to mate connector assembly from point of initial contact, incorporating free floating fixtures at a rate of 0.5 inch/minute; AMP Spec 109-42, cond A, calculate per contact pair. force Contact Retention (Crimped Contacts) Contacts shall not dislodge from normal locking position. Apply axial load of 8 pounds to contact lead; AMP Spec 109-30. Contact Engaging Force 10 ounces maximum per contact. Measure force to engage using gage 1, see Figure 7; AMP Spec 109-35. Figure 1 (cont) amp | AMP 1251-13 REV 10-85 AMP INCORPORATED Harrisburg,Pa. 17105 108 -9031Test Description Requirement Procedure Contact Separating .7 ounces minimum. Size 3 times using Force gage 1, see Figure 7, insert page 2 and measure force to separate; AMP Spec 109-35, Crimp Tensile Wire Crimp Tensile Size, pounds AWG minimum 28 3.0 26 5.0 24 8.0 22 12.0 20 20.0 18 30.0 16 42.0 Determine crimp tensile at a vate of linch/ minute; AMP Spec 109-16. Durability No physical damage. Mate and unmate connector assemblies with 30 microinches gold for 250 cycles with gage 1. see Figure 7; AMP Spec 109-27. ENV IRONMENTAL Thermal Shock No physical damage. Subject mated connectors to 5 cycles between -55 and 105C; AMP Spec 109-22. Humidity, Steady State 1000 megohms final, Subject unmated insulation resistance. connectors to steady state humidity at 40C and 90-95% RH; AMP Spec AMP 1251-13 REV 10-85 109-23, method II, cond A. (a) Shall show no evidence of damage, cracking or chipping. Figure 1 (end) PAGE | NO REV [LOC AMP Aovisburg.ea T7108. 4 108-9031 |B i4.6. Comector Qualification and Requalification Tests and Sequences Hl Test Group (a) Test or Examination 1 L.2 | 3 Test Sequence (b) Examination of Product 1 1 1 Termination Resistance, Current Termination Resistance, Dry Circuit 3,14 3,16 Dielectric Withstanding Voltage 5,13 5,19, Insulation Resistance 4,12 4,14 Crimp Resistance 2,4 Current Cycling 3 Vibration 9 11 Physical Shock id 12 Connector Mating Force 2 2 Gontact Retention 15 17 Contact Engaging Force 6 Contact Separating Force B 7,10 Crimp Tensile 5 Durability 7 9 Thermal Shock 6 8 Humidity, Steady State : ll 13 (a) See Para 4.1.4, (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. Test samples shall consist of six connectors of the greatest number of positions of each connector type offered, three each test group L and test group 2. Two additional specimens shall be selected from the least number of positions offered and tested to group 2. When connectors are mated, use PC boards as illustrated in Figure 4, Thirty contacts of each style and desired wire size shall be tested to test group 3. B. Test Sequence Qualification inspection shall be verified by testing samples as specified in Figure 2. AMP INCORPORATED Harrisburg,Pa. 17105 AMP 108-9031 AMP 1251-13 REV 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 s denote the sample average and standard deviation, respectively, of the test data. Let k denote the normal distribution one-sided tolerance factor for %5% confidence and 99% teliability. 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 is as follows: based on the test data, and assuming a normal distribution for 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 piven by KXbar -_ ks. This has aie similar interpretation and corresponding application to lower requirement values. (2) Pailures attributed to equipment, test setup, or operator deficiencies shall mot disqualify the product. When product failure occurs, 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 program provided that it is conducted within the required time period. 4.3, Quality Conformance InspectLlon 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 product drawing and this specification. AMP INCORPORATED PAGE | WO | Rev | Loc amp | Harrisburg,Pa. 17105 6 108-9031 |B - . a AMP 1251-13 REV 10-85Altitude feet Test Voltage, rms .100cL -1251].156cl Sea Level 1000 1500 1800 59,000 400 325 675 70,000 280 375 450 5 ma maximum leakage No breakdown or flashover Figure 3 AMP | AMP 1251-13 REV 10-85 AMP INCORPORATED Harrisburg,Pa. 17105 108-9631I . - O15 (See Note 3) | | t Daw | on A BSC Typ - . 062 Section D-D t Daw ag . 062 _A -}-~$a eg C +. 005 (See Note 6) =|.004 (S)|A (S) Connector Contact A B . BSC Spacing .100 -100 {.0352 2125 ,125 $.078 156 156 7.094 NOTES : 1. Dimensions are in inches. 2. Unless otherwise specified, tolerance is t/-.005. 3. The test card shall extend 4.00 +/-.02 from the receptacle after insertion. 4. Number of contacts shall be the same as on the corresponding printed wiring board. Printed circuit test board shall be 2 ounces copper and gold over nickel plated per MIL-STD-275. This dimension shall be the minimum connector card slot length minus .008. Conductor configuration optional beyond card slot depth. Printed wiring shall be identical on both sides. Figure 4 Connector Description AMP 1251-13 REV 10-85 | nev [Loc AMP INCORPORATED Harrisburg,Pa. 17105 AMF I 108-9031Printed Circuit 3 Faot Minimum Length : Board of Continuous Lead for Termination Resistance Measurement Points Heat Dissipation Figure 5 Termination Resistance Test Cirecult Crimp Resistance Measurement Points 375 7] Figure 6 Crimp Resistance PAGE | NO REV | 108-9031 AMP INCORPORATED AMF | Harrisburg,Pa. 17105 9 AMP 1251-13 REV 10-85eg1. 000+. 015 -375 Min .067 R Typ 15 Typ B . 140+. 015 0135 T 7] Y yp ! x 15 T ye .010+4.005 R Typ 4/ (2 Sides) eg1. 250 Min . 067 R Typ .400 Min 15 Typ $408,009 7 tr _ * | _ a poe Tye 47~ (2 Sides) .0135 Typ .010+,005 R Typ Gage A B Number 1 . 9700 {a) 2 | .0549 (a) (a) Dimension equals card slot length of connector minus .008. NOTES: 1. Tolerances: +/-.005 unless otherwise indicated. 2. Material: Tool steel, hardened to Rockwell C50-55. 3. Gage surface shall be clean of contaminants or lubricants. Fipure 7 Printed Board Simulator AMP INCORPORATED PAGE [NO REV [LOO AMF l Harrisburg,Pa. 17105 108-9031 . c | B . = a AMP 1251-13 REV 10-65 . ~