ALL INTERNATIONAL RIGHTS RESERVED. BY AMP INCORPORATED CGPYRIGHT 1990 AMF QUALIFICATION TEST REPORT Single Line, High Voltage Commercial LGH* Connector 501-117 Rev. Q Product Specification: 108-36034 fter @ CTL No.: CTL4086-001-001 Date: May 24, 1990 Classification: Unrestricted Prepared By: Terrance M. Shingara *Trademark of AMP [Incorporated Corporate Test Laboratory Harrisburg, Pennsylvaniaee ee pO - 8 oe 4 8 #8 Mo PO RO PO PRO PO PO DG PO BRO MO fo PO PG ee ee Wo Ww OF We Wo WW Oo WW WW to Oe ee in > WP bd te WN OWOnaoPwne WOnHAaA pwr 501-117, Rev. 0 Table of Contents INCPODUCTION 2. cece ete eee eee eee een eee Page PUPPOSE Lecce eee cree erence etter e teeter ene tes Page SCOPE cece cece e cee rere rete ene eee tener anne were eenees Page CONCTUSION 0... cc cc ewe ee ee eee eee tenet ene eeeteee Page Product Description .....e cere eee ence ren enen cet eererees Page Test SAMPlTOS .. cee cece cee erent e er tee teen ee tenet erntaes Page Qualification Test Sequence .........-.-.-seeee eee e ees Page Summary Of Testing ...... ccc ee ee cee eee renee net e eens Page Examination of Product 2... ... cee cece eee eee teen eaee Page Termination Resistance, Specified Current ......-...00- Page Dielectric Withstanding Voltage ....--. eee eevee eerrees Page Insulation Resistance .. cece ccc ence eee eee eee arenes Page Temperature Rise vs. Current .....seeeeee reer reece eens Page Vibration, Discontinuity ..... cece cece ee eee eee eens Page Vibration, Energized ...... cece ee eee eee eee teens Page Physical SHOCK .... cece cece eee eet teen nent ne eens Page Mating Force 0.0... . cece ee cece ee eet een ten eennee Page Contact Separating FOrce ....e rece were renee e tener eens Page Durability co.cc cece cece e eee rete teen eee tat eeeees Page Thermal Shock ..... ccc cece ee ence teen enter eer teenies Page Humidity-Temperature CYCTING 2.0... ee cece cree eet e neces Page Test Methods .....c cece cece creer eee cence nee ne teenage Page Examination of Product ........ ccc cece eee ee eee eens Page Termination Resistance, Specified Current ..........44- Page Dielectric Withstanding Voltage ........e eee cere eens Page Insulation Resistance 2... ccc cece ee eee eee eee tes Page Temperature Rise vs Current ....... cee ee es ee eee e renee Page Vibration, Discontinuity cc... cece cece cee eee ener Page Vibration, Energized oc. ccc c cece ee eee eet cnet ne eeeenee Page Physical Shock ......s0 cece cece eee eee teeter tte Page Mating FOrce .... csc secre cece eee ence eet n atten e enna Page Contact Separating Force ......-.. 62s eee e rete eee eens Page DUVADITILY ope ccc cee eee cee eee eee eee eee tenet eee ee nnes Page Thermal Shock ...... ccc ccc eee eee eee eee teen enaee Page Humidity-Temperature Cycling ......see eee eee e nese eens Page Validation .. ccc ccc cee eee eer ee eect een e ener eens Page (R4086TS1) RO PO RO eS ee re Nn Pp & SS So lwo WG Ww SANS AAAAHOH o501-117, Rev. 0 AMP AMP INCORPORATED HARRISBURG, PENNSYLVANIA 17105 PHONE: 717-564-0100 TWX: 510-657-4110 CORPORATE TEST LABORATORY Qualification Test Report Single Line, High Voltage Commercial LGH Connector 1.1 1.2 1.3 [Introduction Purpose Testing was performed on AMPs Commercial LGH Connector to determine if it meets the requirements of AMP Product Specification 108-36034, Rev. 0. Scope This report covers the electrical, mechanical, and environmental performance of the Commercial LGH Connector, manufactured by the Federal Systems Unit of the Aerospace & Government Systems Sector. The testing was performed between October 25, 1989 and March 26, 1990. Conclusion The Commercial LGH Connector meets the electrical, mechanical, and environmental performance requirements of AMP Product Specification 108-36034, Rev. 0.501-117, Rev. 9 Page 2 1 1, ] 4 5 6 Product Description The Commercial Single Line Connectors incorporate crimp, Snap-In contacts of the Type XI, XII, and III+ families. Housings are made of self-extinguishing plastic, UL rated 94V-0. The 10 kVac connectors accept 20/24 AWG wire. The 20 kVac connectors accept 22/20 AWG and 18/16 AWG wires. The 30 kVac connectors accept 16/8 AWG wire. Test Samples The test samples were randomly selected from current production, and the following part numbers were used for test: Test Group Quantity Part Number Description 1,2,3 15 863103-2 LGH Plug (12 kVac) 15 863104-2 LGH Receptacle {12 kVac) 15 66261-1 Type XII Pin (12 kVac) 15 66740-8 Type XII Soc. (12 kVac) 1,3 10 867157-1 LGH Ptug ( 8 kVac) 10 867156-1 LGH Receptacle { 8 kVac) 10 203816-6 Type XI Pin ( 8 kVac) 10 203802-6 Type XI Soc. { 8 kVac) 10 861610-1 LGH Plug ( 4 kVac) 10 861753-1 LGH Receptacle ( 4 kVac) 10 66400-1 Type II[+ Pin ( 4 kVac) 10 6399-1 Type [II+ Soc. ( 4 kac) Qualification Test Sequence Test Groups Test or Examination 1 2 3 Examination of Product l, Termination Resistance, Specified Current 3, Dielectric Withstanding Voltage 2, Insulation Resistance 3, T-Rise vs. Current 3,8 Vibration, Discontinuity 5 Vibration, Energized 6 Physical Shock Mating Force Contact Separating Force Durability Thermal Shock Humidity-Temperature Cycling | CO] Pot co 4 5 On = The numbers indicate sequence in which tests were performed.2.1 2.2 2.3 2.4 .. cli7, Rev. U Page 3 Summary of Testing Examination of Product - All Groups All samples submitted for testing were selected from normal production lots. They were inspected and accepted by the Product Assurance Department of the Federal Systems Unit of the Aerospace & Government Systems Sector. Termination Resistance, Specified Current - Groups 1,2 All termination resistance measurements taken at the specified current were less than the specification requirements. Test No. of Spec. Group Samples Condition Max. Max. l 5 Initial 1.40 0.3] 5 9.00 2.19 5 11,00 3.42 1 5 After Mechanical 1.40 0.51 5 9.00 4.55 4 11.00 6.59 2 5 Initial 1.40 0.4? 2 5 After Current Verification 1.40 0.77 All values in milliohms Dielectric Withstanding Voltage - Group 3 There was no dielectric breakdown or flashaver between adjacent contacts, when tested in accordance with table below: ea Connector eve Ratin Cc vac Vac Vac Vv V Vac c Cc Leakage current was less than 1.0 milliamperes. Insulation Resistance - Group 3 All insulation resistance measurements were greater than the specification requirement of 5000 megohms for the initial measurement, and 100 megohms for measurement taken after test.501-117, Rev. 0 Page 4 2.5 2.6 2.7 2.8 2.9 Temperature Rise vs. Current - Group 2 (Type XII Contact) All samples had a temperature rise of less than 30C above ambient, when specified current was applied. Wire Siza Wire Test Temperature Condition AWG Size Current Rise (Max. ) Initial 12 AWG 15.0 6.0 After Current Verification 12 AWG 15,0 11.9 All Temperatures in Degrees Celsius Vibration, Discontinuity - Group 1 There were no discontinuities of the contacts greater than one microsecond during vibration. Following vibration, there were no cracks, breaks, or Foose parts on the connector assemblies. Vibration, Energized - Group 2 Following vibration, there were no cracks, breaks, or loose parts on the connector assemblies. Physical Shock - Group 1 There were no discontinuities of the contacts greater than one microsecond during physical shock. Following physical shock testing, there were no cracks, breaks, or loose parts on the connector assemblies. Mating Force - Group 1 All mating force measurements were less than the specification requirement of 2.0 pounds for Type XI contacts, 3.0 pounds for Type III+ contacts, and 15 pounds for Type XII contacts. Contact Separating Force - Group 1 All contact separating forces were greater than the specification minimum requirement of 0.75 ounces for Type X1 contacts, 1.5 ounces for Type IIi+ contacts, and 5.0 ounces for Type AIT contacts. Durability - Group 1 There was no physical damage to the samples, as a result of mating and unmating the connector 500 times.3.1 3.2 501-117, Rev. 0 Page 5 Thermal Shock - Groups 2,3 There was no evidence of physical damage to either the contacts or the connector, as a result of thermal shock. Humidity-Temperature Cycling - Groups 2,3 There was no evidence of physical damage to either the contacts or the connector, as a result of exposure to humidity temperature cycling. Test Methods Examination of Product The product drawings and inspection plans were used to examine the samples, They were examined visually and functionally. Termination Resistance, Specified Current Termination resistance measurements taken at the specified current were made, using a four terminal measuring technique (Figure 1). | Termination Resistance LW Measurement Points A SY Supply Figure 1 Typical Termination Resistance Measurement Points501-117, Rev. 0 Page 6 3.3 3.4 3.5 3.6 3.7 3.8 Dielectric Withstanding Voltage The test potential was applied between the adjacent contacts. This potential was applied for 3 minutes and then returned to zero. Insulation Resistance Insulation resistance was measured between adjacent contacts, using a test voltage of 500 volts dc. This voltage was applied for one minute, before the resistance was measured. Temperature Rise vs. Specified Current The 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, Discontinuity, Sine Mated connectors were subjected to sinusoidal vibration having a simple harmonic motion with an amplitude of 0.06 inch, double amplitude. The vibration frequency was varied uniformly between the limits of 10 and 55 Hz and returned to 10 Hz in 1 minute. This cycle was performed 120 times in each of three mutually perpendicular planes, for a total vibration time of 6 hours. Connectors were monitored for discontinuities greater than one microsecond, using a current of 100 milliamperes in the monitoring circuit. Vibration, Energized, Sine Mated connectors were subjected to sinusoidal vibration having a simple harmonic motion with an amplitude of 0.06 inch, double amplitude. The vibration frequency was varied uniformly between the limits of 10 and 55 Hz and returned to 10 Hz in 1 minute. This cycle was performed 120 times in each of three mutually perpendicular planes, for a total vibration time of 6 hours. Connectors were energized at specified current, and total circuit voltage drop was monitored. Physical Shock Mated connectors were subjected to a physical shock test, having a sawtooth waveform of 30 gravity units (g peak) and a duration of 11 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.3.9 3.12 501-117, Rev. 0 Page 7 Mating Force The force required to mate individual contacts was measured, using a free floating fixture with the rate of travel at 0.5 inch/minute. Contact Separating Force Separating forces were acquired by withdrawing a 0.0615 inch gage from the Type III+ Socket, a 0.0390 inch gage from the Type XI Socket, and a 0.250 inch gage from the Type XII Socket. Durability Connectors were mated and unmated 500 times, at a rate not exceeding 200 per hour. Thermal Shock Mated connectors were subjected to five cyctes of temperature extremes, with each cycle consisting of 30 minutes at each temperature. The temperature extremes were -15C and 85C. 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%.501-117, Rev. 0 Page 8 Validation Prepared by: Laman 2? Kon 4 /10/ 90 Terrance M. Shingara<~ Test Engineer Design Assurance Testing Corporate Test Laboratory Reviewed by: dice XG. salt df wef Richard A. Groft Supervisor Design Assurance Testing Corporate Test Laboratory Approved by: hci A? KE be SWE sects M. Lankard Manager Reliability Federal Systems