THIS INFORMATION 13 CONFIDENTIAL AND 15 DISCLOSED To YOU ON CONDITIGNH THAT MO FUATHER DISCLOSURE 1$ MAGE BY YOU TO OTHFR THAN AMP PERSONNEL WITHOUT WRITTEN AUTHORIZATION FROM AMP INCORPORATES, HARRISBURG, Pa, 1. ~ 408-9,100 NUMBER 2. 3. cLassirication Customer Release AMP SECURITY PRODUCT SPECIFICATION AMP PRE-INSULATED DIAMOND GRIP TAPER PIN CONTACTS PART NUMBERS - 66171, 66172 and 66173 SCOPE: 1.1 SCOPE - The purpose of this specification is to establish the requirements for pre-insulated diamond grip taper pin contacts listed above. APPLICABLE DOCUMENTS: 2.] REFERENCES - The following specifications and/or documents form a part of this specification to the extent specified herein: MIL-=T-7928 Terminals, Crimp Style MIL-G-45204 Gold Plating; Electrodeposited MIL-M=-20693A Plastics, Molding, Polyamide QGQ-B-626B Brass - Leaded and Non-Leaded QQ-N-290 Nickel Plating; Electrodeposited QQ-C-576B Copper Products REQUIREMENTS: 3.1 CONTACTS - The taper pin contacts furnished to this specification shall be @ product that has successfully met all the requirements of this specification. 3.2 MATERIALS - The materials used to fabricate this product shall be as specified herein. When a substitute material is used, it must meet all the performance requirements of this specification. 3.2.1 PIN BODY MATERIAL - The material used for the body shall be a copper alloy conforming to QQ=-B-626B. The plating of this contact shall be as specified by the applicable product drawing. 3.2.2 INSULATING MATERIAL - The material used for the plastic sleeve shall be polyamide conforming to MIL-M~20693A. 3.2.3 SLEEVE MATERIAL - The material used for the diamond grip sleeve shall be a copper alloy conforming to QQ@-C-576A. The sleeve shall be plated gold over nickel in accordance with MIL-G-45204 and QQ-N-290 to a thickness specified on the applicable product drawing. 3.3 DESIGN AND CONSTRUCTION - The taper pin contacts shall be of the design, construction, and physical dimensions specified on the applicable product drawing. 3.4 CURRENT RATING ~ These taper pin contacts shall have a maximum current rating equivalent to that of the conductor onto which it is crimped, but not to exceed the maximum operating temperature. 3.95 OPERATING TEMPERATURE = Taper pin contacts shall have a maximum operating temperature of +105C. anda minimum operating temperature of -40C, E.5. 8-3-3 oR awe 6/ s" AMP INCORPORATED HARRISGURG, PENNA, Ti Fesiebe * 108-9,100 REV C A Sr We, 4 rut Shieh PRINT OST C | Revised perECN 1690 re B| Rev. Per ECN W-429 [W i, Fo SHEET PRODUCT SPECIFICATION FOR ~ LTR REVISION RECORD OR [CHEK IDATE 1 OF a TAPER P| N 5 AMP 1250 REV 7/60" oo le _108-9, 100 NUMBER Customer Release AMP SECURITY CLASStFEC ATION ' 3.6 TEST SAMPLES ~ Sufficient samples to satisfy the quantities specified for each group in Table ill or |V shall be selected from current production. Each group shall be tested for the assigned characteristics specified in Table Ill and IV. The samples shal! represent each Part No. (66171, 66172, and 66173). The pins shall be crimped to wire which conforms to the requirements of MIL-W-16878, Type B with Hand Tool 90153-1, One 12 inch sample of the insulating tubing representing each part number used fo insulate the sleeves assembled to the pins that are being qualified. See Tables Ill and \V for wire and tubing lengths required. 3.7. PERFORMANCE AND TEST REQUIREMENTS - 3.7.1 TEST CONDITIONS - Unless otherwise specified herein, tests and exam- inations required by this specification shall be made under any combination of conditions within the range below. Any specified condition shall not affect the other two ambient ranges. Temperature: 20 to 30C, Relative Humidity: 30 to 80 percent Barometric Pressure: 24 to 31 inches of mercury 3.7.2 EXAMINATION OF PRODUCT - The taper pin contacts shall meet the dimensional requirements as indicated on the applicable product drawing. There shal! be no evidence of faulty assembly, peeling or chipping of the plating and finish. See Paragraph 3.7.2.1 for equipment required fo measure parts. 3.7.2.1 EXAMINATION OF PRODUCT - The taper pins sha!l be measured using standard shop tools such as optical comparator,micrometer, plug gages and etc. The measured parts shall conform to Paragraph 3 7 2 . , * co cnure cee . i. . . ; 3.7.3 TERMINATION RESISTANCE - When tested in accordance with Paragraph 3.7.3.1 the potential drop shall not exceed the values shown in Table | when measured as shown in Figure |. TABLE | CRIMP RESISTANCE. AFTER TEST WIRE TEST VOLTAGE DROP Voltage Drop SIZE CURRENT (In Millivolts) (In Millivolts) 24 4.5 8.0 13.0 22 9.0 7.0 12.0 20 11.0 6.0 10.0 18 16.0 5.0 7.0 16 22.0 7.0 10.0 3.7.3.1 TERMINATION RESISTANCE - The test current specified in Table | shall be applied to the taper pins subjected to this test. The millivolt _ drop shall be measured at the points shown in Figure |. Measurements shall be made after the temperature of the wire has stabilized. The millivolt drop shall not exceed the values specified in Table | and the applicable paragraph . AMP |NCORPORATED HARRISBURG. PENNA SHEET 2ZOFU meet REV Cc Loc NO _ A ~708-9,100 - NAME PRODUCT SPECIFICATION FOR E.S. 8-3-3 """ TAPER PINS AMP 1251 REV 7/60= ah NUMBER 108-9,100 AMP SECURITY CLASSIFICATICN Customer Release 3.7.4 3.7.5 3.7.6 E.S, 8-3-3 DIELECTRIC STRENGTH - When tested in accordance with Paragraph 3.7.4.1, there shall be no arcing or breakdown when the voltage of 1500 volts AC ms is applied for one minute. 3.7.4.1 DIELECTRIC STRENGTH - The pin of the contact shall be dipped in hot beeswax, having a temperature not exceeding 154C., to a depth sufficient to completely cover the metallic pin without covering the edge of the crimp. When the beeswax has hardened, the samples shall be immersed in a 5% salt water salution to a depth sufficient to cover the crimped areas of the wire and insulation barrel. The voltage specified in 3.7.4 shall then be applied for one minute between the test sample and salt water. CRIMP TENSILE - When tested in accordance with Paragraph 3.7.5.1, all samples shall meet the minimum requirements as specified in Table Il. TABLE II CRIMP TENSILE WIRE SIZE MUNIMUM TENSILE (Pounds) 24 10 22 15 20 20 18 38 16 40 3.7.5.1 TENSILE STRENGTH ~ Samples shail be placed in a standard tensile-testing machine and sufficient force applied to pull the wire out of the sample or break the wire. The mechanical! connection of the wire and the sample shall not break or become distorted to the extent that it is unfit for further use before the minimum tensile strengths, as specified in Table II are reached. The test shall be made with a speed of head travel of 1 inch per minute. VIBRATION - After being subjected to the vibration test specified in Paragraph 3.7.6.1, the terminals shall not exceed the After Test" voltage drop requirements specified in Table | nor have a tensile strength less than that specified in Table Il. 3.7.6.1 VIBRATION - The crimped pins shall be inserted into a standard taper pin housing and secured to the vibration table by means of a mounting plate. The wires shall be secured to a stable support 12 inches away from the housing with all stack and tension removed from the wire. The samples shall then be vibrated in accordance with Method 201 of MIL-STD-202 for 18 hours on each of the perpendiculars to the axis of the wire ata total amplitude of 0.060 inch, at a cycling frequency of 10 to 55 to 10 CPS, the cycle frequency to be accomplished in I minute. Following this test the parts shall meet the requirements of Paragraph 3.7.6. SHEET AMP INCORPORATED HARRISBURG. PENNA 3 L1fice ZOFM A nt 108-9,100 | REV Cc TAPER PINS NAME PRODUCT SPECIFICATION FOR AMP 1251 REY 7/60NUMBER 108-9,100. AMP SECURITY CLASSIFICATION Customer Release 3.7.7.) 3.7.8.1 34/7 .9.1 E.S, 8-3-3 3.7.7 \MMERSION - After immersion in the fluids specified in Paragraph 3.7.7.1 the crimped pins shall conform to the dielectric strength requirements of Paragraph 3.7.4. IMMERSION - The crimped taper pins shall be immersed in aviation hydraulic fluid (petroleum base) conforming to MIL-H-5606 and aircraft lubricating oil conforming to MIL-L-7808 at a temperature of 25C fora period of 20 hours. Four terminals shall be immersed in each of the above specified fluids. Upon removal from the fluid, the terminals shall be air-dried for 1 hour at room temperature, after which time any remaining excess fluid may be wiped from the terminal. The terminals shall then meet the requirements of Paragraph 3.7.7. 3.7.8 FLAMMABILITY - The sample shall be self-extinguishing within 20 seconds after removal from the flame specified in Paragraph 3.7.8.1. FLAMMABILITY - One twelve inch sample of tubing representing each part number used fo insulate the sleeve assembled to the pins being qualified (See Paragraph 3.6) shall be tested as follows: A wing shaped, flame spreader having a 1/16 by 2 inch opening, shall be fitted to the top of a bunsen burner, having a 1/4 inch inlet, a nominal bore of 3/8 inch and a length of approximately 4 inches. The flame shal! be adjusted to a height of 2 inches with on inter-cone approximately 1/3 its height. The burner shal! be placed in an enclosure which permits a flow of sufficient air for complete combustion but be free from drafts. The sample shall be held in a horizontal position and the end of the tubing applied to the tip of the flame for a period of 10 seconds and then removed. The sample shall meet the requirements of Paragraph 3.7.8. 3.7.9 CORROSION RESISTANCE - After the exposure to the corrosive atmosphere specified in 3.7.9.1 the termination resistance shail conform to the "After Test" values specified in Table |. The termination resistance shall be measured in accordance with Paragraph 3.7.3. After completion of the test, there shall be no exposure of base material or under-plate. CORROSION RESISTANCE - The samples shall be tested in accord- ance with Method 101 of MIL-STD-202 for 100 hours and meet the requirements of 3.7.9. The samples shall have been crimped to short lengths of wire and mounted in the salt spray chamber ina horizontal position. Adjacent samples shall be separated by at least 1/4 inch. During this test the samples shall not come in contact with metallic or wooden objects. The salt spray shall have free access to the samples. Before conducting the voltage drop test specified in 3.7.9, samples shall be washed with tap water, air dried for a minimum of 1 hour. Any oxide deposit on the taper portion of the pin shall be removed by use of a soft brush. AMP INCORPORATED SH EET HARRISBURG FENN REY Cc NAME PRODUCT SPECIFICATION FOR TAPER PINS AMP I125| REV 7/60108-9, 100 3.7.10 HEAT AGING - The crimped taper pin leads shall be tested in accordance with Paragraph 3.7.10.1. After being subjected to the heat aging the insulation shall show no signs of being ruptured or cracked. The samples shall then be subjected to and comply with the dielectric strength test specified in 3.7.4. 3.7.10.1 HEAT AGING - The crimped taper pin leads shall be maintained at a temperature of 120 to 122C for a period of 120 hours. After removal from the chamber, the terminals shall be cooled to a temperature between 20 and 25C within a period of 1 hour. - |NUMBER CLASSIFICATION Customer Release AMP SECURITY Upon completion of the heat age test the crimped pins shall meet the requirements of 3.7.10. 3.7.11 LOW TEMPERATURE CRIMP - The crimped taper pin leads shall be tested in accordance with Paragraph 3.7.11.1. After being subjected to the low temperature test the insulation shall show no signs of being ruptured or cracked. The samples shall then be subjected to and comply with the dielectric strength test specified in 3.7.4. 3.7.11.1 LOW TEMPERATURE CRIMP - Uncrimped pins, wire, and the crimping tool shall be maintained at a temperature of -15C for a period of 1 hour; the pins shall then be crimped to their proper size wire at -15C. The leads shal! then be exposed to -55C and maintained at that temperature for 1 hour. The terminals shall then be exposed ta room temperature (20 to 25C) for 1 hour. Following this test the pins shal! meet the requirements of Paragraph 3.7.11. 3.7.12 AXIAL LOAD - 3.7.12.1 AXIAL LOAD CRIMPED - The insulation and metal sleeve shall withstand a minimum axial force of 8 pounds in either direction without moving more than 1/32 inch on the barrel of the terminal when tested in accordance with 3.7.12.1.1., 3.7.12.1.1 AXIAL LOAD CRIMPED - The crimped samples representing each wire size shall be tested by applying an 8 pound force axially with the centerline of the pin in both directions (toward the wire end and toward the contact end).See Figure 2. A measurement of sleeve displacement shall be made at the point indicated as "D" on Figure 2. The measurement shall be made prior to applying any load and after each force application and meet the requirements of Paragraph 3.7.12.1. 3.7.12.2 AXIAL LOAD UNCRIMPED - The insulation and metal sleeve shall not pull from the terminal body when a three pound Joad is applied as specified in 3.7.12.2.1. AMP INCORPORATED HASPISSURG. PENNA NAME PRODUCT SPECIFICATION FOR E.S, 8-3-3 _ TAPER PINS AMP 1251 REV 7/60NUMBER 3.7.12.2.1 AXIAL LOAD UNCRIMPED - The uncrimped samples representing each wire size shall be tested by applying a three pound force to the insulating sleeve axially toward the wire end of this pin. (See Figure 3) The pin shail meet the requirements of Paragraph 3.7.12.2. 3.7.13 CURRENT CYCLING - When tested in accordance with 3.7.13.1 the crimped terminals shail meet the "After Test" voliage drop requirements in Table 1. 3.7.13.1 CURRENT CYCLING - Taper pins shall be crimped to 3 foot 108-9,100 AMP SECURITY lengths of the appropriate wire and shall be subjected to 50 current cycles. Each cycle shall consist of 30 minutes at 125 percent of the test current specified in Table |, follawed by 15 minutes at no load. Voltage drop measurements shall be made at test current specified in Table | after the test assembly has returned to room temperature and meet the requirements of Peragraph 3.7.13. 4. QUALITY ASSURANCE PROVISIONS: 4.) PERIODIC REQUALIFICATION = The tests specified in Table IV shall be performed on production parts each 18 months. CLASSIFICATION Customer Release SHEET} 6 i No ae . SOF LUT ape AMP INCORPORATED HARFISBURG. PENNA REV 9, 100 iC NAME PRODUCT SPECIFICATION FOR E.S. 8-3-3 TAPER PINS AMP 125) REV 7/60- 108-9,100 NUMBER TABLE Il Customer Release AMP SECURITY CLASSIFICATION QUALIFICATION TESTS F REQUIREMENT NUMBER WIRE GROUP EXAMINATION OR TEST PARAGRAPH OF SAMPLES LENGTH/INCH | Examination of Product 3.7 42 35 - Termination Resistance Safad tl Current Cycling 3.7.13 4 36+ Termination Resistance BaF od Termination Resistance 3.7.3 Vibration 3.7.6 Mt Termination Resistance 3.7.3 4 24 Tensile Strength 3.7.5 IY Immersion 3.7.7 8 as gerne Dielectric Strength 3.7.4 : Vv Flammability 3.7.8 sa 8) 12" Tubing Termination Resistance 3.7.3 VI Corrosion Resistance 3.7.9 4 8 Termination Resistance 3.7.3 Tensile Strength 3.7.5 Heat Aging 3.7.10 Vil Dielectric Strength 3.7.4 4 8 vi | Sitiecree Snes | giza 4 8 (See37.11.1) IX Axial Load (Crimped) 3.7.12.1 5 8 x Axial Load (Uncrimped) 3.7.12 .2 5 - i SHEET AMP INCORPORATED 7 oO Ful Loc NO REV a A 168-9,100 Cc NAME PRODUCT SPECIFICATION FOR E.S. &3-3 fh : TAPER PINS AMP 1251 REV 7/60108-9,100 NUMBER CLASSIFICATION Customer Release AMP SECURITY TABLE IV PERIODIC RE QUALIFICATION TESTS REQUIREMENT NUMBER WIRE GROUP | EXAMINATION OR TEST PARAGRAPH OF SAMPLES | LENGTH/INCH | Examination of Product 3.7.2 23 - Immersion 3.7.7 io Ml Dielectric Strength 3.7.4 s 8 * PLN. : HI Flammability 3.7.8 (see 3.7.8) 12" Tubing Heat Aging 3.7.10 IV Dielectric Strength 3.7.4 4 8 Vv Low Temperature Crimp 3.7.11 4 3 Dielectric Strength 3.7.4 vi Axial Load (Uncrimped) 3.7 .12.2 5 - SHEET AMP INCORPORATED 8 OF ee PREV ~ 108-9, 100 Cc NAME PRODUCT SPECIFICATION FOR E.S. 8-3-3 TAPER PINS AMP [251 REV 7/60108-9, 100 NUMBER Customer Release AMP SECURITY CLASSIFICATION Potential Drop Probe Point Ww ] 3 2 TERMINATION RESISTANCE FIGURE 1 SHEET = AMP INCORPORATED G OF Liftoc no REV , 108-9, 100 e NAME PRODUCT SPECIFICATION FOR E.S. 8-3-3 TAPER PENS AMP 1251 REV 7/60S oo ob 2 si CONTACT END 3 z g > S| DIRECTION , >| OF APPLIED > I FORCE | | a > E 2 5 i > 6 FIXTURE =k zg Gi <u E.S. 8-3-3 HOLDING / _> bead 0 ( ) WIRE END | tiie < SLEEVE DISPLACEMENT *~ FIXTU END VIEW OF HOLDING FIXTURE FIGURE 2 METHOD FOR APPLYING AXIAL LOAD (See Paragraph 3.7.12.1) SHEET IOOF 1 a DIRECTION <- OF APPLIED FORCE PN HOLDING RE MP INCORPORATED MARAISBURG. PENNA Loc NO . REV A 108-9, 106 c NAME PRODUCT SPECIFICATION FOR TAPER PINS AMP 1251 REV 7/60NUMBER | 108-9,100 | AMP SECURITY CLASSIFICATION Customer Release - WIRE | END - - ~~ _i Mme eH } DIRECTION ! > e<- OF APPLIED - ee ed 4, _* FORCE nt 7 os ~_ ML Nd Noro FIXTURE \ x y! ~~ lw END VIEW OF HOLDING FIXTURE FIGURE 3 METHOD FOR APPLYING AXIAL LOAD (See Paragraph 3.7 .12.2) SHEET AMP INCORPORATED V1 OFU ioc NOG . _ REV _ A 108-9, 100 C AME PRODUCT SPECIFICATION FOR E.S. 8-3-3 TAPER PINS AMP 1251 REV 7/60