ALL INTERNATIONAL RIGHTS RESERVED. BY AMP INCORPORATED COPYRIGHT 1992 ANF QUALIFICATION TEST REPORT Connector, AMPLIMITE* HD-20, Printed Circuit Board Mounted 501-168 Rev. 0 Product Specification: 108-40025, Rev.0 CTL No.: CTL4941-090-004 Date: February 28, 1992 Classification: Unrestricted Prepared By: James D Angelo *Trademark of AMP Incorporated Corporate Test Laboratory Harrisburg, Pennsylvania= . eet ee oe e 8 & Ou & Gh "28 @ 6 1.0 OT om WwW Po ee RO PO MO BO RO FS RO MO BO PO BS Ro RO Ro RO BO -_ e 8 . s-e 2 WO) OG) Oo GS td Go od Oo OG) Go Go GD ft tu "8 8 eo 8 8 8 ew 1 OO OS On fe Pe 7 e _ + et et es wm & & Po " e _ e & at et et on fm WP 501-168, Rev. 0 Table of Contents INtrOdUction .. ec ccc ce eee eee rere teen eet an ence an eeeraes Page PUPPOSE oo cece cece reece rene tere e etree e eee reer erenees Page SCOPE woe ce cee r cence ne ere ects ene ena eee teen errr ere eeee Page CONCTUSION .o ccc ccc eee eee teeter eee een aeraeeeane Page Product Description ........ 2. ccc eee ene eet ee eee Page Test Samples .... cece cece eee teen erent enna teen eeeeans Page Qualification Test Sequence ........ ccc c eee eect eects Page Summary Of TeSting ....... ccc c ewe cece eect ee eee n ee eenee Page Examination of Product .......-ccceee ene ees rere rer eenee Page Termination Resistance, Dry Circuit ....ce cece ence eeees Page Dielectric Withstanding Voltage .........ee eee renee Page Insulation ReSiStance 2... cc cece ccc e eee cee e cere neenee Page Temperature Rise vs. Current ............ cece eee neces Page Vibration ...... cc ce cee cece ew twee cence cece eee en enes Page Physical Shock 2... 0... 2 cece ccc cee eee eee te ence enane Page Mating Force 22... cece eee ee eect eee ee eee nee eneeee Page Unmating Force 1... .. cece cece eee e eee e eee es ener eneteee Page Durability 1... cece cece cece ewer ence nee enn cereneaeee Page SOlderaDiLity .... ccc cece cee eee reer eee renee eeecens Page Thermal Shock 1.2... cece ecw eee eee eee e ee teen eee Page Humidity-Temperature Cycling .......cecere cece cs canvees Page Industrial Mixed Flowing Gas ........ 0... ccc scene eee Page Temperature Life ..... cc ccc cece cece cece cence re eneees Page Test Methods .....csceec cece cree e tac e cers cere seneanaeee Page Examination of Product ........ cc cece eee ce enter e eee eens Page Termination Resistance, Dry Circuit .....-... eee een eeee Page Dielectric Withstanding Voltage ......c cece cece erences Page Insulation Resistance ........ cc eee eee eee crete eee tereee Page Temperature Rise vs Current ........c eee r cee n er eee e tees Page Vibration . oi. c eee cece eee ee eet eee tee eee eee Page Physical Shock ........-c cece cece ce cece escent ete eennene Page Mating Force ...... 2-2 cece eee cnet eet eneeneees Page Unmating Force ...cc ccc c cece eee e teem eee enn ee ee erene Page Durability .... ccc cc ccc ce ee eee eee eee ee eet eee tere ees Page Solderability 2... ..cccesc ese v eve recv eee teens eee eeesees Page Thermal SHOCK .....c. cece cece cece tence cece ect eeneeences Page Humidity-Temperature Cycling .... ccc cece eect ee ec ereee Page Industrial Mixed Flowing GaS ........cccs ewe tere e ee neee Page Temperature Life ..... csc cece eee eee eet et eee ererees Page Validation 2.0... cece ce cece ete teen nee Page (R4941JD) Wo wo 16 4o 40 00 Co Oo 06 OO 0 SIS td AMAaAaAanaananduaanini iw PANS ee _ So501-168, Rev. 0 ANP AMP INCORPORATED HARRISBURG, PENNSYLVANIA 17105 PHONE: 717-564-0100 TWX: 510-657-4116 CORPORATE TEST LABORATORY Qualification Test Report Connector, AMPLIMITE HD-20, Printed Circuit Board Mounted 1.1 1.2 1.3 Introduction Purpose Testing was performed on AMPs AMPLIMITE HD-20 Connector, Printed Circuit Board Mounted, to determine its conformance to the requirements of AMP Product Specification 108-40025, Rev.0. Scope This report covers the electrical, mechanical, and environmental performance of the AMPLIMITE HD-20, PC Board Mounted Connector manufactured by the Interconnection Components and Assemblies Products of the Capital Goods Business Unit. The testing was performed between January 22,1992 and February 24,1992. Conclusion The AMPLIMITE HD-20, PC Board Mounted Connector meets the electrical, mechanical, and environmental performance requirements of AMP Product Specification 108-40025, Rev. 0.501-168, Rev. 0 Page 2 1.4 1.5 Product Description AMPLIMITE HD-20 printed circuit board mounted connectors are available in right angle front metal shell, straight posted all plastic and front metal shell, and right angle & straight posted full metal shell. All housings for plug and receptacle connectors are a molded black thermoplastic with a 94V-0 rating. The front metal shell is made of steel with tin plating. The ful? metal shell is made of steel with either tin or zinc plating. Test Samples The test samples were randomly selected from normal current production lots, and the following part numbers were used for test: Test Group Quantity Part Number Description ] 5 745781-2 9 Pos. Recept., Front-Metal Rgt. Angle, PC Board Mounted 5 *205204-3 9 Pos. Plug, W/O Grd. Indents 5 207830-4 50 Pos. Recept., All-Plastic Straight Post, Board Mounted 5 *205212-2 50 Pos. Plug, W/O Grd. Indents 2,3 5 745784-2 37 Pos. Recept., Front-Metal Rgt. Angle, PC Board Mounted 5 *205210-2 37 Pos. Plug, W/O Grd. Indents 4 35 747462-1] 37 Pos. Recept., All-Plastic Rgt. Angle, PC Board Mounted 35 745098-1 37 Pos. Recept., All-Plastic Rgt. Angle, PC Board Mounted 35 745100-1 50 Pos. Recept., All-Plastic Rgt. Angle, PC Board Mounted 5 2 747467-3 9 Pos. Plug, All-Plastic Rgt. Angle PC Board Mounted 2 *205203-3 9 Pos. Receptacle, Standard 2 747470-1 37 Pos. Plug, All-Plastic Rgt. Angle, PC Board Mounted 2 *205209-2 37 Pos. Receptacle, Standard 2 747459-] 9 Pos. Recept., All-Plastic Rgt. Angle, PC Board Mounted 2 *205204-4 9 Pos. Plug, W/Grd. Indents 2 747462-1 37 Pos. Recept., All-Plastic Rgt. Angle, PC Board Mounted 2 *205210-3 37 Pos. Plug, W/Grd. Indents 2 747009-2 9 Pos. Plug, Front-Metal Rgt. Angle PC Board Mounted 2 *205203-3 9 Pos. Receptacle, Standard501-168, Rev. 0 Page 3 Test Group Quantity Part Number Description 5 (Cont.) 2 747049-2 37 Pos. Plug, Front-Metal Rgt. Angle, PC Board Mounted 2 *205209-2 37 Pos. Receptacle, Standard 2 747010-2 9 Pos. Recept., Front-Metal Rgt. Angle, PC Board Mounted 2 *205204-3 9 Pos. Plug, W/O Grd. Indents 2 747050-2 37 Pos. Recept., Front-Metal Rgt. Angle, PC Board Mounted 2 *205210-2 37 Pos. Plug, W/O Grd. Indents 2 745351-4 9 Pos. Plug, Metal-Shell Rgt. Angle, PC Board Mounted 2 *205203-3 9 Pos. Receptacle, Standard 2 745355-4 50 Pos. Plug, Metal-Shell Rqt. Angle, PC Board Mounted 2 *205211-2 50 Pos. Receptacle, Standard 2 745112-2 9 Pos. Recept., Metal-Shell Rgt. Angle, PC Board Mounted 2 *205204-3 9 Pos. Plug, W/O Grd. Indents 2 745116-2 50 Pos. Recept., Metal-Shell Rgt. Angle, PC Board Mounted 2 *205212-2 50 Pos. Plug, W/O Grd. Indents 6 3 747461-1 25 Pos. Recept., All-Plastic Rgt. Angle, PC Board Mounted 3 747469-1 25 Pos. Plug, All-Plastic Rgt. Angle, PC Board Mounted 3 747048-2 25 Pos. Recept., Front-Metal Rgt. Angle, PC Board Mounted 3 747047 -2 25 Pos. Plug, Front-Metal Rgt. Angle, PC Board Mounted 3 745114-2 25 Pos. Recept., Metal-Shell Rgt. Angle, PC Board Mounted 745353-2 25 Pos. Plug, Metal-Shel] Rgt. Angle, PC Board Mounted 5 207830-4 50 Pos. Recept., All-Plastic Straight Post, Board Mounted 7 3 747461-3 25 Pos. Recept., All-Plastic Rgt. Angle, PC Board Mounted 3 747469-3 25 Pos. Plug, Alt-Plastic Rgt. Angle, PC Board Mounted 3 747047-4 25 Pos. Plug, Front-Metal Rgt. Angle, PC Board Mounted 8 747150-2 9 Pos. Recept., Front-Metat Straight Post, Board Mounted 2 *205204-4 9 Pos. Plug, W/Grd. Indents501-168, Rev. 0 Page 4 1.6 Test Group Quantity Part Number Description 8(Cont.) 2 747299-2 15 Pos. Recept., Front-Metal Straight Post, Board Mounted 2 *205206-3 15 Pos. Plug, W/Grd. Indents 2 745967-2 25 Pos. Recept., Front-Metal Straight Post, Board Mounted 2 *207464-2 25 Pos. Plug, W/Grd. Indents 2 747301-2 37 Pos. Recept., Front-Metal Straight Post, Board Mounted 2 *205210-3 37 Pos. Plug, W/Grd. Indents * - Mated with connectors for test purposes only. Qualification Test Sequence Test Groups Test or Examination 1 2 3 4 5 6 7 a Examination of Product 1, 1,6 1,6 1,3 1,5 1,8 31,3 1,5 Termination Resistance, Dry Circuit 3, 2,5 2,5 2,4 Dielectric Withstanding Voltage 3,7 Insulation Resistance 2,6 T-Rise vs. Current 2 Vibration 5 Physical Shock 6 Mating Force 2 2 Unmating Force 8 4 Durability 4 3 3 Solderabitity 2 Thermal Shock 4 Humidity-Temperature Cycling 4 5 Industrial Mixed Flowing Gas 3 Temperature Life 4 The numbers indicate sequence in which tests were performed.2.1 2.2 2.3 2.4 2.5 501-168, Rev. 0 Page 5 Summary of Testing Examination of Product - All Groups All samples submitted for testing were selected from normal current production lots. They were inspected and accepted by the Product Assurance Department of the Capital Goods Business Sector. Termination Resistance, Dry Circuit - Groups 1,2,3, & 5 All termination resistance measurements, taken at 100 milliamperes dc. and 50 millivolts open circuit voltage, the initial neasurements were less than 15 milliohms and final measurements were less than 20 milliohms. Test No. of Group Samples Condition Min. Max. Mean ] 10 Initial 3.30 7.80 5.00 After Phy. Shock 3.37 8.35 5.10 2 5 Initial 5.28 7.35 6.25 Aft. Temp. Life 5.69 9.02 7.09 3 5 Initial 5.41 7.44 6.31 Aft. Temp/Hum. 5.46 7.94 6.58 5 24 Initial 5.94 10,25 7.50 After I.M.F.G. 5.41 10.83 7.79 All values in milliohms Dielectric Withstanding Voltage - Group 6 No dielectric breakdown or flashover occurred when a test voltage was applied between adjacent contacts. Insulation Resistance - Group 6 All insulation resistance measurements were greater than 5000 megohms initially and 100 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 P/N AWG Current Above Ambient (Max} 747462-1 18 6.0 13.3C 745098-1 24 4.3 12.9C 745100-1 28 2.9 9.4C501-168, Rev. 0 Page 6 2.6 2.7 2.8 2.9 2.10 2.1] 2.12 2.13 2.14 2.15 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 Jess than the specification requirements. Unmating Force - Groups 1 & B Alt unmating force measurements were less than the specification requirements. Durability - Groups 1,2,3, & 8 No physical damage occurred to the samples as a result of mating and unmating the connector 500 times. Solderability - Group 7 The contact leads had a minimum of 95% solder coverage. 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.3.1 3.2 3.3 3.4 501-168, Rev. 0 Page 7 Test Methods Examination of Product Product drawings and inspection plans were used to examine the samples. They were examined visually and functionally. 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. _ C ) Power Supply P.C. Board Rc. Angle Connector Ley Card Edge Connector Termination Resistance Measurement Points Figure 1 Typical Termination Resistance Measurement Points 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. Insulation Resistance Insulation resistance was measured between adjacent contacts, using a test voltage of 500 volts dc. This voltage was applied for 2 minutes before the resistance was measured.501-168, Rev. 0 Page 8 3.5 3.6 3.7 3.8 3.9 3.10 Temperature Rise vs Specified Current Connector temperature was measured, while a single circuit was 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 0 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 0.3 G /Hz at 100 Hz. The spectrum is flat at 0.3 G /Hz from 100 to 1000 Hz. The spectrum slopes down at 6 dB per octave tg 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 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. Mating Force The force required to mate individual connectors were 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 were measured, using a free floating fixture with the rate of travel at 1.0 inch/minute. Durability Connectors were mated and unmated 500 times at a rate not exceeding 200 per hour.3.1] 3.12 3.14 501-168, Rev. 0 Page 9 solderability Connector assembly contact solder tails were subjected to a solderability test by immersing them in a Nonactivated Rosin flux for 5 to 10 seconds, allowed to drain for 10 to 60 seconds, then held over molten solder without contact for 2 seconds. The solder tails were then immersed in the molten solder, at a rate of approximately one inch per second, held for 3 to 5 seconds, then withdrawn. After cleaning in isopropyl alcohol, the samples were visually examined for solder coverage. The solder used for testing was 60/40 tin lead composition and was maintained at a temperature of 245C. Thermal Shock Mated connectors were subjected to 100 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 128s 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%. (During five of the first nine cycles, the connectors were exposea to a cold shock at -10C for 3 hours.) Industrial Mixed Flowing Gas, Class III Mated connectors were exposed for 20 days to an industrial mixed flewing gas Class III exposure. Class III exposure is defined as a temperature of 30C and a relative humidity of 75%, with the pollutants of Cla at 20 ppb, NOs at 200 ppb, and HS at 100 ppb. Temperature Life Mated samples were exposed to a temperature of 105C for 500 hours.501-168, Rev. 0 Page 10 Validation Prepared by: / Ome ACU fd B72. Lf J A. D Angelo ineering Assistant roduct Test Section Corporate Test Laboratory Reviewed by: W200 Co hs Richard A. Groft | Supervisor Design Assurance Testing Corporate Test Laboratory Approved by: tA beh Edward L. Gil [7 Manager, Engineering & Design Assurance Capital Goods Business Unit Spo 92 B12 Ge