RIGHTS RESERVED. AMP PRODUCTS MAY BE COVERED BY US. AND BY AMP INCORPORATED HAARISBURG, PA. ALL INTERNATIONAL FOREIGN PATENTS ANO/OR PATENTS PENDING. COPYRIGHT 19 75,86 PRODUCT SPECIFICATION 1. SCOPE 1.1. Content This specification covers the performance, tests, and quality requirements for the AMP-LEAF*t Connector assembly, with gold and tin plated contacts and housings molded with diallyl phthalate, phenolic and nylon material. 1,2, 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. 2s APPLICABLE DOCUMENTS The following documents form a part of this specification to the extent specified herein. In the event of conflict between 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 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 EIA RS-364) C. Corporate Bulletin 76: Cross-reference between AMP Test Specifications and Military or Commercial Documents DD. 501- : Test Report 2.3. Military Standard MIL-STD-275: Printed Wiring for Electronic Equipment *Trademark of AMP Incorporated. DR CHK H.J. Hagan 8/27/75 C.E. Fritz 8/27/75 AMP INCORPORATED AMP | Harrisburg, Pa. 17105 APP Loc | NO _ D.N. Bushey 8/27/75| B 108-9013 REV G I G | Revise per sofeg TITLE em ECN AD-0398 L120 ou. | SHEET GONNECTOR, AMP~LEAF 14 1OF 11 LTR REVISION RECORD APP | DATE _ AMP 1250-16 REV 4-823. REQUIREMENTS 3.1. Design and Construction Connectors shall be of the design, construction and physical dimensions specified on the applicable product drawing. 3.2. Material A. Contacts (1) Phosphor bronze, gold over nickel plating (2) Beryllium copper, gold over nickel plating (3) Phosphor bronze, tin over nickel plating (4) Beryllium copper, tin over nickel plating B. Housings (1) Diallyl phthalate (2) Phenolic (3) Polyester 3.3, Ratings A. Current: 5 amperes maximum with not more than 6 adjacent or opposing circuits carrying this current B. Operating Temperature: (1) Dially! phthalate: -65 to 125C (2) Phenolic and Polyester: +55 to 105C 3.4. Performance and Test Description Connectors shall be designed to meet the electrical, mechanical, and environmental performance requirements specified in Figure 1. Loc SHEET NO REV AMP AMP INCORPORATED Harrisburg, Pa. 17105 Bi 2 OF 11 108-9013 G AMP 1251-13 REV 4+82OO 3.5. Test Requirements and Procedures Summary Test Description Examination of Product Requirement Meets requirements of product drawing. Visual, dimensional, Procedure and functional per applicable inspection plan. ELECTRICAL Termination Resistance, Dry Circuit 6 milliohms maximum. Subject mated contacts assembled in housing to 50 mv open circuit at 100 ma maximum, see Figure 4; AMP Spec 109-6-1. Dielectric Withstanding Voltage Test Voltage Altitude (rms) Feet 1800 Sea Level 675 50,000 2 ma maximum leakage current. No breakdown or flashover. Test between adjacent contacts of unmated connector assemblies; AMP Spec 109-29-1. Insulation Resistance 5000 megohms minimum initial. 1000 megohms minimum final. Test between adjacent contacts of unmated connector assembly; at 500 vde: AMP Spec 109-28-4. Current Cycling Crimp resistance shall not exceed final value. Resistance, Wire milliohms Size, Current maximum AWG amperes Final 26 1,0 4.0 24 3.0 3.3 22 5.0 2.0 20 745 1.2 18 10.0 8 Subject mated contacts to 50 cycles at 125% rated current for 30 minutes "ON" - 15 minutes "OFF"; AMP Spec 109-51, cond B, test method 3. Figure 1 (cont) a Loc | SHEET REV AMP AMP INCORPORATED Harrisburg, Pa. 17105 Bl] 3 OF 11 108-9013 G a a AMP 1251-13 REV 4-82AMP 1251-13 REV 4-82 - Test Description Requirement Procedure Crimp Resistance, Wire Resistance, Measure potential drop Specified Current Size, milliohms across crimped contact AWG Initial Final at 1 ampere maximum, 26 2.5 4.0 see Figure 5; AMP 24 z.0 3.3 Spec 109-25, 22 1.2 2.0 29 0.7 l. 4 18 0.5 0.8 MECHANICAL Vibration (a) No discontinuities Subject mated greater than 1 connectors to 10-55-10 microsecond. Hz traversed in 1 minute at .06 inches total excursion; 2 hours in each of 3 mutually perpendicular planes; AMP Spec 109~2i-1, Physical Shock (a). No discontinuities Subject mated greater than 1 connectors to 100 G's microsecond, sawtooth in 6 milli- seconds; 3 shocks in each direction applied along the 3 mutually perpendicular planes total 18 shocks; AMP Spec 109-26-9. Contact Retention Contacts shall not Apply axial load of 10 dislodge from its pounds to crimped normal locking contacts on 20 or position. larger AWG wire; AMP Spec 109-30 except grip wire. Contact Engaging Force 16 ounces maximum Measure force to engage per contact pair. using gage 2, see Figure 6; AMP Spec . 109-35, Contact Separating Force 2 ounces minimum Size 3 times using per contact pair. gage 2, see Figure 6, insert gage 1 and measure force to separate; AMP Spec 109-35. Figure 1 (cont) Loc NO REV AMP | AMP INCORPORATED 8 SHEET Harrisburg, Pa. 17105 4 OF lI 108-9013 GTest Description Requirement Procedure Crimp Tensile Wire Crimp Tensile, Determine crimp tensile Size, pounds at a rate of 1 inch/ AWG minimum minute; AMP Spec 26 5 109-16, 24 8 22 12 20 20 18 30 Durability No physical damage. Microinches Cycles 15 Gold 100 30 Gold 250 50 Gold 500 Tin 100 Mate and unmate, using gage 2, see Figure 6, for 250 cycles. AMP Spec 109-27. ENVIRONMENTAL Thermal Shock {a} No physical damage. Subject mated connectors to 5 cycles between -65 and 125C, for diallyl phthalate and between -55 and 105C for phenolic and nylon; AMP Spee 109-22 Humidity-Temperature Cycling 5000 megohms minimum final insulation resistance. Subject mated connectors to 10 humidity-temperature cycles between 25 and 65C at 953 RH; AMP Spec 109-23, Method III, Cond B, with cold shock at -10C. L (a) Shall show no evidence of damage, cracking or chipping. Figure 1 (end) nA AMP INCORPORATED x - | Harrisburg, Pa. 17105 B 5 OF il Loc | =SHEET NO REV 108-9013 G AMP 1251-13 REV 4-823.6, Connector Qualification and Requalification Tests and Sequences Test Group (a) Test or Examination L {2 L.3 ][4 (ec) Test Sequence (b) = = 4 Examination of Product 1 1 l 1 Termination Resistance, Dry Circuit 2 2,10 2,4 Dielectric Withstanding Voltage 7 Insulation Resistance 9 Current Cycling 3 Crimp Resistance, Specified Current 2 Vibration 8 Physical Shock 9 Contact Retention 8 1] Contact Engaging Force 3 i Contact Separating Force 5 4,7 Crimp Tensile 4 Durability 4 1 Thermal Shock 3 5 Humidity-Temperature Cycling 6 3 (a) See Para 4.1.4. {b) Numbers indicate sequence in which tests are performed. {c) Tin plated contacts only. 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 9 cennectors of the greatest number of positions of each connector type offered, 6 each test group 1 and 3 each for test group 2. Test group 1 shall have 3 connectors board mounted and 3 connectors unmounted. The unmounted samples shall be tested for humidity, insulation resistance and dielectric. Two additional specimens shall be selected from the least number of Positions offered and tested to test group 2. Thirty contacts of each style and desired wire size shall be tested to test group 3. Test group 4 shall consist of 3 connectors of the greatest number of positions board mounted. B. Test Sequence Qualification inspection shall be verified by testing samples as specified in Figure 2. f Loc SHEET NO REV ARAP | AMP INCORPORATED Harrisburg, Pa. 17105 Bi 6 OF 11 108-9013 AMP 1251-13 REV 4-82 on Cc. 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 X bar 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 95% confidence and 99% reliability. 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 X bar + 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 X bar + 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 X bar + ks does not exceed the requirement value. The lower one-sided tolerance limit for 95% confidence and 99% reliability is given by xX bar - ks. This has a. similar interpretation and corresponding application to lower requirement values. (2) Failures attributed to equipment, test setup, or operator deficiencies shall not 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 Inspection 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. Loc] SHEET | NO REV AMP INCORPORATED AMP | Harrisburg, Pa. 17105 B] 7 OF 11 108-9013 G AMP 1251-13 REV 4-62+.005 | pe 094 7 ogg Typ [P| .003 Total .156 BSC Typ-- _ . | 062 h wy N & N (See Note 3) ; O15 iY } _t | ' r 062 ose je | | F \ Section B-B B | -| Lt -062 j ~A- mt (+ .005 = = (See Note 6) =}A!.004 Total Notes: 1. Dimensions are in inches. Z. Unless otherwise specified, tolerance is +/-.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 connector. 5. Printed circuit test beard shall be 2 oz copper and gold over nickel plated per MIL-STD-275. 6. This dimension shall be the minimum connector card slot length minus 008. 7. Printed wiring shall be identical on both sides. Figure 3 toc] SHEET | NO REV Harrisburg, Pa. 17105 AMP | AMP INCORPORATED 8 OF 11 108-9013 AMP 1251-13 REV 4-82a) Power Supply . Printed Circuit 3 ft min length of ~ - - - Board , see continuous lead for Termination Resistance Ficure 4 heat dissipation Measurement Points . Figure 4 Termination Resistance Measurement Points LOC SHEET NO REV AMP INCORPORATED AMP | Harrisburg, Pa. 17105 Bi 5 OF wy 108-9013 G AMP 1251-13 REV 4-82Crimp Resistance Measurement Points Crimp Resistance Measurement Point Figure 5 Note: The resistance of 3 inches of wire shall be measured and that amount deducted from the total value so as to show only the crimp resistance. AMP INCORPORATED AMP | Harrisburg, Pa. 17105 Loc SHEET 10 OF 41 NO 108-9013 REV AMP 1251-13 REV 4-82be 1. OOO#. 015 375 .067 R Typ 15 Typ B - 140%. O15 [ pore Typ . } i> F A ise T yp _010#,005 R Typ 4/ (2 Sides) L. Tolerance: .005 or +2 as applicable, unless otherwise specified. 2. Material: Tool steel, AISI] type 02 per AMP Specification 100-15. 3. Heat treat: Rockwell C50-55, 4, Gage surface shall be clean of contaminants or lubricants. B Nase A Centerline 100 & .125 -156 =a 1 05407 * 0000 ~.0001 065 -088 2 o7097 2001 . -.0000 Figure 7 Engaging and Separating Force Gages | LOG 7 | NO REV ARAP AMP INCORPORATED SHEE Harrisburg, Pa. 17105 B 1] OF 41 108-9013 G AMP 1251-13 REV 4-62