TYPE
PRODUCT SPECIFICATION
NUMBER
BUS-12-022
TITLE PAGE REVISION
1 of 14 J
AUTHORIZED BY DATE
Solder Plated Clincher Connector
C. Martinez Aug 25 06
CLASSIFICATION
UNRESTRICTED
Copyright FCI
Form E-3334
Rev. E
GS-01-001
1.0 GENERAL
Purpose
This specification defines the performance, test, quality and reliability requirements for Solder Plated
Clincher™ Connector.
Scope
This specification covers the Solder Plated Clincher™ Connector designed to terminate flat conductor, flat
flexible cable and to interconnect this cable with 0.025 inch square or round pins on 0.100 inch centers. All
product where the part number ends in ‘LF’ meet the requirements of theEuropean Union Directives of
Restrictions for Hazardous Substances (Directive 2002/95/EC) and other country regulations as described in
GS-22-008. The part number that do not end in ‘LF’ meet all regulations except for PB an SnPb plating.
This specification is composed of the following sections.
Paragraph Title Page
1.0 GENERAL 1
2.0 APPLICABLE DOCUMENTS 1
3.0 REQUIREMENTS 2
3.1 Qualification 2
3.2 Material 2
3.3 Finish 2
3.4 Design and Construction 3
3.5 Electrical Characteristics 3
3.6 Mechanical Characteristics 5
3.7 Environmental Conditions 6
4.0 QUALITY ASSURANCE PROVISIONS 10
4.1 Equipment Calibration 10
4.2 Inspection Conditions 10
4.3 Qualification Inspection 10
4.4 Quality Conformance Inspection 12
4.5 Acceptance Inspection 12
5.0 NOTES AND DEFINITIONS 13
2.0 APPLICABLE DOCUMENTS
The following documents, of the issue in effect on the date of the latest revision of this specification, shall
form a part of this specification to the extent specified herein.
Military Specifications
MIL-G-45662 Calibration System Requirement
Military Standards
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Rev. E
GS-01-001
MIL-STD-105 Sampling Procedures and Tables for Inspection by Attributes
MIL-STD-202 Test Methods for Electrical and Electronic Component Parts
EIA-364 Test Methods for Electrical Connectors
Federal Specifications
QQ-C-533 Beryllium Alloy Copper Strip
Industry Specifications/Standards
UL-94 Tests for Flammability of Plastic Materials
IPC-FC-220 Specification for Flat Cable, Flat-Conductor, Flexible, Unshielded
ASTM B122 Copper-Nickel-Tin Alloy, Copper-Nickel-Zinc Alloy (Nickel Silver), and Copper-Nickel
Alloy Plate, Sheet, Strip and Rolled Bar
ASTM B545 Electrodeposited Coatings of Tin
ASTM B579 Electrodeposited Coatings of Tin-Lead Alloy (Solder Plate)
3.0 REQUIREMENTS
3.1 Qualification
Connectors furnished under this specification shall be products capable of meeting and qualification
test requirements specified herein.
3.2 Material
The material for each part shall be as specified herein, or equivalent. Substitute material shall meet
the performance requirements of this specification.
3.2.1 Metallic Parts
3.2.1.1 Contact Body. The body shall be half-hard (HO2 Temper) Copper-
Nickel-Tin Alloy 725 in accordance with ASTM B122.
3.2.1.2 Contact Spring. The spring shall be half-hard beryllium copper in
accordance with QQ-C-533, heat treated to full-hard condition.
3.2.2 Housing. The housing shall be molded of flame retardant polypropylene. The material
shall be rated V-O in accordance with UL-94.
3.3 Finish
3.3.1 Contact Body. The body material shall be pre-plated 100 microinches (minimum) tin-lead
(solder) or pure tin for Lead Free option.
3.3.2 Contact Spring. The spring shall be plated on its convex side with 10 microinches
(minimum) tin-lead (solder) or pure tin for Lead Free option.
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TITLE PAGE REVISION
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C. Martinez Aug 25 06
CLASSIFICATION
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Copyright FCI
Form E-3334
Rev. E
GS-01-001
3.4 Design and Construction
3.4.1 Installation. The connector shall simultaneously terminate up to 32 signal leads on 0.100
inch centers.
3.4.2 Mating. The connector shall be capable of mating and unmating by hand without the use
of special tools within the specified temperance range.
3.4.3 Workmanship. Connectors shall be uniform in quality, and shall be free from burrs,
scratches, cracks, voids, chips, blisters, pin holes, sharp edges, and other defects that
will adversely affect life or serviceability.
3.4.4 Interchangeability. The connector shall be capable of mating with any appropriately
constituted male connector or pin field (see Figure 2) of the same population without
degradation in performance.
3.5 Electrical Characteristics
3.5.1 Current Rating. The maximum current rating of the connector shall be 2.0 ampere DC.
3.5.2 Contact Resistance. The contact resistance shall not exceed 20 milliohms (25 milliohms
after environmental exposure) when measured in accordance with MIL-STD-202, Method
307; the following details shall apply:
a. Method of Connection - Attach current and voltage leads as shown in Figure 1.
b. Test Current - 1.0 ampere DC
3.5.3 Low Level Circuit Resistance. The low level circuit resistance shall not exceed 20
milliohms (25 milliohms after environmental exposure) when measured in accordance
with EIA-364 TP45; the following details shall apply:
a. Method of Connection - See Figure 1
b. Test Current - 10 milliamperes DC, approximate
c. Open-Circuit Voltage - 50 millivolts, maximum
3.5.4 Insulation Resistance. The insulation resistance of this unterminated connector shall be
not less than 5000 megohms (10 megohms within 15 minutes after exposure to the
humidity environment described in 3.7.2) when measured in accordance with MIL-STD-
202, Method 302; the following details shall apply:
a. Test Condition - B (500 volts DC)
b. Points of Measurement - Between adjacent contacts
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Rev. E
GS-01-001
FIGURE 2 - MATING HEADERS
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Form E-3334
Rev. E
GS-01-001
3.5.5 Dielectric Withstanding Voltage. There shall be no evidence of arc-over, insulation
breakdown, or excessive leakage current (>1.0 milliampere) when the unterminated
connector is tested in accordance with MIL-STD-202, Method 301; the following details
shall apply:
a. Test Potential - 1000 volts RMS, 60 Hz (sea-level pressure)
b. Test Duration - 60 seconds
c. Points of Measurement - Between adjacent contacts
3.6 Mechanical Characteristics
3.6.1 Total Mating and Unmating Force. The total force to mate (or unmate) the terminated
connector with an appropriately populated header consisting of properly configured (see
Figure 2) 0.025 inch square or round pins shall not exceed 375 grams times the number
of terminals. The test shall be in accordance with EIA-364 TP13, at a cross-head speed
of one (1) inch per minute.
For product with an external mechanical locking device, the total mating force shall not
exceed 375grams times the number of terminals plus 521gm for the mechanical latch.
For product with an external mechanical locking device, the total unmating force shall not
be more than 375 grams times the number of terminals plus 1200gm for the mechanical
latch.
3.6.2 Individual Contact Withdrawal Force. When measured using a minimum gage configured
as shown in Figure 3, the individual contact withdrawal force shall be not less than 30
grams. The test shall be in accordance with EIA-364 TP37; the following details shall
apply:
a. Test Procedure - 1
b. Speed of Withdrawal - 1 inch per minute
c. Insertion Depth - 0.230 to 0.250 inch
d. Number of Prior Activations - 1 (with maximum gage shown in Figure 3)
3.6.3 Cable Retention. The contact termination shall withstand, without loss of continuity, an
evenly distributed force of 10 pounds per inch-of-cable-width applied to the cable in a
direction parallel to the contact axis.
3.6.4 Cable Flex Resistance (see 5.1). The contact termination shall withstand, without loss of
continuity, 100 cycles of flexing; the following details shall apply:
a. Tension on Cable - 2 pounds per inch-of-cable-width
b. Flex Angle - 140o as shown in Figure 4
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C. Martinez Aug 25 06
CLASSIFICATION
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Copyright FCI
Form E-3334
Rev. E
GS-01-001
3.6.5 Durability. After 100 mating cycles of the connector and an appropriately populated header
consisting of properly configured (see Figure 2) 0.025 inch square or round pins, the total
mating and unmating force shall not exceed 375 grams times the number of terminals (see
3.6.1), the individual contact withdrawal force shall be not less than 30 grams (see 3.6.2)
and the contact resistance shall not exceed 25 milliohms (see 3.5.2).
3.6.6 Mechanical Latch Retention. Total Force required to dislodge the latch only of an
unloaded housing with the appropriate mating header shall be 4lbs. Minimum.
3.6.7 Mechanical Latch Normal Force. Force required to depress the mechanical latch .040
of an inch. Is 3 lb. Maximum at ambient temperature. (See Figure 6)
3.6.8 Latch Durability. Latch to be depressed .040 of inch and return to it’s original position +/-
.010 after initial and 25 cycles at ambient temperature and at –65 C degrees. There shall
be no evidence of cracking of the latch after cycling.
3.7 Environmental Conditions
3.7.1 Thermal Shock (see 5.2). After exposure of the mated connector and header to alternate
periods of extreme high and low temperature, there shall be no evidence of cracking or
crazing of the insulator or other physical damage to the connector; the dielectric
withstanding voltage of an unterminated connector shall be not less than 1000 volts RMS,
60 Hz (see 3.5.5). The test shall be in accordance with MIL-STD-202, Method 107; the
following details shall apply:
a. Test Condition - B (5, 1-hour cycles)
b. Temperature Range - -65oC to +105oC
c. Time at each Temperature - 30 minutes, minimum
d. Transfer Time - 30 seconds, maximum
3.7.2 Humidity. Within one (1) hour after exposure to a high humidity environment, the
insulation resistance of an unterminated connector shall be not less than 5000 megohms
(see 3.5.4); the low level circuit (contact) resistance of the mated connector and header
shall not exceed 20 milliohms (see 3.5.3). The test shall be in accordance with MIL-STD-
202, Method 103; the following details shall apply:
a. Test Condition - B (96 hours)
b. Chamber Temperature - +40oC
c. Relative Humidity - 90%
3.7.3 High Temperature Life (see 5.2). After exposure of the unterminated connector to a high
temperature operating environment, the insulation resistance shall be not less than 5000
megohms (see 3.5.4); the contact resistance of the mated connector and header shall not
exceed 20 milliohms (see 3.5.2). The test shall be in accordance with MIL-STD-202,
Method 108; the following details shall apply:
a. Chamber Temperature - +85oC, (+105oC, unterminated connector only)
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Form E-3334
Rev. E
GS-01-001
b. Test Condition - B (250 hours)
c. Operating Conditions - 0.5 ampere DC current through all signal contacts of
terminated connector; duty cycle: 45 minutes ON and 15 minutes OFF
3.7.4 Shock (see 5.3). There shall be no evidence of physical or mechanical damage or
disassociation of parts when the mated connector and header are subjected to transient
accelerations. During and after each shock, the contacts shall exhibit no discontinuity
greater than 1 microsecond. The test shall be in accordance with MIL-STD-202, Method
213; the following details shall apply:
a. Test Condition - 1 (100g, 6 millisecond sawtooth)
b. Number of Shocks - 3 shocks in both directions along each of three (3) orthogonal
axes (18 total)
c. Mounting - see Figure 5
3.7.5 Vibration (see 5.3). There shall be no evidence of physical or mechanical damage or
disassociation of part when the mated connector and header are subjected to prolonged
mechanical vibration; during vibration along each axis, the contacts shall exhibit no
discontinuity greater than 1 microsecond. At the completion of the test, the individual
contact withdrawal force shall be no less than 30 grams (see 3.6.2) and the contact
resistance shall not exceed 20 milliohms (see 3.5.2). The test shall be in accordance
with MIL-STD-202, Method 204; the following details shall apply:
a. Test Condition - B (15g, 10 to 2000 Hz)
b. Test Duration - 4 hours along each of three (3) orthogonal axes (12 hours total)
c. Mounting - see Figure 5
3.7.6 Hydrogen Sulfide (H2S) Atmosphere. After exposure of the mated connector and header
to a moist H2S atmosphere (approximately 3 ppm), the low level circuit (contact)
resistance shall not exceed 20 milliohms (see 3.5.3). The following details shall apply:
a. Test Medium - solution of 120 grams Na2.9h2O in 500 ml of distilled water, with 14
grams K2HPO4 added immediately prior to test
b. Test Temperature - +40o
c. Test Duration - 48 hours in a sealed 9000 cubic centimeter glass container
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Rev. E
GS-01-001
FIGURE 3 - GAUGE
FIGURE 4 – FLEX RESISTANCE
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Form E-3334
Rev. E
GS-01-001
FIGURE 5 - MOUNTING FOR SHOCK AND VIBRATION
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Form E-3334
Rev. E
GS-01-001
4.0 QUALITY ASSURANCE PROVISIONS
4.1 Equipment Calibration
All test equipment and inspection facilities used in the performance of any test shall be maintained in
a calibration system in accordance with MIL-C-45662.
4.2 Inspection Conditions
Unless otherwise specified herein, all inspections shall be performed under the following ambient
conditions.
a. Temperature - 25oC +_ 5oC
b. Relative Humidity - 30 to 80%
c. Barometric Pressure - local ambient
4.3 Qualification Inspection
Qualification inspection shall be performed on sample units produced with equipment and
procedures normally used in production.
4.3.1 Sample. Nine (9) connectors shall be subjected to the Qualification Inspection.
4.3.2 Preparation of Samples. The various test samples shall be configured and terminated as
shown in Table III. The cable shall conform to the requirements of IPC Specification FC-
220, Type A and B, Tolerance Class IV, except that the margin shall be 0.069 inch
(nominal) and the conductor width shall be 0.062 +_ 0.003 inch.
TABLE III - QUALIFICATION INSPECTION SAMPLES
Number of Crimp Mating Header
Sample Number Positions Height Square Pin Round Pin
1, 2, 4, 5, 6, 10 19 Max. X ---
3 19 --- --- ---
7, 8, 9 5 Min. --- X
4.3.3 Test Sequence. The sample connectors shall be subjected to the inspections specified in
Table IV, in the order shown.
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Rev. E
GS-01-001
TABLE IV - QUALIFICATION INSPECTION
Sample Number
Examination or Test Para 1 2 3 4 5 6 7 8 9 10*
Total Mating and Unmating 3.6.1 - - - X X X X X X X
Force
Individual Contact Insertion 3.6.2 - - - X X X X X X -
and Withdrawal Force
Cable Retention 3.6.3 - X - - X X X - - -
Cable Flex Resistance 3.6.4 X - - X - - X X - -
Contact Resistance 3.5.2 X X - X X X X X X -
Insulation Resistance 3.5.4 - - X - - - - - - -
Dielectric Withstanding 3.5.5 - - X - - - - - - -
Voltage
Thermal Shock 3.7.1 X X X - - - - - - -
Humidity 3.7.2 X X X - - - - - - -
High Temperature Life 3.7.3 X X X - - - - - - -
Shock 3.7.4 - - - X X - - - - -
Vibration 3.7.5 - - - X X - - - - -
Durability 3.6.5 - - - X - X X X X -
Hydrogen Sulfide Atmosphere 3.7.6 - - - X X X X X X -
Mechanical Latch Retention 3.6.6 - - - - - - - - - X
Mechanical Latch Normal Force 3.6.7 - - - - - - - - - X
Mechanical Latch Durability 3.6.8 - - - - - - - - - X
*Latching clincher test sequence 10 on separate sample groups for each test.
4.4 Quality Conformance Inspection
Quality conformance inspection shall be performed on sample units produced with equipment and
procedures normally used in production.
4.4.1 Sample. Six (6) of the largest population connectors, available at the time of test, shall
be selected at random from items produced and subjected to the Quality Conformance
Inspection.
4.4.2 Preparation of Samples. The various test samples shall be configured and terminated as
shown in Table V.
4.4.3 Test Sequence. The sample connectors shall be subjected to the inspections specified in
Table VI, in the order shown.
4.4.4 Failure. If the connector fails to pass the Quality Conformance Inspection, appropriate
corrective action shall be taken on the materials or processes and additional sample units
shall be subjected to the Quality conformance Inspection to verify the effectiveness of the
action.
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Rev. E
GS-01-001
TABLE V - QUALITY CONFORMANCE INSPECTION SAMPLES
Mating Header
Sample Number Crimp Height Square Pin Round Pin
1, 2, 4, 5, 7 Maximum X -
3 --- - -
6 Minimum - X
TABLE VI - QUALITY CONFORMANCE INSPECTION
Sample Number
Examination or Test Para 1 2 3 4 5 6 7*
Total Mating and Unmating Force 3.6.1 - - - X X X X
Force
Individual Contact Insertion 3.6.2 - - - X X - -
and Withdrawal Force
Cable Retention 3.6.3 X - - X - - -
Cable Flex Resistance 3.6.4 - X - - X - -
Contact Resistance 3.5.2 X X - X X X -
Insulation Resistance 3.5.4 - - X - - - -
Dielectric Withstanding Voltage 3.5.5 - - X - - - -
Thermal Shock 3.7.1 X - X - - - -
Humidity 3.7.2 X X X - - - -
Durability 3.6.5 X X X X - X -
Hydrogen Sulfide Atmosphere 3.7.6 - - - X X X -
Mechanical Latch Retention 3.6.6 - - - - - - X
Mechanical Normal Force 3.6.7 - - - - - - X
Mechanical Latch Durability 3.6.8 - - - - - - X
*Latching Clincher test sequence 10 on separate sample groups for each test.
4.5 Acceptance Inspection
Acceptance inspection shall consist of the examinations and inspections specified in Table VII.
TABLE VII - ACCEPTANCE INSPECTION
AQL
Examination Major Minor
Visual and Mechanical 1% 4%
4.5.1 Inspection Lot. An inspection lot shall consist of all connectors produced under
essentially the same conditions and offered for inspection at one time.
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Form E-3334
Rev. E
GS-01-001
4.5.2 Sampling Plan. Statistical sampling and inspection shall be in accordance with MIL-STD-
105 for General Inspection, Level II. The acceptable quality level (AQL) shall be as
specified in Table VII. Major and minor defects shall be as defined in MIL-STD-105.
4.5.3 Rejected Lots. Rejected lots shall be reworked to correct the defects or screened to
remove defective units and re-submitted for inspection.
4.5.4 Disposition of Sample Units. Sample units that have been subjected to the acceptance
inspection shall be considered deliverable on the contract or purchase order.
5.0 NOTES AND DEFINITIONS
5.1 Cable Flex Resistance
The connector design does not provide the strain relief usually considered necessary for the type of
extreme handling represented by this test. While the connector-cable interface will withstand
repeated flexing under the specific conditions of test described in this specification, long-term use in
a similar environment should include specific provisions for anchoring the cable close to the
connector.
5.2 High-Temperature Limit
The Underwriters Laboratories "Temperature Index" for the material used in the housing is +65oC,
for purposes of long term exposure. The rating must be kept in mind in any projected connector
use.
5.3 Shock and Vibration Environment
The overall connector design (low contact population, single row layout, low force contacts, etc.)
precludes self-retention during these mechanical environments. Some latching or other retention
technique must be provided by the user if the connector will be exposed to these conditions.
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Rev. E
GS-01-001
REVISION RECORD
REV PAGE DESCRIPTION EC # DATE
A 4 Item 3.5.1 - Change 1.0 ampere to 2.0 5709 06/10/80
ampere
All Everywhere word "Clincher" appears, the
letters "tm" should be added to indicate
trademark status
B All Changes/corrections 8669 06/21/82
C 4 In section 3.5.2 change 10 to 15 10521 01/18/84
milliohms
D All Change .031 to .013 12349 12/07/84
E All V11789 06/24/91
F All Revised format to be consistent with V01904 07/28/00
GS-01-001, and change BERG, Dupont,
etc. references to FCI.
G ALL Add section 3.6.6, 3.6.7 and 3.6.8 V03-0776 07/15/03
Add mating/unmating information for
External locking device to 3.6.1,
Add fig. 6
Add sequence 10 to table IV & add sequence
7 to table VI.
H ALL Change logo. M06-0183 05/18/06
1 Add Scope and ‘LF’ option .
8 Switch titles for figure 3 & 4.
J 2 MIL-STD-1344 was replaced by EIA-364 M06-0326 08/25/06
PDM: Rev:J Released .STATUS: Printed: Nov 28, 2010
Mouser Electronics
Authorized Distributor
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FCI / Amphenol:
65801-002LF 65801-004LF 65801-003LF 65801-007LF 65801-010LF 65801-011LF 65801-013LF 65801-014LF
65801-015LF 65801-018LF 65801-019LF 65801-021 66226-009LF 66226-004LF 66226-008LF 65801-109LF
65801-106LF 65801-118LF 65801-102LF 65801-110LF 65801-104LF 65801-112LF 10022753-012LF 67516-008
66226-004 65801-021LF 65801-024LF 67516-012LF 10022753-019LF 10022753-024LF 10022753-025LF
10022753-026LF 10022753-031LF 10022753-106LF 10022753-109LF 10022753-111LF 10022753-112LF
10022753-115LF 10022753-119LF 10022753-120LF 10022753-122LF 10022753-123LF 10022753-124LF
10022753-127LF 10022753-130LF 10022753-132LF 65801-023LF 65801-027LF 65801-115LF 65801-121LF
65801-126LF 65801-130LF 65801-132LF 66226-002LF 66226-005LF 66226-015LF 66226-019LF 66226-029LF
67516-015LF 67516-511LF 67516-516LF 10027313-120LF 67516-502LF 67516-503LF 67516-510LF 67516-512LF
10022753-010LF 10022753-009LF 10022753-013LF 65801-022LF 65801-105 65801-115 66226-005 65801-111
10027313-025LF 10027313-111LF 10027313-118LF 10027313-020LF 10027313-114LF 10027313-108LF
10027313-012LF 10027313-011LF 10027313-107LF 10027313-131LF 10027313-031LF 10027313-015LF
10027313-128LF 10027313-027LF 10027313-127LF 10027313-030LF 10027313-112LF 10027313-019LF
10027313-109LF 10027313-033LF 10027313-133LF 10027313-123LF 10027313-126LF 10027313-022LF
10027313-032LF 10027313-013LF
