copraicnt 19 82,88 BY AMP INCORPORATED ALL INTERNATIONAL RIGHTS RESERVED. PRODUCT SPECIFICATION 1. SCOPE 1,1. Content This specification covers the performance, tests and quality requirements for the AMPLIMITE* HD-20 cassette assembly connector system which consists of a cassette and holder assembly. Cassette assembly includes a 33 position right angle AMPLIMITE socket connector and the holder assembly includes a 33 position right angle AMPLIMITE pin holder. 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. 2. APPLICABLE DOCUMENTS The following documents form a part of this specification to the extent specified herein. In the event of conflict between the 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 Documents A. 109-1: General Requirements for Test Specifications B. 109 Series: Test Specifications as indicated in Figure 1. (comply .with MIL-STD-202, MIL-STD-1344 and EIA RS-364) Cc. Gorperate Bulletin 401-76; Cross-reference between AMP Test Specifications and Military or Commercial Documents D. 501-85 : Test Report E. IS 6662: Instruction Sheet AMPLIMITE Connector Cassette and Holder Units 3. REQUIREMENTS 3.1. Design and Construction Product shall be of the design, construction and physical dimensions specified on the applicable product drawing. *Trademark of AMP Incorporated Pe Lickel off 6? a = AMP INCORPORATED CHE, a of 22439 IN Harrisburg, Pa. 17105 - - , +77 hes ; e Krced cu: ae AC u oie oe APR, f., [NO REV | Loc ve Neg be nye af7 [sq lO 8 ~ 40 0 [ 6 o B 0 Release per [2722 ro TITLE CONNECTOR SYSTEM AMPLIMITE ECN BD-2835 9 PAGE CASSETTE HD-20 LTA REVISION RECORD APP OATE 1 OF AMP 125016 REV 7-87Material A. Contacts: (1) Socket, phosphor bronze (2) Pin, Brass alloy Housing: Thermoplastic Ratings Voltage: 250 vac Temperature: -55 to 95C 3.4. Performance and Test Description The product is designed to meet the electrical, mechanical and environmental performance requirements specified in Figure 1. All tests are performed at ambient temperature unless otherwise specified. 3.5. Test Requirements and Procedures Summary Test Description Requirement Examination of Product Meets requirements of product drawing. Procedure Visual, dimensional and functional per applicable quality inspection plan. ELECTRICAL Termination Resistance, Dry Circuit 35 milliohms maximum. Subject mated contacts assembled in housing ta 50 mv open circuit at 100 ma maximum, see Figure 4; AMP Spec 109-6-1. Dielectric Withstanding Voltage 1 kvac dielectric with- standing voltage, one minute hold. One milli- ampere maximum leakage current. Test between adjacent eantacts of mated connector assemblies; AMP Spec 109-29-1 Insulation Resistance 5000 megohms minimum initial. Test between adjacent contacts of mated connector assembly; AMP Spec 109-28-4. Figure 1 (cont) AMP INCORPORATED AMF | Harrisburg,Pa. 17105 AMP 1251-13 REV 10-85 108 -40016Test Description Requirement MECHANICAL Procedure Vibration, Sinusoidal High Frequency No discontinuities greater 1 microsecond. See note (a) Subject mated connectors to 20 G's, between 10- 2000 Hz traversed in 20 minutes, 4 hours in each of 3 mutually perpendicu lar planes, see Fiz 3; AMP Spec 109-21-4. Physical Shock No discontinuities preater 1 microsecond. See note (a) Subject mated connectors to 50 G's half-sine shock pulses of 11 millisecond duration; 3 shocks in each direction applied along the 3 mutually perpendicular planes total 18 shocks, see Figure 3; AMP Spec 109-26-1, Mating Force 16.5 pounds maximum initial. Measure force necessary to mate connector assembly a distance of .175 from point of initial contact, ftncorp ating free floating fixture at a rate of 1 inch/minute; AMP Spec 109-42, cond A. Unmating Force 1.5 pounds minimum final. Measure force necessary to unmate connector assembly at a rate of i inch/minute; AMP Spec 109-42, cond A, Durability Termination resistance, Mate and unmate connector dry circuit. assemblies for 2000 eycles at a maximum rate of 200 cycles/hour; AMP Spec 109-27. Solderability Solderable area shall Subject contacts to have a solder coverage of 95% minimun. solderability: AMP Spec 109-11-5. ENVIRONMENTAL Thermal Shock Meet all subsequent tests. Subject mated comnectors to 5 cycles between -55 and 95C; AMP Spec 109-22. Figure 1 (cont) AMP INCORPORATED 3 AMP Harrisburg,Pa. 17105 AMP 1251-13 REV 10-85 PAGE [NO REV |LOG 108-40016 o BTest Description Requirement an ete Procedure Humidity-Temperature Cycling 1000 megohms final insulation resistance; termination resistance, Subject mated connectors to 10 humidity- temperature cycies dry circuit. between 25 and 65 C; AMF Spec 109-23, method III, cond B, with cold shock at -10C, less step /b, Subject mated connectors Industrial Mixed Flowing Gas Termination resistance, dry circuit. to environmental class III for 20 days; AMP Spec 109-85-3. (a) Shall remain mated and show no evidence of damage, cracking or chipping. Figure 1 (end) 3.6. Product Qualification, Requalification and Retention Tests Test Groups (a)(c Test or Examination 3 4 5 est equence Examination of Product Termination Resistance, D Cireuit electric tand Insulation Resistance ibration sica oc Mati orce mmat orce Durabili older ermal Shock -Temperature clin trial Mixed owing Gas Voltage (a) See Para 4.1.A. (b) Numbers indicate sequence in which tests are performed (c) Test groups 6 and 7 are for retention of qualification only. Figure 2 PAGE {NO REV | Loc AMP INCORPORATED 4 108-40016 oO AMP | AME NconponaTE B AMP 1251-13 REV 10-854. QUALITY ASSURANCE PROVISIONS 4.1 Qualification Testing A, Sample Selection Connector housing and contacts shall be prepared in accordance with applicable Instruction Sheets. They shall be selected at random from current production. Test groups 1 thru 5 shall consist of 6 cassette connectors with their full compliment of contacts. All mating contact circuits in each cassette connector system shall be identified and used for all measurements unless otherwise specified. Connectors shall be mounted on printed circuit boards. A minimum of 1 contact per row of each header shall be identified and used for inspection purposes for group 5 only. B. Test Sequence Qualification inspection shall be verified by testing samples as specified in Figure 2. 4,2. Retention of Qualification If, in a three-year period, no changes to the product or process cccur, the product shall be subjected to the two groups of the testing described in the test sequence, see Figure 2. Test groups 6 and 7 shall consist of ? cassettes with their full compliment of contacts. Justification for exceeding this time limit must be documented and approved by the division manager. 4.3, Requalification Testing If changes significantly affecting form, fit, or function are made to the product or to the manufacturing process, product assurance shall coordinate requalification testing, consisting of all or part of the original testing sequence as determined by development/product, quality, and reliability engineering. 4.4. Acceptance Acceptance is based on verification that the product meets the requirements of Figure 1. 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. Testing to confirm corrective action is required before resubmittal. 4.4. Quality Conformance Inspection The applicable AMP quality 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. PAGE | NCO REV | Loc AMP INCORPORATED 5 108-40016 0 AMP | Harrisburg,Pa. 17105 5 AMP 1251-13 REV 10-85Reliability Estimates Estimated reliability is provided relative to acceptance criteria for specific failure mechanisms using environmental test conditions (Heat Age and Industrial Mixed Flowing Gas) with known acceleration factors. Heat Age testing and IMFG testing have acceleration factors that are generally accepted by industry. Corresponding failure mechanisms are stress relaxation and corrosion. "Estimated reliability refers to the estimated proportion of product whose values of the performance parameter (e.g., change in interface resistance) will be on the acceptable side of the acceptance criterion. See Para 4.6. B. Humidity/temperature testing is performed and estimated reliability relative to the test is provided, but there are no accepted acceleration factors for relating humidity/temperature testing conditions and duration to operating conditions and life. Therefore these estimates of reliability refer only to the specified test conditions, not to the operating conditions, and are for information or comparative purposes only. Cc. Product reliability relative to a specified acceptance criterion for a particular performance parameter is estimated from environmental test data using one-sided tolerance limit factors (k-factors) for the normal distribution. Greatly simplified, the procedure is as follows: Samples of the product are subjected to environmental stress testing, and measurements are taken of some performance parameter such as change in interface resistance for pressure connections, or resistance across a solder joint for surface-mounted devices, etc. The data are tested for goodness of fit to a normal distribution. If the data provide a satisfactory fit to a normal distribution, then the k-factor" is computed from k = (UL-X)/S, where UL denotes the specified allowable upper limit, or acceptance eriterion, for the performance parameter (measurements greater than UL indicate product failure), X denotes the average of the sample measurements, and denotes the standard deviation of the sample measurements (calculated using a denominator of n-1l, where n denotes the sample size) The calculated value of k is then compared with a table of factors for one-sided tolerance limits for a normal distribution to determine the product reliability and associated confidence" that may be claimed, based on the test data. D. The acceptance criterion used is the maximum change in contact resistance permitted in the dry circuit resistance test as determined from contact physics (constriction resistance and super-temperature for high current contacts at rated current). Variables data of change in termination resistance are considered acceptable for making estimates of preduct reliability if a normal probability plot and appropriate statistical analysis indicate agreement of the data with a normal distribution. AMP INCORPORATED Harrisburg,Pa. 17105 AAP | 1108-40016 AMP 1251-13 REV 10-854.6, Reliability Tests The following tests shall be performed to determine estimates of reliability: A. Industrial Mixed Flowing Gas Fifty contacts shall be tested according to class III of Test Specification 109-85-3. Separable conmections shall be mated and unmated for 10 cycles before submission to the Industrial Mixed Flowing Gas test. B. Humidity/Temperature Fifty contacts shall be tested at 25-65C and 95% humidity in a Humidity/Temperature chamber according to the requirements of Test Specification 109-23, method III, cond B, Figure 3 Mounting and Clamping Locations for Vibration and Physical Shock AMP INCORPORATED PAGE | NO O16 REV |Loc AMP 7 108-40 5 | Harrisburg,Pa. 17105 B AMP 1251-13 REV 10-85Printed cr? le J ar Circuit 4 Board i A Daughter Board 125 Maximum Printed Cireuit Board PS AANBRANAAANAAS Y 125 _ Mocher Beard Maximum Termination Resistance Measurement Points Figure 4 Resistance and Temperature Measurement Points AMP INCORPORATED AMP | Harrisburg,Pa. 17105 AMP 1251-13 REV 10-85 8 108-40016