PRODUCT SPECIFICATION BUS-12-071 1.0 GENERAL

TYPE
NUMBER
PRODUCT SPECIFICATION
TITLE
BUS-12-071
PAGE
Low Profile Jumper – Gold Plated
REVISION
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1.0
GENERAL
Scope - This specification covers gold plated low profile jumper connectors designed for low power
interconnection of two adjacent 0.025 inch square pins, free standing or in headers, on 0.100 inch centers.
This specification is composed of the following sections.
Paragraph
1.0
2.0
3.0
3.1
3.2
3.3
3.4
3.5
3.6
3.7
4.0
4.1
4.2
4.3
4.4
5.0
2.0
Title
Page
GENERAL
APPLICABLE DOCUMENTS
REQUIREMENTS
Qualification
Material
Finish
Design and Construction
Electrical Characteristics
Mechanical Characteristics
Environmental Conditions
QUALITY ASSURANCE PROVISIONS
Equipment Calibration
Inspection Conditions
Qualification Inspections
Requalification Testing
NOTES AND DEFINITIONS
1
1
2
2
2
2
3
3
6
7
11
11
12
12
13
16
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-M-24519
MIL-C-45662
MIL-P-55110
MIL-G-45204
MIL-STD-202
MIL-STD-275
MIL-STD-1344
Molding Plastics, Polyester, Thermoplastics
Calibration System Requirements
Printed Wiring Boards
Gold Plating, Electrodeposited
Test Methods for Electronic and Electrical Component Parts
Printed Wiring for Electronic Equipment
Test Methods for Electrical Connectors
Federal Specifications
QQ-N-290
QQ-B-750
Nickel Plating (Electrodeposited)
Phosphor Bronze
Copyright 2000 FCI USA, INC.
Form E-3334
06/20/00
GS-01-001
PDM: Rev:D
STATUS: Released
Printed: Aug 04, 2004
TYPE
NUMBER
PRODUCT SPECIFICATION
TITLE
BUS-12-071
PAGE
Low Profile Jumper – Gold Plated
REVISION
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Industry Specifications/Standards
3.0
ASTM B-103
Phosphor Bronze Plate, Sheet, Strip and Rolled Bar, Spec. for DOD ADOPTED
UL-94
Tests for Flammability of Plastic Materials
REQUIREMENTS
3.1
Qualification
Connectors furnished under this specification shall be products capable of meeting the 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.
3.3
3.2.1
Terminal. The body shall be 1/2 hard phosphor bronze strip C51000 in accordance with
QQ-B-750 and CA-510 specification.
3.2.2
Insulator Housing. The housing material shall be unfilled Polyester in accordance with
BUS-16-028. The material shall be rated flame retardant 94 V-O in accordance with UL-94.
or
3.2.3
Insulator Housing. The housing material shall be 7-15% glass filled Polyester in
accordance with BUS-16-025. The material shall be rated flame retardant 94 V-0 in
accordance with UL-94.
Finish
3.3.1
Terminal.
3.3.1.1
The terminal shall be plated in the contact area with 15 microinches
(minimum) gold per MIL-G-45204, Type II, Grade C over 50 microinches
(minimum) nickel per QQ-N-290, Class 2 or
3.3.1.2
The terminal shall be plated in the contact area with 30 microinches
(minimum) nickel per QQ-N-290, Class 2.
Copyright 2000 FCI USA, INC.
Form E-3334
06/20/00
GS-01-001
PDM: Rev:D
STATUS: Released
Printed: Aug 04, 2004
TYPE
NUMBER
PRODUCT SPECIFICATION
BUS-12-071
TITLE
PAGE
Low Profile Jumper – Gold Plated
REVISION
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3.4
Design and Construction
The connector typically shall be a two piece assembly comprising two interconnected contacts
retained in a plastic housing. The female (disconnect) end of the contact shall interface with 0.025
inch square (or round) pins on 0.100 inch centers.
3.5
3.4.1
Mating. The connector shall be capable of being mated or unmated by hand without the
use of special tools within the specified temperature range.
3.4.2
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.
3.4.3
Interchangeability. The connector shall be capable of mating with any appropriately
constituted male connector of the same population without degradation in performance.
Electrical Characteristics
3.5.1
Current Rating. The maximum current rating of the connector shall be 3.0 amperes DC (2.5
amperes for multi-position assembly).
3.5.2
Contact Resistance. (see 5.1) The contact resistance shall not exceed the value specified
in Table 1, 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 ampere DC
FIGURE 1 - CONTACT RESISTANCE
Copyright 2000 FCI USA, INC.
Form E-3334
06/20/00
GS-01-001
PDM: Rev:D
STATUS: Released
Printed: Aug 04, 2004
TYPE
NUMBER
PRODUCT SPECIFICATION
BUS-12-071
TITLE
PAGE
Low Profile Jumper – Gold Plated
REVISION
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TABLE 1 - CONTACT RESISTANCE
Maximum Resistance - Milliohms
Initial
After Test
11
15
3.5.3
3.5.4
3.5.5
3.5.6
Low Level Circuit Resistance. (see 5.1) The low level circuit (contact) resistance shall not
exceed the value specified in Table 1, when measured in accordance with MIL-STD-1344,
Method 3002. The following details shall apply:
(a)
Method of Connection - See Figure 1
(b)
Test Current - 1 milliampere DC
(c)
Maximum Open Circuit Voltage - 20 millivolts DC
Capacitance. (see 5.3) The capacitance between adjacent positions of the unmated
connector shall not exceed 2.0 pf, when measured in accordance with MIL-STD-202,
Method 305. The following details shall apply:
(a)
Points of Measurement - Between adjacent contact positions
(b)
Test Frequency - 1 megahertz
Insulation Resistance. (see 5.3) The insulation resistance between adjacent positions of
the unmated connector shall be not less than 50,000 megohms (20,000 megohms after
exposure to the humidity environment specified in paragraph 3.7.2), when tested in
accordance with MIL-STD-202, Method 302. The following details shall apply:
(a)
Points of Measurement - Between adjacent contact positions
(b)
Test Potential - B (500 volts)
(c)
Time of Application - 60 seconds
Dielectric Withstanding Voltage. (see 5.3) There shall be no evidence of insulation
breakdown, arc-over, or excessive (>1 milliampere) leakage current when the unmated
connector is tested in accordance with MIL-STD-202, Method 301. The following details
shall apply:
(a)
Test Potential - 1500 volts RMS, 60 Hz at sea-level
(b)
Test Duration - 60 seconds
(c)
Points of Measurement - Between adjacent contact positions
Copyright 2000 FCI USA, INC.
Form E-3334
06/20/00
GS-01-001
PDM: Rev:D
STATUS: Released
Printed: Aug 04, 2004
TYPE
NUMBER
PRODUCT SPECIFICATION
BUS-12-071
TITLE
PAGE
Low Profile Jumper – Gold Plated
REVISION
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3.6
Mechanical Characteristics
3.6.1
Contact Retention. (see 5.2) The contact pair shall not be dislodged from the housing
when an axial force of 3.0 pounds (1.5 pounds per contact) is applied in the direction of
insertion. The force shall be applied at a crosshead speed of 1 inch per minute using
Fixture #MF 407.1. ( See Figure 6 )
3.6.2
Total Mating Force. The total force to mate the connector with an appropriate header having
properly configured (see Figure 2) 0.025 inch square pins shall not exceed the value shown
in Table II.
TABLE II - INSERTION/WITHDRAWAL FORCE
Individual Contact Force-Grams
Insert (Max.)
Withdraw (Min.)
.026” Gage Pin
450*
.024” Gage Pin
30*
Total Mating Force
for 2 Contacts (Grams Avg.)
Total Withdraw Force
for 2 Contacts (Grams Avg.)
.025” Gold Pin
350
.025” Gold Pin
150
* Multiply by number of positions for multi-position assembly.
3.6.3
Individual Contact Insertion Force. When measured using a maximum gage configured as
shown in Figure 3, the individual contact insertion force shall not exceed the value shown in
Table II.
3.6.4
Individual Contact Withdrawal Force. After three insertions of a maximum gage, the force
required to withdraw a minimum gage, configured as shown in figure 3, shall be not less
than the value shown in Table II.
3.6.5
Durability. After the number of mating cycles specified in Table III, the individual contact
withdrawal force shall be not less than the value shown in Table II (see 3.6.4) and the
contact resistance shall not exceed the value specified in Table I (See 3.5.2).
TABLE III - DURABILITY
Gold Plating Thickness
30 u”
15 u”
Mating Cycles
50
50
Copyright 2000 FCI USA, INC.
Form E-3334
06/20/00
GS-01-001
PDM: Rev:D
STATUS: Released
Printed: Aug 04, 2004
TYPE
NUMBER
PRODUCT SPECIFICATION
TITLE
BUS-12-071
PAGE
Low Profile Jumper – Gold Plated
REVISION
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3.7
Environmental Conditions
3.7.1
Thermal Shock. After exposure of the mated connector to alternate periods of extreme high
and low temperature, there shall be no evidence of cracking or crazing of the insulator
housing or other physical damage to the connector; the dielectric withstanding voltage of
the unmated connector shall be not less than 2500 volts RMS (see 3.5.6). The test shall be
in accordance with MIL-STD-202, Method 107. The following details and exceptions shall
apply:
(a)
3.7.2
(b)
Test Condition - A (5, 1-hour cycles)
Temperature Range - +120oC to -55oC
(c)
Exposure time at each temperature - 30 minutes, minimum
(d)
Transfer time - 30 seconds maximum
Humidity. After exposure of the mated connector to a high humidity environment, the
contact resistance shall not exceed the value specified in Table I (see 3.5.2). The insulation
resistance of the unmated connector shall be not less than 20,000 megohms (see
paragraph 3.5.5). The test shall be in accordance with MIL-STD-202, Method 106
(excluding steps 7a and 7b). The following details shall apply:
(a)
3.7.3
Test Duration - 10 days (240 hours)
High Temperature Life. After exposure of the mated connector to a high temperature
operating environment, the contact resistance shall not exceed the value specified in Table I
(see 3.5.2). The insulation resistance of the unmated connector shall be not less than
50,000 megohms (see 3.5.5). The test shall be in accordance with MIL-STD-202, Method
108. The following details shall apply:
(a)
Chamber Temperature - Adjusted to achieve +120oC temperature of contact under
load.
(b)
Test Condition - B (250 hours)
(c)
Operating Conditions - Rated current (see 3.5.1) through both contacts; duty cycle:
45 minutes ON and 15 minutes OFF.
Copyright 2000 FCI USA, INC.
Form E-3334
06/20/00
GS-01-001
PDM: Rev:D
STATUS: Released
Printed: Aug 04, 2004
TYPE
NUMBER
PRODUCT SPECIFICATION
TITLE
BUS-12-071
PAGE
Low Profile Jumper – Gold Plated
REVISION
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FIGURE 2 - MATING HEADER
Copyright 2000 FCI USA, INC.
Form E-3334
06/20/00
GS-01-001
PDM: Rev:D
STATUS: Released
Printed: Aug 04, 2004
TYPE
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PRODUCT SPECIFICATION
TITLE
BUS-12-071
PAGE
REVISION
Low Profile Jumper – Gold Plated
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FIGURE 3 - INSERTION/WITHDRAWAL FORCE GAGE
Copyright 2000 FCI USA, INC.
Form E-3334
06/20/00
GS-01-001
PDM: Rev:D
STATUS: Released
Printed: Aug 04, 2004
TYPE
NUMBER
PRODUCT SPECIFICATION
TITLE
BUS-12-071
PAGE
Low Profile Jumper – Gold Plated
REVISION
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FIGURE 4 - MOUNTING FOR STOCK/VIBRATION
Copyright 2000 FCI USA, INC.
Form E-3334
06/20/00
GS-01-001
PDM: Rev:D
STATUS: Released
Printed: Aug 04, 2004
TYPE
NUMBER
PRODUCT SPECIFICATION
BUS-12-071
TITLE
PAGE
Low Profile Jumper – Gold Plated
REVISION
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3.7.4
3.7.5
3.7.6
Shock. There shall be no evidence of physical or mechanical damage when the mated
connector is subjected to transient accelerations. During and after each shock, the
contacts shall evidence 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 ms sawtooth).
(b)
Number of Shocks - 3 shocks in each direction along three orthogonal axes (18
total).
(c)
Mounting - See Figure 4
(d)
Restraining Method - None
Vibration. There shall be no evidence of physical or mechanical damage when the mated
connector is subjected to prolonged mechanical vibration; and the individual contact
withdrawal force shall be not less than the value specified in Table II (see 3.6.4). During the
vibration along each axis, the contacts shall evidence no discontinuity greater than 1
microsecond. At the completion of the test, the contact resistance shall not exceed the
value specified in Table I (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 orthogonal axes (12 hours total)
(c)
Mounting - see Figure 4
(d)
Restraining Method - None
Hydrogen Sulfide (H2S) Atmosphere. After exposure of the mated connector to moist
contaminated environment, the low level circuit resistance shall not exceed the value
specified in Table I (see 3.5.3). The following details shall apply:
(a)
3.7.7
(b)
Test Medium - 3 ppm H2S in air
Test Temperature - +40oC
(c)
Test Duration - 48 hours
Salt Spray. After exposure of the mated connector to a salt fog atmosphere, the low level
circuit resistance shall not exceed the value specified in Table I (see 3.5.3). The test shall
be in accordance with MIL-STD-202, Method 101. The following details shall apply:
(a)
Salt Solution - 5 percent by weight
(b)
Test Condition - B (48 hours)
Copyright 2000 FCI USA, INC.
Form E-3334
06/20/00
GS-01-001
PDM: Rev:D
STATUS: Released
Printed: Aug 04, 2004
TYPE
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PRODUCT SPECIFICATION
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BUS-12-071
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Low Profile Jumper – Gold Plated
REVISION
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4.0
QUALITY ASSURANCE
4.1
Equipment Calibration
All test equipment and 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 normally used in
production.
4.3.1
Sample. Qualification Inspection shall be performed on five (5) groups of connectors; each
group shall comprise five (5) connectors of each type for which qualification under this
specification is desired. For multi-position connectors, a sixth sample (one connector) shall
be required for Group 3 tests.
4.3.2
Preparation of Samples
4.3.3
4.3.2.1
Printed Wiring Test Boards - Five (5) test boards conforming to the
applicable requirements of MIL-P-55110 and MIL-STD-275 shall be prepared
as shown in Figure 5.
4.3.2.2
Mating Headers - Five (5) mating headers of the appropriate population and
configuration and conforming to the requirements of Figure 2 shall be
prepared.
4.3.2.3
Header Mounting - The headers shall be installed on, and hand soldered to,
the test boards; an appropriately active flux shall be used to ensure that the
connection does not contribute any degradation.
4.3.2.4
Sample Configuration - When mated with the headers, the connectors shall
form a series connected circuit.
Test Sequence. The connectors shall be subjected to the inspections specified in Table IV,
in the order shown.
Copyright 2000 FCI USA, INC.
Form E-3334
06/20/00
GS-01-001
PDM: Rev:D
STATUS: Released
Printed: Aug 04, 2004
TYPE
NUMBER
PRODUCT SPECIFICATION
TITLE
BUS-12-071
PAGE
Low Profile Jumper – Gold Plated
REVISION
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4.4
Requalification Testing
If either of the following conditions occur, the product responsible engineer shall initiate requalification
testing.
4.4.1
A significant design change is made to an existing product previously qualified under this
specification. A significant design change shall be defined to include, but not be limited to,
changes in contact material composition, contact material thickness, contact force, contact
surface geometry, underlying material composition, underlying material thickness, insulator
design, contact base material, or contact lubrication requirements.
4.4.2
A product failure occurs during production or end use requiring corrective action to be taken
relative to the product design or manufacturing process.
Requalification testing shall consist of all or applicable parts of the Qualification Test Matrix as
determined by development/product, quality, test, and reliability engineering.
Copyright 2000 FCI USA, INC.
Form E-3334
06/20/00
GS-01-001
PDM: Rev:D
STATUS: Released
Printed: Aug 04, 2004
TYPE
NUMBER
PRODUCT SPECIFICATION
BUS-12-071
TITLE
PAGE
Low Profile Jumper – Gold Plated
REVISION
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TABLE IV - QUALIFICATION INSPECTION
Examination or Test
Paragraph
1
2
Total Mating Force
Individual Contact Withdrawal Force
Contact Resistance
Capacitance
Insulation Resistance
Dielectric Withstanding Voltage
Contact Retention
Thermal Shock
Dielectric Withstanding Voltage
Humidity
Contact Resistance
Insulation Resistance
High Temperature Life
Contact Resistance
Insulation Resistance
Shock
Vibration
Contact Resistance
Individual Contact
Durability
Contact Resistance
Individual Contact Withdrawal Force
Hydrogen Sulfide Atmosphere
Low level Circuit Resistance
Salt Spray
Low Level Circuit Resistance
Contact Retention
3.6.2
3.6.4
3.5.2
3.5.4
3.5.5
3.5.6
3.6.1
3.7.1
3.5.6
3.7.2
3.5.2
3.5.5
3.7.3
3.5.2
3.5.5
3.7.4
3.7.5
3.5.2
3.6.4
3.6.5
3.5.2
3.6.4
3.7.6
3.5.3
3.7.7
3.5.3
3.6.1
X
X
X
X
X
X
X
X
X
X
X
X
X
X
-
Sample Group
3
4
5
X
X
X
X
X
X
X
X
X
-
X
X
X
X
X
X
X
X
X
XX
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
-
6
X
X
X
X
X
X
X
X
X
X
X
-
Copyright 2000 FCI USA, INC.
Form E-3334
06/20/00
GS-01-001
PDM: Rev:D
STATUS: Released
Printed: Aug 04, 2004
TYPE
NUMBER
PRODUCT SPECIFICATION
TITLE
BUS-12-071
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Low Profile Jumper – Gold Plated
REVISION
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5.0
NOTES AND DEFINITIONS
5.1
Contact Resistance
Differences in contact resistance between various terminal configurations represent changes in bulk
resistance due to longer lengths of current path.
5.2
Contact Retention
Only terminals employing an integral latching mechanism (e.g. barbs, dimples, etc.) for rigid retention
within the housing are subject to this requirement. Terminals which "free-float" within a housing and
are retained by the closure of some form of hinged cover are not included.
5.3
Multi-Position Connector
Assemblies containing more than one jumper shall be subjected to the Group 3 tests; these tests do
not apply to single position devices.
FIXTURE # 407.1 FIGURE 6
Copyright 2000 FCI USA, INC.
Form E-3334
06/20/00
GS-01-001
PDM: Rev:D
STATUS: Released
Printed: Aug 04, 2004
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BUS-12-071
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REVISION RECORD
REV
PAGE
DESCRIPTION
EC#
DATE
A
ALL
Change from preliminary to released
V10415
02/26/91
B
5
V12241
08/06/91
C
6
V80421
12/10/98
D
ALL
V01904
08/01/00
Delete max. load for 10 seconds, add use Fixture
#407.1 Figure 6, add Figure 6 page
Revised format to be consistent with GS-01-001,
and change BERG, Dupont, etc. references to FCI.
Copyright 2000 FCI USA, INC.
Form E-3334
06/20/00
GS-01-001
PDM: Rev:D
STATUS: Released
Printed: Aug 04, 2004

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