NUMBER TYPE BUS-12-050 PRODUCT SPECIFICATION TITLE PAGE REVISION BERGSTIK(R) /BERGSTIKTM Headers AUTHORIZED BY 1 of 8 M.Zhou L DATE 07 JUL 16 CLASSIFICATION UNRESTRICTED 1.0 GENERAL 1.1 SCOPE This specification covers the Bergstik(R) and BergstripTM Headers, designed for use in low-power applications requiring a printed wiring -board mounted straight or right angle disconnect. The header provides only the pin half of the interconnection, using any 0.025" square pin mateable receptacle to complete the connection. This product is Lead Free and meets the requirement of the European Union Directive of Restrictions for Hazardous Substances (Directive 2002/95/EC). The specification is composed of the following sections: 1.2 Paragraph Title 1.0 1.1 1.2 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 GENERAL Scope Type APPLICABLE DOCUMENTS REQUIREMENTS Qualification Material Finish Design and construction Electrical Characteristics Mechanical characteristics Environmental Conditions QUALITY ASSURANCE PROVISIONS Equipment Calibration Inspection Conditions Qualification Inspection Acceptance Inspection Working parameter current rating: 5A voltage : 110V operating temperature: -65 o to 105o C - Nylon -65o to 130o C - PCT,PPS & LCP This document is the property of and embodies CONFIDENTIAL and PROPRIETARY information of FCI. No part of the information shown on the document may be used in any way or disclosed to others without the written consent of FCI. Copyright FCI. Form E-3005 Rev F GS-01-001 PDS: Rev :L STATUS:Released Printed: Jul 21, 2016 NUMBER TYPE BUS-12-050 PRODUCT SPECIFICATION TITLE PAGE REVISION BERGSTIK(R) /BERGSTIKTM Headers AUTHORIZED BY 2 of 8 M.Zhou L DATE 07 JUL 16 CLASSIFICATION UNRESTRICTED 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-F-14256 Flux, Soldering, Liquid (Rosin Base), Activated MIL-G-45204 Gold Plating, Electrodeposited MIL-P-45209 Palladium Plating, Electrodeposited MIL-P-55110 Printer Wiring Boards MIL-P81728 Plating, Tin-Leaded (Electrodeposited) Federal Specifications QQ-N-290 QQ-W-343 QQ-S-571 Nickel Plating (Electrodeposited) Wire, Electrical and Nonelectrical, Copper (Uninsulated) Solder: Lead Alloy, Tin-Lead Allow, and Tin Alloy, Flux Cored Ribbon and Wire, and Solid Form Military Standards MIL-STD-105 MIL-STD-202 MIL-STD-275 MIL-STD-1344 ISO-9000 Sampling Procedures & Tables for Inspection by Attributes Test Methods for Electrical and Electronic Component Parts Printed Wiring for Electronic Equipment Test Methods for Electrical Connectors Calibration System Requirements Industry Specifications/Standards UL-94 ASTM B-159 ASTM D-2897 Tests for Flammability of Plastic Materials Phosphor Bronze Wire Reinforced & Filled Nylon Injection Molding & Extrusion Materials FCI Labs Reports- Supporting Data ZA5-2625 3.0 Lead Free Plating Investigation REQUIREMENTS 3.1 Qualification Headers furnished under this specification shall be products capable of meeting or exceeding the qualification test requirements specified herein. 3.2 Material This document is the property of and embodies CONFIDENTIAL and PROPRIETARY information of FCI. No part of the information shown on the document may be used in any way or disclosed to others without the written consent of FCI. Copyright FCI. Form E-3005 Rev F GS-01-001 PDS: Rev :L STATUS:Released Printed: Jul 21, 2016 NUMBER TYPE BUS-12-050 PRODUCT SPECIFICATION TITLE PAGE REVISION BERGSTIK(R) /BERGSTIKTM Headers AUTHORIZED BY 3 of 8 L DATE M.Zhou 07 JUL 16 CLASSIFICATION UNRESTRICTED The material for each part shall be specified herein, or equivalent. Substitute material shall meet or exceed the performance requirements of this specification. 3.2.1 Contact. The contact shall be Phosphor Bronze Alloy UNS C51000 in accordance with ASTM B-159 or other copper alloy as specified on the product drawing. 3.2.2 3.3 Insulator. The insulator shall be glass- or mineral-filled nylon in accordance with ASTM D-2897, polyphenylene sulfide (PPS) ,PCT or LCP. All plastic material shall be rated V-0 in accordance with UL-94. Finish The finish of the contact shall be specified herein for the particular type of header under consideration. 3.4 3.3.1 Solder tails. As defined by product drawings, will be plated with the specified thickness of pure tin for Lead Free. Or 93/7 tin-lead per MIL-P-81728 option. Or gold per MIL-G-45204 Type II, Grade C option. Or palladium alloy per MIL-P-45209 option. Tin plated "LF" product has 100% tin plating in the interface and has not been tested for whisker growth in all interconnect environments 3.3.2 Contact Area. As defined by product drawings, will be plated with the specified thickness of pure tin for Lead Free. Or 93/7 tin-lead per MIL-P-81728 option. Or gold per MIL-G45204 Type II, Grade C option. Or palladium alloy per MIL-P-45209 option. Tin plated "LF" product has 100% tin plating in the interface and has not been tested for whisker growth in all interconnect environments 3.3.3 All other areas. Will be plated with 50 microinches of nickel per QQ-N-290, Class 2. Design and Construction The header shall be a multi-piece assembly having one or two rows of contacts with solderable tail ends for installation in .040 inch diameter holes in printed wiring boards of standard thickness. The Bergstik(R) header contacts shall be insert molded or post-inserted in the insulator on rectangular grids of .100, .125, or .150 inches or multiples thereof and shall be available in straight or right angle configurations. The BergstripTM header contacts shall be post-inserted into the insulator on rectangular grids of .100 inch and shall be available in straight configurations. The contacts shall be available in various above- and below-board lengths suitable for use as 0.025 inch square male disconnects or as similarly configured wrapposts for solderless wrapped connections in accordance with MIL-STD-1130. This document is the property of and embodies CONFIDENTIAL and PROPRIETARY information of FCI. No part of the information shown on the document may be used in any way or disclosed to others without the written consent of FCI. Copyright FCI. Form E-3005 Rev F GS-01-001 PDS: Rev :L STATUS:Released Printed: Jul 21, 2016 NUMBER TYPE BUS-12-050 PRODUCT SPECIFICATION TITLE PAGE REVISION BERGSTIK(R) /BERGSTIKTM Headers AUTHORIZED BY 4 of 8 M.Zhou L DATE 07 JUL 16 CLASSIFICATION UNRESTRICTED 3.5 3.4.1 Polarization (Optional). Removal or omission of individual contact(s) shall provide polarization/keying to insure correct orientation of the header and an appropriately configured mating part. 3.4.2 Workmanship. Headers shall be uniform in quality and shall be free from burrs, voids, chips, blisters, holes, sharp edges, or other defects that will adversely affect life or serviceability. Electrical Characteristics 3.5.1 Insulation Resistance. The insulation resistance of the unmated and unsoldered headers shall be not less than 5000 megohms when measured in accordance with MIL-STD-1344, Method 3003. The following details shall apply: a. Test Condition - 500 volts DC applied for l minute. b. Points of Measurement - Between individually paired adjacent and opposing contacts. 3.5.2 Dielectric Withstanding Voltage. There shall be no evidence of arc-over, insulation breakdown, or excessive leakage current (>1 milliampere) when the unmated and unsoldered header is tested in accordance with MIL-STD-1344, Method 3001. The following details shall apply: a. Test Potential - See Table I. b. Test Duration - 50 seconds. c. Test Condition - I (760 Torr - sea level). d. Points of Measurement - Between individually paired adjacent and opposing contacts. TABLE I - DIELECTRIC WITHSTANDING VOLTAGE Contact Spacing ( inch ) Test Voltage VRMS .100 .125 .150 1500 1500 1500 This document is the property of and embodies CONFIDENTIAL and PROPRIETARY information of FCI. No part of the information shown on the document may be used in any way or disclosed to others without the written consent of FCI. Copyright FCI. Form E-3005 Rev F GS-01-001 PDS: Rev :L STATUS:Released Printed: Jul 21, 2016 NUMBER TYPE BUS-12-050 PRODUCT SPECIFICATION TITLE PAGE REVISION BERGSTIK(R) /BERGSTIKTM Headers AUTHORIZED BY 5 of 8 M.Zhou L DATE 07 JUL 16 CLASSIFICATION UNRESTRICTED 3.6 Mechanical Characteristics 3.6.1 3.7 Contact Retention. Individual contacts in an unsoldered header shall withstand a load applied in either direction, along the contact axis, without dislodgement from the insulator, of 5.0 pounds in the case of insert molded contacts and 2.0 pounds in the case of post inserted contacts. Environmental Conditions 3.7.1 Thermal Shock. After exposure of an unmated and unsoldered header to alternate periods of extreme high and low temperature, there shall be no evidence of cracking or crazing of the insulatornot include open knit line or other physical damage to the header. The dielectric withstanding voltage shall be not less than 750 volts RMS 60 HZ (see Paragraph 3.5.2). The following details shall apply: a. Test Conditions - B (1 hour cycles). b. Temperature Range - -65o to 105o C - Nylon -65o to 130o C - PCT,PPS & LCP 3.7.2 High Temperature Life. After exposure of an unmated and unsoldered header to a high temperature operating environment, the insulation resistance of the header shall be not less than 5,000 megohms (see Paragraph 3.5.1). The test shall be in accordance with MIL-STD-202, Method 108. The following details shall apply: a. Test Chamber Temperature -105o C ( + 2o)-Nylon;130oC( + 2o) PCT,PPS & LCP b. Test Condition (Duration) B (250 hours). c. Operating Conditions - No Current 3.8 Solderability Plated pins shall be capable of passing BUS-19-002. 3.9 Re-Qualification product If either of the following conditions occurs, the responsible product engineer shall initiate requalification testing, consisting of all applicable parts of the qualification test matrix, table II a. A significant design change is made to the existing product. A significant change shall include, but is not limited to, changes in the contact material composition, contact material thickness, contact force, contact surface geometry, underlying material composition, underlying material thickness, insulation design, contact base material or contact lubrication requirements. b. A significant change is made to the manufacturing process which impacts the product form, fit or function. c. A significant event occurs during the production or end use requiring corrective action to be taken relative to the product design or manufacturing process. This document is the property of and embodies CONFIDENTIAL and PROPRIETARY information of FCI. No part of the information shown on the document may be used in any way or disclosed to others without the written consent of FCI. Copyright FCI. Form E-3005 Rev F GS-01-001 PDS: Rev :L STATUS:Released Printed: Jul 21, 2016 NUMBER TYPE BUS-12-050 PRODUCT SPECIFICATION TITLE PAGE REVISION BERGSTIK(R) /BERGSTIKTM Headers AUTHORIZED BY 6 of 8 L DATE M.Zhou 07 JUL 16 CLASSIFICATION UNRESTRICTED 4.0 QUALITY ASSURANCE PROVISIONS 4.1 Equipment Calibration 4.2 All test equipment and inspection facilities used in the performance of any test shall be maintained in a calibration system in accordance with ISO 9000. Inspection Condition Unless otherwise specified herein, all inspections shall be performed under the following ambient conditions: a. Temperature: 25oC + 5o C. 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. The qualification sample shall consist of two of the largest size headers of the particular design, configuration, and type that are the subject of the test. 4.3.2 Test Sequence. The sample headers shall be subjected to the inspections specified in Table II in the order shown. TABLE II - CONNECTOR QUALIFICATION INSPECTION Examination or Test Contact Retention Insulation Resistance Dielectric Withstanding Voltage Thermal Shock Insulation Resistance Dielectric Withstanding Voltage High Temperature Life Insulation Resistance Dielectric Withstanding Voltage Solderability 4.4 Paragraph 3.6.1 3.5.1 3.5.3 3.7.1 3.5.1 3.5.2 3.7.2 3.5.1 3.5.2 3.8 Test Sample 2 1 X X X X X X X X X - X Acceptance Inspection Acceptance inspection shall consist of the examinations specified in Table III. Appropriate inprocess inspection may, at the option of FCI, be substituted for the indicated lot sampling/inspection provided the process output quality level is maintained. This document is the property of and embodies CONFIDENTIAL and PROPRIETARY information of FCI. No part of the information shown on the document may be used in any way or disclosed to others without the written consent of FCI. Copyright FCI. Form E-3005 Rev F GS-01-001 PDS: Rev :L STATUS:Released Printed: Jul 21, 2016 NUMBER TYPE BUS-12-050 PRODUCT SPECIFICATION TITLE PAGE REVISION BERGSTIK(R) /BERGSTIKTM Headers AUTHORIZED BY 7 of 8 M.Zhou L DATE 07 JUL 16 CLASSIFICATION UNRESTRICTED TABLE III - ACCEPTANCE INSPECTION AQL Examination Visual and Mechanical Major Minor 1.0% 4.0% 4.4.1 Inspection Lot. An inspection lot shall consist of all headers produced under essentially the same conditions and offered for inspection at one time. 4.4.2 Sampling Plan. Statistical sampling and inspection shall be in accordance with MIL-STD105, General Inspection Level II. The Acceptance Quality Level (AQL) shall be as specified in Table III. Major and minor defects shall be as defined in MIL-STD-105. 4.4.3 Reject Lots. Rejected lots shall be reworked to correct the defects or screened to remove defective units and resubmitted for inspection. 4.4.4 Deposition of Sample Units. Sample units that have been subjected to the acceptance inspection shall be considered deliverable on the contract or purchase order. This document is the property of and embodies CONFIDENTIAL and PROPRIETARY information of FCI. No part of the information shown on the document may be used in any way or disclosed to others without the written consent of FCI. Copyright FCI. Form E-3005 Rev F GS-01-001 PDS: Rev :L STATUS:Released Printed: Jul 21, 2016 NUMBER TYPE BUS-12-050 PRODUCT SPECIFICATION TITLE PAGE REVISION BERGSTIK(R) /BERGSTIKTM Headers AUTHORIZED BY 8 of 8 L DATE M.Zhou 07 JUL 16 CLASSIFICATION UNRESTRICTED REVISION RECORD REV PAGE B C 5 2 to 7 D 3 E 1 to 8 F 1,3,5 G All H J K 1 to 3 5 1,3,4,5 L 1 DESCRIPTION Delete MIL-STD-1130, add polyphenylene sulfide (PPS) to 3.2.2, delete 3.4.1,3.5.3,3.6.2 & 3.6.3. Delete Figure 1. Delete Wrappost Torque and Contact Retention from table II Update 3.2.2 to add PCT resin, delete the word minimum on 3.3.1 & 3.3.3 Add BergstripTM Header to Title. Replace connector with header. Replace unterminated with unsoldered. Replace DuPont with Berg. Change Title from Packaging Spec to Product Spec. 3.3.2 change 150 to 120. 3.7.1 & 3.7.2 add temperature -65 to 130 add name ( Nylon). Revised format to be consistent with GS-01-001, and change BERG, Dupont, etc. references to FCI. Add lead free information Add r-qualification notes 3.9 Delete notes 1.2,change note 3.3 of the plating, delete ``cracks and scratches'', add ``not include open knit line''. Add working parameter content EC# DATE V11389 V12665 05/10/91 09/24/91 V40635 03/17/94 V80237 02/04/98 V81231 06/23/98 V01904 07/28/00 M06-0161 M07-0280 3/13/06 06/20/07 09/19/11 ELX-N-006141 ELX-N-24463 07/07/16 This document is the property of and embodies CONFIDENTIAL and PROPRIETARY information of FCI. No part of the information shown on the document may be used in any way or disclosed to others without the written consent of FCI. Copyright FCI. Form E-3005 Rev F GS-01-001 PDS: Rev :L STATUS:Released Printed: Jul 21, 2016 Mouser Electronics Authorized Distributor Click to View Pricing, Inventory, Delivery & Lifecycle Information: FCI / Amphenol: 67997-400HLF 67998-400HLF 68000-100HLF 68000-102HLF 68000-400HLF 68000-403HLF 68002-100HLF 68015-236HLF 68024-400HLF 68691-400HLF 78511-100HLF 78511-400HLF 67996-172HLF 68004-102HLF 68015-401HLF 67996-130HLF 67996-140HLF 67996-234HLF 68015-407HLF 68020-172HLF 67996-108HLF 67996-120HLF 67996-126HLF 67996-164HLF 67996-210HLF 67996-410HLF 67996-414HLF 67997-104HLF 67997-106HLF 67997-108HLF 67997-120HLF 67997-124HLF 67997-138HLF 67996-416HLF 68000-409HLF 78290-136HLF 78511-136HLF 78511-404HLF 87901-440HLF 87901-472HLF 94063-416HLF 67996-124HLF 67996-402HLF 67996-412HLF 67996-426HLF 67996-434HLF 67997-118HLF 68000-116HLF 68000-220HLF 68000-225HLF 68000-407HLF 68000-411HLF 68000-412HLF 68000-413HLF 68000-416HLF 68000-418HLF 68000-420HLF 68000-422HLF 68000-424HLF 68000-425HLF 68000-426HLF 68000-428HLF 68000-432HLF 68000-433HLF 68002-104HLF 68002-105HLF 68002-106HLF 68002-110HLF 68002-111HLF 68002-112HLF 68002-114HLF 68002-115HLF 68002-118HLF 68002-121HLF 68002-122HLF 68002-124HLF 68002-125HLF 68002-127HLF 68002-129HLF 68002-131HLF 68002-133HLF 68002-135HLF 68002-204HLF 68002-205HLF 68002-207HLF 68002-208HLF 68002-209HLF 68002-212HLF 68002-217HLF 68002-218HLF 68002-220HLF 68002-223HLF 68002-224HLF 68002-227HLF 68002-228HLF 68002-230HLF 68002-232HLF 68002-234HLF 68002-403HLF 68002-405HLF