Product Specification 108-5342 06 MAR 08 Rev.D3 040 040/070 070 Hybrid I/O Connector Connector MKMK- for WireWire-toto-Board Termination 1. Scope : 1.1 Contents : This specification covers the requirements for product performance, test methods and quality assurance provisions of 040/070 Hybrid I/O Connector MK- for Wire-to-Board Termination. Applicable product descriptions and part numbers are as shown in Appendix 1. 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 AMP Specifications : A. 109-5000: Test Specification, General Requirements for Test Methods. Application Specification B. 114-5159 : Crimping 040 Series Receptacle & Tab Contact 114-5160 : Crimping 070 Series Receptacle & Tab Contact 114-5198 : Crimping 070 (Unsealed) Receptacle Contact 501-5303 : Test Report 2.2 Commercial Standards and Specifications : A. JASO D605 Multi-pole Connector for Automobiles B. JASO D7101 Test Methods for Plastic Molded Parts C. JIS C3406 Low Voltage Wires and Cables for Automobiles D. JIS D0203 Method of Moisture, Rain and Spray Test for Automobile Parts E. JIS D0204 Methods of High and Low Temperature Test for Automobile Parts F. JIS D1601 Vibration Testing Method for Automobile Parts G. JIS R5210 Portland Cement H. MIL-STD-202 Testing Method 208: Method of Soldering 3-5-8 TEL.044-844-8079 FAX.044-812-3203 Copyright 1998 by Tyco Electronics AMP K.K.. All Rights Reserved. 1 of 12 Product Specification 108-5342 3. Requirements : 3.1 Design and Construction : Product shall be of the design, construction and physical dimensions specified in the applicable product drawing. 3.2 Materials : A. Contact : a. Receptacle Contact : Pre-Tin Brass or Pre-tin Phosphor Bronze, or Plain Brass with Selective Gold plating over nickel under plating, or plain Phosphor Bronze with Selective Gold plating over nickel under plating. b. Tab Contact : Pre-Tinned Brass or Selective-Tin Plain Brass with Selective Gold plating over nickel under plating. B. Housing : PBT resin 3.3 Ratings : Temperature Rating: -30 to 105 3.4 Performance and Test Descriptions : The product shall be designed to meet the electrical, mechanical and environmental performance requirements specified in Fig.2. All tests shall be performed in the room temperature, unless otherwise specified. 2 of 12 Rev.D3 108-5342 Product Specification 3.5 Test Requirements and Procedures Summary: Para. 3.5.1 Test Items Confirmation of Product Requirements Product shall be conforming to the requirements of applicable product drawing and Application Specification. No. 114-5159, 114-5160 Procedures Visually, dimensionally and functionally inspected per applicable quality inspection plan. Electrical Requirements 3.5.2 Termination Resistance (Specified Current) 3.5.3 Termination Resistance (Low Level) (040) 10mMax. (Initial) 20mMax. (Final) (070,) 3mMax. (Initial) 10mMax. (Final) 10mMax. (Initial) 20mMax. (final) (070,) 3mMax. (Initial) 10mMax. (final) Subject mated contacts assembled in housing to closed circuit current of 10mA Max. at open circuit voltage of 20mVMax. Fig.3. AMP Spec. 109-5311-1 No creeping discharge nor flashover shall occur. 1kVAC for 1 minute. Test between adjacent circuits of mated/unmated connectors. AMP Spec. 109-5301 100MMin. Impressed voltage 500V DC. Test between adjacent circuits of mated connectors. AMP Spec. 109-5302 1mA Max. 12V DC impressed 1min. AMP Spec. 109-5312 (040) 3.5.4 Dielectric Strength Measure initial millvolt drop of contact test circuit in mated connectors, Fig.3 AMP Spec. 109-5311-2 3.5.5 Insulation Resistance 3.5.6 Current Leakage 3.5.7 Temperature Rising 60Max. under loaded specified current. Measure temperature rising by energized current. AMP Spec. 109-5310 Current Cycling (040 ) 20mMax. (Final) (070 ,) 10mMax. (Final) No ignition is allowed during the test. Applied Current : Fig 6 & 7. 45minutes "ON", 15minutes "OFF" 200 cycles. AMP Spec. 109-5308 3.5.8 Fig. 1 (To be continued) 3 of 12 Rev.D3 108-5342 Product Specification Physical Requirements Para. Test Items Requirements Procedures Vibration Frequency : 2020020Hz/3min. Accelerated Velocity : Vibration(High 3.5.9 No electrical discontinuity greater than 1sec. Shall occur. (040) 20m Max.(Final) Frequency) (070,) 10m Max.(Final) 44.1m/s2 (4.5G) Vibration Direction Up and Back and Right Down Forth and Left Direction 4 hours 2 hours 2 hours AMP Spec. 109-5202 Vibration Frequency : 2020020Hz/3min. Accelerated Velocity : 3.5.10 Vibration + Current Cycle No electrical discontinuity greater than 1sec. Shall occur. (040) 20m Max.(Final) (070,) 10m Max.(Final) 44.1m/s2 (4.5G) Vibration Direction Up and Down Back and Forth Right and Left Direction 4 hours 2 hours 2 hours Test Current : (040 ) 4.4A DC (070 ,) 10A DC 3.5.11 Contact Mating Force 040 Series : 5.8N Max. 070 , Series : 5.8N Max. Operation Speed : 100mm/min. Measure the force required to mate contacts. AMP Spec. 109-5206 3.5.12 040 Series : 0.98N Min. (Sn) 0.69N Min. (Au) Contact Unmating 070 , Series : 0.98N Min. (Sn) Force 0.69N Min. (Au) Operation Speed : 100mm/min. Measure the force required to unmate contacts. AMP Spec. 109-5206 3.5.13 12Pos. 69N Max. Connector Mating 16Pos. 69N Max. 22Pos. 88.3N Max. Force 26Pos. 98.1N Max. Operation Speed : 100mm/min. Measure the force required to mate contacts. AMP Spec. 109-5206 3.5.14 Connector Unmating Force 3.5.15 Housing Locking Strength 3.5.16 Contact Insertion Force 12Pos. 16Pos. 22Pos. 26Pos. 69N Max. 69N Max. 88.3N Max. 98.1N Max. Operation Speed : 100mm/min. Measure the force required to unmate contacts. AMP Spec. 109-5206 98N Min. Measure housing locking strength. Operation Speed : 100mm/min. AMP Spec. 109-5210 9.8N Max. per contact Measure the force required to insert contacts into housing. AMP Spec. 109-5211 Fig. 1 (To be continued) 4 of 12 Rev.D3 108-5342 Product Specification Para. Test Items Requirements Procedures 3.5.17 Contact Retention Force (Pre-Lock) 49N Min. Apply an axial pull-off load to crimped wire. Operation Speed: 100mm/min. AMP Spec. 109-5212 3.5.18 Contact Retention Force 78N Min. (Secondary Lock) Measure contact retention force with secondary lock set in effect. Operation Speed: 100mm./min. Wire Size 2 Crimp Tensile mm (AWG) N Crimp Tensile 0.3 #22 58 min. Strength 0.5 #20 88 min. 0.85 #18 127 min. 1.25 #16 177 min. 3.5.19 Apply an axial pull-off load to crimped wire of contact secured on the tester. Operation Speed: 100mm/min. AMP Spec. 109-5205 3.5.20 Durability (Repeated Mate/Unmating) (040) 20m Max.(Final) (070,) 10m Max.(Final) Operation Speed: 100mm/min. No. of Cycles: 30 Cycles. AMP Spec. 109-5213 3.5.21 Resistance to "Kojiri" (040) 20m Max.(Final) (070,) 10m Max.(Final) Repeated mating/ unmating by hand, 30 cycles AMP Spec. 109-5215 Solder Temperature: 2305 Immersion Duration: 30.5 seconds Flux: Alpha 100 AMP Spec. 109-5203 Wet Solder Coverage: 95% Min. 3.5.22 Solderbility (Plated Area only) 3.5.23 Handling Ergonomic 3.5.24 Double Lock Plate Locking Strength Matte Tin plating only Solder bath : Sn-3Ag-0.5Cu Solder Temperature :2505 Immersion Duration :50.5sec. Flux :ULF-300R No abnormalities allowed in manual mating/unmating handling. Manually operated 59N Max. Operation Speed: 100mm/min. Measure the force required to lock the double lock plate. Fig. 1 (To be continued) 5 of 12 Rev.D3 108-5342 Product Specification Environmental Requirements Para. Test Items 3.5.25 Thermal Shock (040) 20m Max.(Final) (070,) 10m Max.(Final) -30/120min, 80/120min. Making this a cycle, repeat 5 cycles. AMP Spec. 109-5103 3.5.26 Humidity, Steady State Insulation resistance (Final) 100M Min. Termination resistance (040) 20m Max.(Final) (070,) 10m Max.(Final) Mated/unmated Connector, 9095% R.H., 60 96 hours AMP Spec. 109-5105 3.5.27 Industrial Gas (SO2) (040) 20m Max.(Final) (070,) 10m Max.(Final) SO2 Gas : 10ppm, 95% R.H. 20, 24 hours AMP Spec. 109-5107 3.5.28 Temperature Life (Heat Aging) (040) 20m Max.(Final) (070,) 10m Max.(Final) 120, Duration: 120 hours AMP Spec. 109-5104 3.5.29 Resistance to Cold (040) 20m Max.(Final) (070,) 10m Max.(Final) -505, 120 hours AMP Spec. 109-5108 (040) 20m Max.(Final) (070,) 10m Max.(Final) Subject JIS R5210 cement blow of 1.5kg per 10 seconds in 15 minutes intervals for 90 minutes. AMP Spec. 109-5110 3.5.30 Dust Bombardment Requirements Procedures Fig.1 (End) 6 of 12 Rev.D3 108-5342 Product Specification 4. Product Qualification Test Sequence Test Group 6 7 Test Sequence (a) Test Items 1 2 3 4 5 Confirmation of Product 1 1 1 1 1,9 1,11 3,5,7 3,6,8 Termination Resistance (Specified Current) Termination Resistance (Low Level) 8 9 10 11 1,11 1,13 1,16 1,11 1 3,6,8 3,6, 8,10 2,7, 9,14 3,6,8 4 3 Dielectric Strength 3 4,12 Insulation Resistance 2 3,11 Current Leakage 4 5,10 Temperature Rising 5 Current Cycling 9 Vibration (High Frequency) 7 Vibration + Current Cycle 7 Contact Mating Force 2 Contact Unmating Force 3 Connector Mating Force 2 2,10 2,10 2,12 2,10 Connector Unmating Force 6 4,9 4,9 4,11 4,9 Housing Locking Strength 2 Contact Insertion Force 2 Contact Retention Force(Pre-Lock) Contact Retention Force(Secondary Lock) 3 7 Crimp Tensile Strength 4 Durability (Repeated Mate/Unmating) 6 Resistance to "Kojiri" 5 Solderability 2 Handling Ergonomics Double Lock Plate Locking Strength 8 Thermal Shock 4 Humidity, Steady State 6 5 5 15 4 8 Industrial Gas (SO2) 13 Temperature Life(Heat Aging) 5 Resistance to Cold 7 Dust Bombardment 7 Fig. 2 (a) Numbers indicate sequence in which tests are performed. 7 of 12 Rev.D3 108-5342 Product Specification 75mm 75mm Y Y' v Thermocouples Mounted Here A From the measured readings, deduct the resistance of the 150mm long wire used for termination. When testing for rated current measurement, apply 12V DC, 1A to the circuit. For obtaining uniformity of the current density on the probing points Y-Y', apply soldering on the probing points prior to testing. Fig.3 Measurement Measurement of Termination Resistance Measuring Apparatus Wrap metallic foil to cover the connector surface. Between the Contacts and Housing Between the Adjacent Contacts Fig.4 8 of 12 Rev.D3 Product Specification 108-5342 Fig.5 Maximum Allowable Current ( max.) Wire Size (mm2) Allowable Current (DC A) 0.3 8 0.5 11 0.85 15 1.25 19 2.0 25 Fig.6 Reduction Coefficient (Kd) Number of Energized Reduction Coefficient Contacts 1 1 23 0.75 45 0.6 68 0.55 912 0.5 13 0.4 Fig.7 1 I1=KdImax Current applied to all positions 2 I2= Imax Current applied to every other positions in multiple connector 9 of 12 Rev.D3 108-5342 Product Specification Wire Size (mm2) 0.3 0.5 0.85 1.25 Test Method Test Current (A) Duration (Minutes) 25 30 40 5 45 2.0 Test Method Test Current (A) Duration (Seconds) 50 80 110 5 170 70 250 Fig.8 5mm Max 20kgfcm Mated Connector Sturdy Bench Fig.9 20 +5 -0 mm Connector 50mm Approx. 40mm Approx. Clamped +5 45 - 0 mm Fig.10 10 of 12 Rev.D3 Product Specification 108-5342 1 Hour 803 1 Cycle 5 Minutes Max. Room Temperature -303 1 Hour Fig.11 The applicable product descriptions and part numbers are as shown in Appendix 1. Appendix 1 Prod. P/N Description X-178845-X 040/070 Hybrid I/O Conn. MK- 12Pos. Plug Housing. Assembly (Signal) X-178881-X 040/070 Hybrid I/O Conn. MK- 12Pos. Plug Housing. Assembly (Power) X-178795-X 040/070 Hybrid I/O Conn. MK- 16Pos. Plug Housing. Assembly X-178883-X 040/070 Hybrid I/O Conn. MK- 16Pos. Plug Housing. Assembly X-177545-X 040/070 Hybrid I/O Conn. MK- 16Pos. Plug Housing. Assembly X-178798-X 040/070 Hybrid I/O Conn. MK- 22Pos. Plug Housing. Assembly X-178801-X 040/070 Hybrid I/O Conn. MK- 26Pos. Plug Housing. Assembly X-178885-X 040/070 Hybrid I/O Conn. MK- 26Pos. Plug Housing. Assembly X-178888-X 040/070 Hybrid I/O Conn. MK- 26Pos. 3Row Plug Housing. Assembly X-178897-X 040/070 Hybrid I/O Conn. MK- 26Pos. 3Low Profile Plug Housing. Assembly X-175571-X 040/070 Hybrid I/O Conn. 26Pos. Cap Housing. Assembly X-178811-X 040/070 Hybrid I/O Conn. 26Pos. Cap Housing. Assembly X-175569-X 040/070 Hybrid I/O Conn. 26Pos. Cap Housing. Assembly X-178762-X 040/070 Hybrid I/O Conn. 26Pos. Cap Housing. Assembly X-5178762-X X-176206-X 040/070 Hybrid I/O Conn. 26Pos. 3Row Cap Housing. Assembly X-178900-X 040/070 Hybrid I/O Conn. 26Pos. 3Row Low Profile Cap Housing. Assembly X-178209-X 040/070 Hybrid I/O Conn. 26Pos. Low Profile Cap Housing. Assembly X-175444-X 040/070 Hybrid I/O Conn. 34Pos. Cap Housing. Assembly X-5175444-X X-176255-X 040/070 Hybrid I/O Conn. 34Pos. Cap Housing. Assembly (30 Pos.) X-175521-X 040/070 Hybrid I/O Conn. 38Pos. Cap Housing. Assembly 11 of 12 Rev.D3 Product Specification 108-5342 Prod. P/N Description X-178093-X 040/070 Hybrid I/O Conn. 38Pos. Cap Housing. Assembly X-353245 -X 040/070 Hybrid I/O Conn. 38Pos. Cap Housing. Assembly (V-Type) X-175446-X 040/070 Hybrid I/O Conn. 42Pos. Cap Housing. Assembly X-5175446-X X-176242-X 040/070 Hybrid I/O Conn. 42Pos. Cap Housing. Assembly X-177542-X 040/070 Hybrid I/O Conn. 42Pos. Cap Housing. Assembly X-174917-X 040/070 Hybrid I/O Conn. 48Pos. Cap Housing. Assembly X-5174917-X X-175448-X 040/070 Hybrid I/O Conn. 54Pos. Cap Housing. Assembly X-1318471-X 040/070 Hybrid I/O Conn. 54Pos. Cap Housing. Assembly without 16Pos. X-174518-X 040/070 Hybrid I/O Conn. 64Pos. Cap Housing. Assembly X-5174518-X X-178764-X 040/070 Hybrid I/O Conn. 64Pos. Cap Housing. Assembly X-177609-X 040/070 Hybrid I/O Conn. 64Pos. Cap Housing. Assembly X-176122-X 040/070 Hybrid I/O Conn. 64Pos. Cap Housing. Assembly X-174915-X 040/070 Hybrid I/O Conn. 76Pos. Cap Housing. Assembly X-176142-X 040/070 Hybrid I/O Conn. 76Pos. Cap Housing. Assembly X-178780-X 040/070 Hybrid I/O Conn. 76Pos. Cap Housing. Assembly X-353468-X 040/070 Hybrid I/O Conn. 76Pos. Cap Housing. Assembly X-353469-X 040/070 Hybrid I/O Conn. 76Pos. Cap Housing. Assembly X-175265-X 040 S Receptacle Contact (Pre-Tin) X-175266-X 040 S Receptacle Contact (Selective Gold) X-175268-X 070 S Receptacle Contact (Pre-Tin) X-175275-X 070 S Receptacle Contact (Selective Gold) X-175269-X 070 M Receptacle Contact (Pre-Tin) X-175276-X 070 M Receptacle Contact (Selective Gold) X-1318629-X 070 ML Receptacle Contact (Pre-Tin) Note: Parts number is consisted from listed base number and 1 digit numeric prefix and suffix with dash. Refer to catalog or customer drawing for specific part numbers for each base number. When prefix is zero, zero and dash are omitted. 12 of 12 Rev.D3