Product Specification 108-5280 26 MAR 10 Rev.F5 I/O .040/.070 .040/.070 Hybrid I/O Conn. For Printed Circuit Board 1. 1. Scope 1.1 .040/.070 I/O 1 1.1 Contents This specification covers the requirements for product performance, test methods and quality assurance provisions of .040/.070 Hybrid I/O Conn. For Printed Circuit Board. Applicable product descriptions and part numbers are as shown in Appendix 1. 2 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 A. 109-5000 2.1 AMP Specifications A.109-5000 Test Specification, General Requirements for Test Methods. B. 114-5111 040 114-5091 .070 C. 501-5253 B.114-5111 Application Specification .040 Series Receptacle Contact 114-5091 Application Specification. .070 Series Receptacle Contact C.501-5253 2.2 :Qualification Test Report 2.2 Commercial Standards and Specifications A. JASO 7002 A. JASO 7002 B. JASO 7101 B. JASO 7101 C. JIS C3406 C. JIS C3406 D. JIS D0203 D. JIS D0203 3-5-8 TEL.044-844-8079 FAX.044-812-3203 Copyright 1998 by Tyco Electronics AMP K.K.. All Rights Reserved. Multi-pole connector for Automobiles Test Methods for Plastic Molded Parts Low Voltage wires and Cables for Automobiles Method of Moisture, Rain and Spray Test for Automobile Part 1 of 17 108-5280 Product Specification E. JIS D0204 E. JIS D0204 F. JIS D1601 F. JIS D1601 G. JIS R5210 G. JIS R5210 H. MIL-STD-202 208 H. MIL-STD-202 3. Requirements 3. Methods of High and Low Temperature Test for Automobile Parts Vibration Testing Method for Automobile Parts Portland Cement Testing Method208: Method of Soldering 3.1 Design and Construction 3.1 Product shall be of the design, construction and physical dimensions specified in the applicable product drawing. 3.2 A. B. C. 3.2 Materials A.Contact: Tab and Receptacle: Brass or Phosphor Bronze, Pre-tinned or Gold-plated PBT B.Housing: PBT resin C.Others: 3.3 A. -30~105 B. 1.60.15mm 3.3 Ratings A. Temperature Rating: -30 to 105 B. Application print circuit board Board thickness: 1.60.15mm Hole diameter: See each customer drawing 3.4 Performance and Test Descriptions 3.4 Fig.2 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 17 Rev.F5 108-5280 Product Specification 3.5 Test Requirements and Procedures Summary: Para. Test Items Requirements Procedures 3.5.1 AMP Confirmation of Product Product shall be conforming to Visually, dimensionally and product drawing and quality inspection plan. the requirements of applicable Application Specification. functionally inspected per applicable 3.5.2 Electrical Requirements () 1 (A) mV/A .040 10m Fig.3 AMP 109-5311-2 20m .070 3m 10m Termination Resistance (Specified Current) Test(A): 1Current Resistance: mV/A(Max) (.040) 10mMax.(Initial) 20mMax.(final) (.070) 3mMax.(Initial) Measure initial voltage fall of contact test circuit in mated connectors, Fig.3 AMP Spec. 109-5311-2 10mMax.(final) Fig.2 ()(to be continued) 3 of 17 Rev.F5 108-5280 Product Specification Para. Test Items Requirements Procedures 3.5.3 .070 Termination (.040) (Low Level) (.070) Resistance 3.5.4 .040 10m 20m 3m 10m 10mA Fig.3 20mV AMP 109-5311-1 10mMax.(Initial) Subject mated contacts assembled in 3mMax.(Initial) 10mA Max. at open circuit voltage of 20mMax.(final) 10mMax.(final) housing to closed circuit current of 20mVMax. Fig.3 AMP Spec. 109-5311-1 1kVAC Dielectric Strength 3.5.5 No creeping discharge nor flashover shall occur. .040 .070 .040 Insulation Resistance 3.5.6 (.040) (.070) 100M 100M 100M 1kVAC for 1 minute. Test between adjacent circuits of unmated connectors. AMP Spec. 109-5301 500 VDC AMP 109-5302 100MMin.(Initial) Impressed voltage 500 VDC. 100MMin.(Initial) unmated connectors. 100MMin.(final) 100MMin.(final) 1mA Current 1mA Max. Leakage 4 of 17 .070 100M AMP 109-5301 Test between adjacent circuits of AMP Spec. 109-5302 12 VDC 1 AMP 109-5312 12 VDC impressed 1min. AMP Spec. 109-5312 Rev.F5 108-5280 Product Specification Para. Test Items Requirements Procedures 3.5.7 Temperature 60 Max. under loaded Rising 60 AMP 109-5310 specified current. energized current. Measure temperature rising by AMP Spec. 109-5310 3.5.8 Physical Requirements 1sec. 20~200~20 Hz./ 1 44.1m/s2 .070 10m .040 20m 4 2 2 AMP 109-5202 Vibration (High Frequency) No electrical discontinuity greater than 1sec. shall Fig.10 Vibration Frequency: 20~200~20 Hz./1 min. occur. Accelerated Velocity: (.070) 10mMax. (Final) Vibration Direction: X,Y,Z (.040) 20mMax. (Final) 44.1m/s2 Duration: Y 4hours, Z 2hours, X 2hours each AMP Spec. 109-5202 3.5.9 Current Cycling .040 .070 20m 10m Fig.6 7 45 "ON", 15 "OFF". 200 (.040) 20mMax. (Final) Applied Current: Fig.6 and 7 (.070) 10mMax. (Final) No ignition is allowed during the test. 5 of 17 Fig. 10 AMP 109-5308 45 minutes "ON", 15 minutes "OFF". 200 Cycles. AMP Spec. 109-5308 Fig.2 ()(to be continued) Rev.F5 108-5280 Product Specification para. 3.5.10 Test Items Requirements Procedures + 1sec. 20~200~20 Hz./ 1 44.1m/s2 (4.5G) .070 10m .040 20m 100 50 .040: 4.4A(0.5mm2) DC Vibration+ Current Cycle .070: 10A(1.25mm2) DC No electrical discontinuity Vibration Frequency: occur. Accelerated Velocity: 44.1m/s2 (.070) 10mMax. (Final) Duration: Up and Down; 100 hours, greater than 1sec. shall (.040) 20mMax. (Final) 20~200~20 Hz./1 min. Vibration Direction: X, Z Back and Force, Right and Left; 50 hours each Test Current: .040: 4.4A(0.5mm2)DC 3.5.11 .070: 10A(1.25mm2)DC Connector Mating Force 12 78N 12 88N 16 98N 22 118N 26 137N 16 98N 26 137N (Signal) 12 Pos. 78N Max. (Power) 12 Pos. 88N Max. 16 Pos. 98N Max. 22 Pos. 118N Max. 26 Pos. 137N Max. (Power Tin-Lead Plating Tab) 16 Pos. 98N Max. 26 Pos. 137N Max. 100mm/ AMP 109-5206 Operation Speed: 100 mm/min. Measure the force required to mate connectors. AMP Spec. 109-5206 Fig.2 ()(to be continued) 6 of 17 Rev.F5 Product Specification para. 3.5.12 Test Items Connector Unmating Force 3.5.13 Requirements 12 78N 12 88N 16 98N 22 118N 26 137N 16 98N 26 137N (Signal) 12 Pos. 78N Max. (Power) 12 Pos. 88N Max. 16 Pos. 98N Max. 22 Pos. 118N Max. 26 Pos. 137N Max. (Power Tin-Lead Plating Tab) 16 Pos. 100N Max. 26 Pos. 200N Max. Procedures 100mm/ AMP 109-5206 Operation Speed: 100 mm/min. Measure the force required to unmate connectors. AMP Spec. 109-5206 98N 100mm/ Connector Locking Strength 3.5.14 108-5280 Contact Insertion Force 98N Min. 9.8N AMP 109-5210 Measure connector locking strength. Operation Speed: 100mm/min. AMP Spec. 109-5210 1 9.8N Max. per contact. Measure the force required to insert AMP 109-5211 contact into housing. AMP Spec. 109-5211 Fig.2 ()(to be continued) 7 of 17 Rev.F5 108-5280 Product Specification para. 3.5.15 Test Items Requirements Procedures 59N 100mm/ Contact Retention Force AMP 109-5212 59N Min. Apply an axial pull-off load to crimped wire. Operation Speed: 100mm/min. (Primary Lock) 3.5.16 AMP Spec. 109-5212 98N 100mm/ Contact Retention Force 98N Min. Measure contact retention force with secondary lock set in effect. (Primary and 3.5.17 Operation Speed: 100mm/min. Secondary Lock) mm2 (AWG) 0.5 20 0.3 0.85 Crimp Tensile 1.25 Wire Size Strength 8 of 17 N 18 127 16 20 177 AMP 109-5205 Crimp Apply an axial pull-off load to (min.) the tester. N 22 59 18 127 16 100mm/ 88 Tensile 0.5 1.25 59 (AWG) 0.85 22 mm2 0.3 crimped wire of contact secured on Operation Speed: 100mm/min. AMP Spec. 109-5205 88 177 Fig.2 ()(to be continued) Rev.F5 108-5280 Product Specification para. 3.5.18 Test Items Requirements Procedures .070 10m Durability (Repeated 3.5.19 .040 20m Mate/Unmating) (.040) 20mMax. (Final) (.070) 10mMax. (Final) 100M Humidity, Steady State .040 20m .070 10m Resistance to "Kojiri" AMP 109-5213 Operation Speed: 100mm/min. No. of Cycles: 30 cycles. AMP Spec. 109-5213 90~95% R.H 60 96 AMP 109-5105 Insulation resistance(Final) mated connector, Termination resistance 96 hours 1mA 100MMin. (.070) 10mMax.(Final) 30 (.040) 20mMax.(Final) 3.5.20 100mm/ .040 20m .070 10m (.040) 20mMax.(Final) (.070) 10mMax.(Final) 90~95% R.H, 60 AMP Spec. 109-5215 AMP 109-5215 30 Fig.9 AMP Spec. 109-5215 Repeated mating/ unmating by hand, 30 cycles Fig.9 Fig.2 ()(to be continued) 9 of 17 Rev.F5 108-5280 Product Specification Para. Test Items Requirements Procedures 3.5.21 95% 2305 30.5 100 AMP 109-5203 Sn-3Ag-0.5Cu 2505 50.5 ULF-300R Solderability Wet Solder Coverage:95% Min. (Plated area only) Solder Temperature: 2305 Immersion Duration: 30.5 seconds Flux: Alpha 100 AMP Spec. 109-5203 Matte Tin plating only Solder bath : Sn-3Ag-0.5Cu Solder Temperature :2505 Immersion Duration :50.5sec. Flux :ULF-300R 3.5.22 .040 20m .070 10m -30/120 80/120 1 5 Thermal Shock 3.5.23 Sulfurous Acid Gas Resistivity 3.5.24 (.070) 10mMax.(Final) Life (Heat Aging) -30/120min.80/120min. Making this a cycle, repeat 5 cycles. AMP Spec. 109-5103 .040 20m .070 10m - 10ppm, 90, 24 (.040) 20mMax.(Final) (.070) 10mMax.(Final) (concentration: 10ppm) at 90%min. .040 20m Temperature 10 of 17 (.040) 20mMax.(Final) AMP 109-5103 -Expose connectors to SO2 gas of humidity and normal temperature for 24 hours. 120 5 .070 10m AMP 109-5104 (.070) 10mMax.(Final) AMP Spec. 109-5104 (.040) 20mMax.(Final) 120, Duration: 5 days Rev.F5 Product Specification 3.5.25 3.5.26 .040 20m -505120 Resistance to (.040) 20mMax.(Final) -505, 120 hours .040 20m Cold Dust Bombardment .070 10m (.070) 10mMax.(Final) .070 10m (.040) 20mMax.(Final) (.070) 10mMax.(Final) Fig.2 ()(end) 11 of 17 108-5280 AMP 109-5108 AMP Spec. 109-5108 JIS R5210 14N 15 10 60 AMP 109-5110 Subject JIS R5210 cement blow of 14N per 10 seconds in 15 minutes intervals for 60 minutes. AMP Spec. 109-5110 Rev.F5 108-5280 Product Specification Cap Housing Assembly 1mm 1mm max. Plug Housing 75mm Printed Circuit board Power Source 75mm DC 12V, 1A YY' From the measured readings, deduct the resistance of the 150mm long wire used for termination. When testing for rated current measurement, apply 12 V 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 of Termination Resistance Wrap metallic foil to cover the connector surface. Between the Adjacent Contacts 12 of 17 Fig.4 Between the Contacts and Housing Rev.F5 108-5280 Product Specification Fig.5 (1) (Imax) (Kd) Maximum Allowable Current (Imax) Reduction Coefficient (Kd) Wire Size (mm2) Allowable Current (DC A) Number of Reduction 0.3 9 Energized Contacts Coefficient 0.5 11 1 1 0.85 15 2~3 0.75 1.25 19 4~5 0.6 2.0 25 6~8 0.55 9~12 0.5 13~ 0.4 Fig.6 I1=KdImax Fig.7 I1=KdImax Current applied to all positions (2) I2= Imax 1 I2= Imax Current applied to every other positions in multiple connector Fig.8 DO NOT USED 13 of 17 Rev.F5 108-5280 Product Specification 5mm 20kgfcm Mated Connector Sturdy Bench Fig.9 20+5 -0 mm Connector 50mm Approx.50mm 40mm Approx.40mm Clamped 45+5 -0 mm Fig.10 1 803 1 Hour 1 1 Cycle 5 5 Minutes Max. Room Temperature -303 1 1 Hour Fig.11 14 of 17 Rev.F5 108-5280 Product Specification 2. Product Qualification Test Sequence Test Items Confirmation of Product Termination Resistance (Specified Current) Termination Resistance(Low Level) / Test Group 1 2 3 4 1 1 1 1 5 6 7 8 9 10 1,8 1,11 1,11 1,13 1,15 1,11 3,5,7 3,6,8 3,6,8 3,6, 8,10 2,7, 9,14 4,12 3,6,8 / Test Sequence 4 3 3 Dielectric Strength Insulation Resistance 2 Current Leakage Temperature Rising 5 Current Cycling Vibration (High Frequency) Vibration + Current Cycle 3,11 4 5,10 9 7 Connector Mating Force Connector Unmating Force Connector Locking Strength 7 2 Contact Retention Force Crimp Tensile Strength 3 Durability (Repeated Mate/Unmating) Resistance to "Kojiri" Solderability Thermal Shock Humidity (Steady State) 2,10 2,10 2,12 2,10 6 4,9 4,9 4,11 4,9 2 Contact Insertion Force 2 7 4 6 5 (SO2) 15 of 17 Sulfurous Acid Gas Resistivity (SO2) Temperature Life(Heat Aging) Resistance to Cold Dust Bombardment 2 4 6 5 5 8 13 5 7 7 Rev.F5 108-5280 Product Specification 1 The applicable product descriptions and part numbers are as shown in Appendix 1. 1 Appendix 1 Prod. P/N Description x-175571-x x-178811-x x-175569-x x-178762-x 26 26 Pos. Cap Hsg Ass'y 26 26 Pos. Cap Hsg Ass'y 26 26 26 Pos. Cap Hsg Ass'y . Water Drain . Out Rib 26 Pos. Cap Hsg Ass'y Water Drain Out Rib x-5178762-x x-176206-x 26 x-178900-x 26 x-178209-x x-175444-x 26 Pos. Cap Hsg Ass'y 3 Row 26 Pos. Cap Hsg Ass'y 3 26 26 Pos. Cap Hsg Ass'y 34 34 Pos. Cap Hsg Ass'y 30 30 Pos. Cap Hsg Ass'y 3 Row Low Pro File Low Pro File x-5175444-x x-176255-x x-175521-x x-178093-x x-175446-x 38 38 38 Pos. Cap Hsg Ass'y 38 Pos. Cap Hsg Ass'y 42 42 Pos. Cap Hsg Ass'y 42 42 Pos. Cap Hsg Ass'y 48 48 Pos. Cap Hsg Ass'y 48 48 Pos. Cap Hsg Ass'y 54 54 Pos. Cap Hsg Ass'y 34 34Pos. 22 16 26 12 22Pos.16Pos. 26Pos.+12Pos. x-5175446-x x-176242-x x-177542-x x-174917-x 42 42 Pos. Cap Hsg Ass'y 16 Out Rib New 16 Pos. x-5174917-x x-179375-x x-175448-x x-1318471-x 54 54 Pos. Cap Hsg Ass'y 64 64 Pos. Cap Hsg Ass'y x-178764-x 64 64 Pos. Cap Hsg Ass'y x-177609-x 64 x-174518-x (16 without 16Pos.) x-5174518-x x-176142-x x-178780-x x-177771-x x-174913-x x-175442-x 16 of 17 64 Pos. Cap Hsg Ass'y 64 76 76 12 12 178764 64 Pos. Cap Hsg Ass'y 76 Pos. Cap Hsg Ass'y 76 Pos. Cap Hsg Ass'y 12Pos. Plug Hsg 12Pos. Plug Hsg Water Drain Add New Part Number In Flange Water Drain Signal Power Rev.F5 108-5280 Product Specification x-353492-x x-917635-x x-174514-x x-176243-x 12 12 16 16 x-174515-x 22 x-174516-x 26 x-175567-x x-176206-x x-178747-x 173716-1 173716-2 175061-1 175061-2 175094-1 175094-2 173630-1 173630-2 173631-1 173631-2 26 26 26 12Pos. Plug Hsg Power 12Pos. Plug Hsg Power 16Pos. Plug Hsg Out Rib 16Pos. Plug Hsg 22Pos. Plug 26Pos. Plug Hsg 26Pos. Plug Hsg 26Pos. Plug Hsg 26Pos. Plug Hsg .040 .040 .040 .040 .040 .040 .070 .070 .070 .070 040 Receptacle Contact 040 Receptacle Contact 040 Receptacle Contact 040 Receptacle Contact 040 Receptacle Contact 040 Receptacle Contact 070 Receptacle Contact 070 Receptacle Contact 070 Receptacle Contact 070 Receptacle Contact 3 Out Rib 3 Row Low Pro File Pre-Tinned Selective Gold Pre-Tinned Selective Gold Pre-Tinned Selective Gold Pre-Tinned Selective Gold Pre-Tinned Selective Gold 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. : 17 of 17 Rev.F5