Product Specification 108-2008 18Jun09 Rev E All Paragraphs Revised Cluster Block Assembly 1. SCOPE 1.1. Content This specification covers the general description and perform ance requirem ents for Tyco Electronics cluster block assem blies designed to connect with herm etic headers having 2.29 and 3.18 m m [.090 and .125 in] diam eter pins. The assem bly consists of a 3 circuit housing accepting term inals with various wire and insulation diam eter ranges. 1.2. Qualification W hen tests are perform ed on the subject product line, procedures specified in Figure 1 shall be used. All inspections shall be perform ed using the applicable inspection plan and product drawing. 2. APPLICABLE DOCUM ENTS The following docum ents form a part of this specification to the extent specified herein. Unless otherwise specified, the latest edition of the docum ent applies. In the event of conflict between the requirem ents of this specification and the product drawing, the product drawing shall take precedence. In the event of conflict between the requirem ents of this specification and the referenced docum ents, this specification shall take precedence. 2.1. Tyco Electronics Docum ents ! ! ! 2.2. 109-1: Test Specification (General Requirem ents for Test Specifications) 109 Series: Test Specifications as indicated in Figure 1 114-2019: Application Specification (Cluster Block Housings and Contacts) Industry Docum ents ! ! ASTM D3455: Standard Test Methods for Com patibility of Construction Material with Electrical Insulating Oil of Petroleum Origin EIA-364: Electrical Connector/Socket Test Procedures Including Environm ental Classifications 3. REQUIREM ENTS 3.1. Design and Construction Product shall be of the design, construction and physical dim ensions specified on the applicable product drawing. 3.2. Materials Materials used in the construction of this product shall be as specified on the applicable product drawing. 3.3. Ratings ! ! Voltage: 115/230 volts AC at 60 Hz Current: The m axim um rated current that can be carried by this product is lim ited by the m axim um operating tem perature of the housings and the tem perature rise of the contacts. Variables which shall be considered for each application are wire size, connector size, contact m aterial and am bient tem perature. (c)2009 Tyco Electronics Corporation Harrisburg, PA All International Rights Reserved. * Trademark | Indicates change For latest revision, visit our website at www.tycoelectronics.com\documents. 1 of 8 For Regional Customer Service, visit our website at www.tycoelectronics.com LOC B 108-2008 3.4. Perform ance and Test Description Product is designed to m eet the electrical, m echanical and environm ental perform ance requirem ents specified in Figure 1. Unless otherwise specified, all tests shall be perform ed at am bient environm ental conditions per Test Specification 109-1. 3.5. Test Requirem ents and Procedures Sum m ary Test Description Exam ination of product. Requirem ent Meets requirem ents of product drawing and Application Specification 114-2019. Procedure Visual, dim ensional and functional per applicable inspection plan. ELECTRICAL Dielectric withstanding voltage. 2.7 kilovolts AC at sea level. 1 second hold. AMP Spec 109-29-1. Test between adjacent term inals of m ated sam ples. Tem perature rise vs current. See Figure 3. EIA-364-70, Method 1. Measure tem perature rise at rated current. See Figure 4. MECHANICAL Crim p tensile. Stranded W ire Tensile Size (AW G) (N [lbf] m in) 22 44 [10] 18 110 [25] 16 160 [37] 14 250 [57] 12 310 [70] 10 350 [80] Note: Tensile values for AMPLIVAR* crim p receptacles are 70% m inim um of the wire strength. EIA-364-8. Determ ine crim p tensile at a rate of 25.4 m m [1 in] per m inute. Contact retention in housing. See Figure 6 for product list. 22 N [5 lbf] m inim um for standard product. 60 N [14 lbf] m inim um for high force product. AMP Spec 109-30. Apply an axial load to crim ped contacts in housing by gripping the wire. Contact engaging force onto header. 133 N [30 lbf] m axim um per cluster block assem bly. AMP Spec 109-35. Measure force necessary to engage header using appropriate gage (3 pin gages equally spaced on a 13.46 0.03 m m [.530 .001 in] diam eter circle). See Figures 5 and 6. Contact separating force from header. 12 N [2.75 lbf] m inim um per contact. 36 N [8.25 lbf] m inim um per cluster block assem bly. AMP Spec 109-35. Measure force necessary to separate appropriate gage (3 pin gages equally spaced on a 13.46 0.03 m m [.530 .001 in] diam eter circle) from header. See Figures 5 and 6. Figure 1 (continued) Rev E 2 of 8 108-2008 Test Description Requirem ent Procedure ENVIRONMENTAL Heat resistance. No signs of blistering, delam ination or degradation of physical properties. Subject connector housings to 163/C for 6 hours. W eight loss. 15 m illigram s m axim um for 1 or 2 piece cluster block assem bly. 5 m illigram s m axim um for cover plate (where applicable). Determ ine weight loss as the average of no less than 10 sam ples using the following procedure: 1. Suspend the sam ples in a vacuum oven and bake at 300 20/F for 6 hours to rem ove m oisture. 2. Rem ove the sam ples from the oven and quickly place them in a desiccator containing anhydrous m agnesium perchlorate or calcium chloride to cool for 1 hour. 3. W eigh the sam ple lot. 4. Replace the sam ples in the vacuum oven and bake at 250 2/F for 24 hours. 5. Rem ove the sam ples from the oven and quickly place them in a desiccator containing anhydrous m agnesium perchlorate or calcium chloride to cool for 1 hour. 6. W eigh the sam ple lot. 7. Calculate the average weight loss by subtracting the value recorded in step 3 from the value recorded in step 6 and dividing by the num ber of sam ples. Chem ical requirem ents, housing. Plastic shall not: 1. Exceed 3% dim ensional change. 2. Form sludge in the test oil. 3. Cause the acidity of the oil to exceed .2 cc using .1 N of sodium hydroxide per 100 cc of oil after 2 hours at room tem perature. 4. Cause the saponification num ber of the oil to exceed 0.01 cc. Note: These m axim um s are per sam ple tested. To be perform ed on housings weighing approxim ately 4.5 to 5.5 gram s [.16 to .20 oz] each. Measure overall dim ensions (length, width and height). Dry for 16 hours at 105/C [221/F] per ASTM D3455. Using a suitable vessel, im m erse housings in 55 cc [3.36 cu in] of deaerated com pressor lube (Trane oil 00037 or equivalent) to a depth of 50% and place in an atm osphere of Freon 22 (340.2 g [12 oz]) at a pressure of approxim ately 517.11 kPa [75 psig]. Subject to 107/C [225/F] for 100 hours. Re-m easure dim ensions and then test acidity and saponification. Figure 1 (end) Rev E 3 of 8 108-2008 3.6. Product Test Sequence Test Group (a) Test or Exam ination 1 2 3 4 5 6 7 8 1 1 Test Sequence (b) Exam ination of product 1 Dielectric withstanding voltage 2 Tem perature rise vs current 1 1 1 1 1 2 Crim p tensile 2 Contact retention in housing 2 Contact engaging force onto header 2 Contact separating force from header 3 Heat resistence 2 W eight loss 2 Chem ical requirem ents, housing NOTE (a) (b) 2 See paragraph 4.1.A. Numbers indicate sequence in which tests are performed. Figure 2 Rev E 4 of 8 108-2008 4. QUALITY ASSURANCE PROVISIONS 4.1. Qualification Testing A. Sam ple Selection Sam ples shall be prepared in accordance with applicable Instruction Sheets and shall be selected at random from current production. All test groups shall each consist of 10 cluster block housings or assem blies with a m inim um of 1 assem bly per wire size (except where the wire size is not a factor). B. Test Sequence Qualification inspection shall be verified by testing sam ples as specified in Figure 2. 4.2. Requalification Testing If changes significantly affecting form , fit or function are m ade to the product or m anufacturing process, product assurance shall coordinate requalification testing, consisting of all or part of the original testing sequence as determ ined by developm ent/product, quality and reliability engineering. 4.3. Acceptance Acceptance is based on verification that the product m eets the requirem ents of Figure 1. Failures attributed to equipm ent, test setup or operator deficiencies shall not disqualify the product. If product failure occurs, corrective action shall be taken and specim ens resubm itted for qualification. Testing to confirm corrective action is required before resubm ittal. 4.4. Quality Conform ance Inspection The applicable quality inspection plan shall specify the sam pling acceptable quality level to be used. Dim ensional and functional requirem ents shall be in accordance with the applicable product drawing and this specification. Rev E 5 of 8 108-2008 Figure 3 Tem perature Rise vs Current Requirem ents Rev E 6 of 8 108-2008 NOTE All terminals and leads shall be connected in series. Figure 4 Tem perature Rise vs Current Setup NOTE 1. 2. 3. .0890 +.0005/-.0000 inch diameter pin is used to check .090 inch diameter cluster block pin receptacle. .1240 +.0005/-.0000 diameter pin is used to check .125 inch diameter cluster block receptacle. Material is steel alloy, Rockwell C60-65. Chamfer is optional. Figure 5 Engaging/Separating Gages Rev E 7 of 8 108-2008 Product Type Receptacle Part Num ber 1217172 1217173 1217174 1217175 1217176 1217264 High Force Product 1217670 1217671 1217672 1742096 1742116 1742117 1742657 NOTE Unless listed above, product is a Standard Force type with a 22 N [5 lbf] contact retention in the housing. Figure 6 Rev E 8 of 8