108-5124 Rev. E38 Product Specification (Sins) Dual Line Interlock Connector (D.LI 1%7%7) Following first 9 pages are English version and last 9 pages are Japanese version. This top sheet is not part of the specification but explains both of English and Japanese versions are available. CObhy Si him S BHO 9 M-DILKBMR TC. TORO 9 K-VILAABMRTT. CObySY bd. ARIE ENECAD, KH. DAM AMHSTESRALT WET,at a) | in wo OQ l. mm x tl @ 5 Ba z & a o ew og oO 5a Og a Eis 3. E ee en eS 4, xr banners 4,1 &L1.2 4.1.2 42 4.3 a a a _ z x i 108-5124 Product Specification Dual Line Interlock Connector {(D.L.1I. Connector ) Scope: This specification covers performance requirements and test methods for Dual Line Interlock Connector for wire-to-board termination (D.L.1. connector), Product Descriptions: | Dual Line Interlock Connector comprises cap housing connector with contact posts preloaded in a 4.6mm distance dual row disposition with 3.Omm center line spacing mounted on PCB, and plug housing that capsulates wire-crimped receptacle contacts to mate with pests. Two types of connectors, vertical and horizontal ones are available for cap housing. The bottom end of the post contact is soldered on PCB. This interconnection system is suitable for wire-to-board termination of electronic control circuits for automotive use and other electronic system equipment. The cap housing is secured on printed circuit board with the use of two 3mm dia. screws. Patent: Patent pending (No. 147672, Utility Model, Japan) Definitions of Component: Contact : Receptacle Contact: A wire crimping female contact for mating with post contact in housing. Post Contact: - A male post contact to mate with receptacle contact in the form of cap housing assembly after being mounted on cap housing. Cap Connector Assembly: A connector assembly consisting of cap housing and post contacts, used for PCB termination after mounting on it. Plug Connector Assembly: A connector assembly consisting of plug housing and receptacle contacts. Plug connector assembly completes termination by mating with cap connector assembly. Two types of plug housings are available, being classified by the type of contact locking in position. Standard Type: . Contacts are locked in contact position by the lock- ing-lance provided on the contact. Double Locking Type: After contacts are locked by the contact locking lance, double locking is made by inserting locking plateinto the housing cavity from the rear (wire side) of housing. Two locking plates are used for one connector. Locking plate coannot be applied to standard type connector. tyca Tyco Electronics Electronics AMP K.K. LOG NO Cmaeg te | S| A[ 108-304 REV E3 SHEFT NAME Product Specification 9 Dual Line Interlock Connector 1 OF (D.L-I. Connector) AMP J-522NUMBER 108-5124 SECURITY AMP Customer Release CLASSIFICATION 563 6.3 Material and Finish: Receptacle Contact: Receptacle contact shall be made of 0.3mm thick brass, conforming to C-2600R-H of JIS H 3100 or equivalent: and finished with 0.8m minimum tin-plating. Post Contact: Post contact shall be made of O.4mm square phosphor bronze, conforming to C 510iR-H of JIS H 3110 and finished with tin-plating 0.8ym thich minimum tin-plating. Housing: Housing is made of molded 6/6 Nylon resin (LEONA* 1300S, manufactured by Asahi Chemical Industries Co. Ltd.), conforming to UL 9AV-2. Quality Assurance Provisions: Unless otherwise specified, all the tests shall be performed in accordance with the test methods specified in Para. 8 and test sequence specified in Table 2, The tested preducts shall show the designated performance capabil- ity conforming to the requirements specified in Table 1, Para. 7.2. Test .Conditions: Unless otherwise specified, all the tests shall be performed under any combination of the following test conditions. Room Temperature: 15 7 35C Relative Humidity: A5 = 75% . Atmospheric Pressure: 86.7-107kPa(650-800nnH) Temperature Rating: 2 Temperature rating of the connctors in mated condition shall be within the range of -30 C and 105 Cc. This temperature includes ambient temper- ature and temperature increase produced by the operating energized current. Applicable Wire Sizes: The wires used for terminating receotacle contact shall be of the sizes and composition as specified below: : : - a . Wire Size: 0.56 - 0.3mm (AWG #20-#22) Stranded one wire only Insulation Range: 2.4mm - 1.4mm in diameter Performance: Rating: . Voltage Rating: 250V AC or 350V DC Maximum Current Rating: 5A Continuous, Maximum SHEET | tyca Tyco Electronics flectronics AMP K.K. 2 OF g floc NO 108-5124 REY iJ|A 3 E3 NAME roduct Specification Dual Line Interlock Connector (D.L.I. Connector) AMP 1-923Performance Requirements: When tested in accordance with the test methods specified in Para. 8, the performance requirements specified in Table 1 shall be met. Se mae I ron ME RRS REL Extraction Force Extraction Force: 98InN min. (Initia a 4 | Para-- . . Test graph Test item Specified Requirements Method 2 | Number Para- 2 graph ae : 6 . (Initial 7.2.1 Termination Resistance} - mo. max (Ini lal) . B41. & (Low Level ) 12 mQ max. (Final) a . z a 2 72262 Insulation Resistance | 500 MQ min. at (500V DC) 8.2 Feead Dielectric Strength Must withstand 1000V AC for 1 minute without 8.3: . showing abnormalities. Bal 7.2.4 Temperature Rising 65C increase over ambient temperature max. 8.4 pO w : BS 7.2.5 |} Contact Retention 49N___._min.| Standard Type 8.5" Force 98N | min.|| Double Locking Type a} 7-226 Crimp Tensile Strength{ 78N min. for 0.56mm? (#20 ANG) wire 8.6 > oO . * * ce AON min. for 0.3mm (#22AWG) wire 2 U a : Pe & 7-2-7 Post Retention Force { 19.6N min. Initial 8.7 0. & (Applicable to vertical type only) * 0 7.2.8 Housing Locking . io. Retention Force SON min. 8.8 7.2.9 Vibration No electrical discontinuity greater than LO microseconds shall occur during test. Final 8.9 termination resistance(Low Level) shall be 12 mQ max. 7.2.10 | Humidity Connector shall be free from defects such as , (Steady State) cracks, blister etc. that are detrimental to 8.10 connector function. Final termination resist- ance (Low Level) shall be 12 mQ max. 72.11 Sulfuric Acid Gas Connector shall be free from defects such as Resistibility cracks, blister etc. that are detrimental to 8.11 connector function. Final termination resist- . ance (Low Level) shall be 12 mQ max. 7-22-12 Temperature Cycling Connector shall be free from defects such as cracks, blister tc. that are detrimental to 8.12 connector function. Final termination resist- ance (Low Level) shall be 12 mQ-max. 7.2.13 | Current Cycling Final termination resistance (low level) shall 8.13 be 12 m&2 max. ; _ More than 95% of tested area must be covered 7.2.14 | Solderability with fresh, uniformly working solder. This 8.14 is appliedto plated surfaces of contact only. 7w2el5 Contact Insertion &. Insertion Force: 5,9N max. (Initial) 8.15 yo Table 1 ( To be continued) SHEET ;tyco Tyco Electronics Electronics AMP K.K. 3 OF 9 a A [ 108-5124 53 | NAME roduct epecification Dual Line Interlock Connector (D.L.1I. Connector ) AMP J-523108-5124 NUMBER 722 Le OR A AP RO SRR CN Ro TAT BCP em Fh Performance Requirements (Continued): Para- graph Number Test Method Para graph Test Item Specified Requirements Customer CLASSIFICATION Release AMP SECURITY 72.16 Connector Insertion/ No. | Measured | Insertion Extraction Extraction Force of 5. cycle(s) Force N: Force N 20 Initial 118: Trax. 24,5 min. 50th. Cycle] 118 mmx. 19.6. min, 6.16 Initial 98 . 50th. Cycle TeX. 19.6: min, 98 ax, 14.7 min. 68 Tmax. 14.7 min, 0th. Cycle 68 TEX. 12: min. g Initial 49 TAX. 9.8 min. sOth. Cyclel % nex. 7.8 min. 16 Initial 12 702.17 (REF. ) Salt Spray Connector shall be free from defects such as cracks, blister, etc. that are detrimental to 8.17 connector functions. Final termination resistance (low level) shall be 50 mQ max. 8. 8.1 8.3 Table 1 (End) Test Methods: Termination Resistance: Contact-loaded and mated pair of conmectors are subject to, testing by applying closed circuit current of 50mA at open circuit voltage of 50mV flowing through the circuit as shown in Fig. 1. Low level termination resistance is calculated from the millivolt drop reading after deducting the reSistance of 75mm-long wire used for termination. The probing point on post connector side must be 1 mm apart from: the. botton- @urface. of housing, and measurements shall be done in the-manner one after one to covr:all the connector positions... : Insulation Resistance: Contact-loaded and mated pair of connectors are subject to testing by applying test potential of 500V DC bdtween the adjacent contacts and between the contacts and the ground. Dielectric Strength: Contact-loaded and mated pair of connectors are subject to testing by applying test potential of TOOOV AC for 1 minute between the adjacent contacts and between the contacts and the ground. SHEET | tyca Tyco Electronics __Bectronios AMP K.K. * OF_9 1+ "1 08-5124 BEV _* OF 72. J A 5 ES | MAME Product Specification Dual Line Interlock Connector {(D.L.1. Connector) AMP J-523NUMBER LO8-5124 ~ Customer URITY SEC AMP CLASSIFICATION Release 8.4 8.5 8.6 8.7 8.8 8.9 8.10 Temperature Rising: Contact-loaded and mated pair of connectors are subject to testing by applying test current of 54 DC to the circuits. The temperature rising shali be measured by probing at the wire crimp by using thermocouple. Contact Retention Force: Insert contact which is crimped on an approximately 75mm-long, 0.5 - 0.56mm2 wire, into the connector housing, and after securely fastened on a tensile testing machine, apply an axial pull~-off load to the end of crimped wire by operating the head to travel with the speed at a rate of 100mm a minute. Contact retention force is determined when the wire is broken or contact isdtslodged from housing. Crimp Tensile Strength Securely fasten a wire+crimped contact on a tensile testing machine and apply an axial pull-off load to the crimped wire by operating the head to travel with the speed at a rate of 100mm a minute. Crimp tensile strength is determined when the wire is broken or is pulled off from the wire crimp. Post Retention Force: Accept the post connector: with the test fixture specified as: shown in - Fig. 3. and apply an axial push-in load to the head of post contact vertically to dislodge from the mounted position. The force required to dislodge the post shall be measured. , Housing Locking Mechanism Retention Force: Contact-loaded and mated pair of connectos are subject to testing by applying ah axial load to separate the locked connectors.. The force required to separate the connectors with or without damage of loeking mecanism.shall be measured and recorded. Vibration: Contact-loaded and mated pair of connectors are subject to testing after all the contacts series wired. The connectors are secured onthe vibfatile table, and sweeping vibration to reciprocate from 10 to 55 Hz. changing one cycle a minute, with the accelerated velocity of faMs is applied to it. . . : : . (AAG : : During the vibration, closed circuit current of O.1A at open circuit voltage of 13V DC is applied to the circuit, and monitored for electrical disconti- nuity greater than 10 microsecond taking place in the circuit. Test duration shall be 2 hours each for three axial directions of X, Y and 4, totally 6 hours. Humidity: Contact-loaded and mated pair of connectors are subject to testing by exposing under humidity conditioning in the test chamber, where relative humidity ranging 90 - 95% at the temperature of 40C is maintained. After exposing for 96 hours, the sample shall be taken out from the test chamber and reconditioned in the room temperature for 1 hour before undergoing subsequent measurements. SHEET | tyca Tyco Electronics | fectronics AMP K.K. Sorc Loc NO REY 2? OF 7) J A 108-5124 ES. MAME Product Specification ~ Dual Line Interlock Connector (D.L.1I. Connector ) AMP 3-525 a teNUMSER 108-5124. AMP SECURITY CLASSIFICATIGN Customer Release 8.11 8.12 8.13 8.14 8.15 . 8.16 8.17 Sulfurous Acid Gas Resistibility: Contact-loaded and mated pair of connectors are subject to exposure under sulfurous acid gas atmosphere of 10 p.p.m, with relative humidity of 90% minimum for 48 hours. Temperature Cycling: Contact~loaded and mated pair of connectors are subject to exposure under 5 cycles of temperature conditioning in the oven, each cycle consisting of at -30 12C for 3 hours, followed by at 25+ 9 for 30 minutes, then at 80 feec for 3 hours, and reconditioned at 25 * 5 c for 30 minutes. After completion of test cycles, subsequent measurement shall be made. Current Cycling: Contact-loaded and mated pair of connectors are subject to testing by applying 50-cycles 6f current cycling test conditioning, each cycle consisting of energizing 3A DC for 45 minutes followed by de-energizing for 15 minutes. After completion of test conditioning, subsequent measurement shall be performed. Solderability: Dip soldering area of post contacts of cap connector in flux (resin solution in methanol) for 5 - 10 seconds, then dip into the melted solder (60% tin, 40% lead) temperature of which is controlled at 230C 25C for 3 *0.3 seconds. After immersion, soldered area shali be visually inspected with the aid of X10 magnifying glass. Contact Insertion/Extraction Force: Securely fasten a pair of contacts on tensile testing machine in the manner that they mate and unmate as the head is operated with the speed at a rate of 100 mm a minute. The force required to mate and unmate with the test gage specified in Fig. 4, shall be measured and recorded. Connector Insertion/Extraction Force: Securely fasten contact-loaded cap housing connector on tensile testing machine, and the couterpart plug housing connector to be fixed on the head-in the manner to mate and unmate as the head is operated. Connector: insertion/extraction force is tested by operating the head to travel with the speed at a rate of 100mm a minute. The force required to mate and unmate the connectors is measured and recorded. For this test, locking mechanism must be*kept not set in effect. Salt Spray: Contact-loaded and mated pair of connectors are subject to exposure under spray of 5% salt solution at 35C for 48 hours, After test duration, linse the connector in the tap water, and have it dried in the room temperature for 1 hour before undergoing subsequent measurement, SHEET | tyca Tyco Electronics | Electronics AMP K.-K, & oF_ tee N 108-5124 REV ( J A 5 E3 | NAME, Product Specification Dual Line Interlock Connector . D.L.I, Connector AMP 3-523Trace cnn eenn EA RAR MR ka te NARA NA RAR RNA Zt. 9. Test Sequence: cs : in Tests shall be performed in the sequence specified in Table 2, & by each sample grouped. = w: i Test Sample Grow 3 Method Test Item . 2 P _ 21 graph LL2]}3] 4 6| 7 | 819 Jio] 12 | 12713 | 14] = 1 , 8.1 Termination Resistance Q@ @ ao (Low Level ) @) @) 3) 8) @) oa 8.2 Insulation Resistance '@ bo &) Salo. ; : 8.3 Dielectric Strength @ z=] 8.4 . t Risk rs emperature Rising at 4 id 8.5 Contact Retention Force 6) | a & ut . . = 5 8.6 Crimp Tensile Strength @) 8.7 Post Retention Force , @ 8.8 Housing Locking Mechanism Retention Force 8.9 Vibration @) 8.10 | Humidity GB) (2) 8.11 Sulfurous Acid Gas Resisti- @ bility . : 8.12 Temperature Cycling je): 8.13 Current Cycling 1@) 8.14 Solderability @) "B15 Contact Insertion/Extraction @) Force 8.16 Connector Insertion/Extraction @ Force . 8.17 Salt Spray P (2) Table 2 SHEET | tyca Tyco Electronics Electronics AMP K.K. 7 OF_9_[% NS 108-5124 eid PNT | A 3 3 NAME Product Specification Dual Line Interlock Connector , (D.L.I. Connector) AMP J-523NUMBER 108-5124 Customer AMP SECURITY Release CLASSIFICATION Vertical Type Connector: Printed Circuit . Board Cap Housing Plug Housing ; - (4) Power Source Horizontal Type Connector: Plug Housing ~- Cap Housing. | 1 mm Max. ~S Printed Circuit Board NV Power Source em ecient. Fig 1 Measuring ===> na Apparatus Oe a0 o re) ; \ : O20 Wrap connector with metallic foil. Metallic foil must be kept 5mm apart from the surface of connector contacts. Measurement between Measurement between Contacts Adjacent Contacts and the Ground Fig. 2 SHEET | tyce Tyco Electronics Electronics ANP K.K. _8 OF_9_ Jd A [ 108-5124 ES NAME Product Specification. Dual Line Interlock Connector (D.L.f. Connector) AMP J-523NUMBER 108-5124 Customer Release AMP SECURITY CLASSIFICATION Note: Direction of Applying Test Load a Lt ea A Cap Housing ( Test Fixture \ Fig. 3 0.75 > / burtace ems OE ate a eR TEE MENTE TR PAR Contacting (4 uf | i Non- . contacting Surface ha 6.5 tomating Depth with Receptacle Contact The two contacting surfaces in the area from the tip end of post to a length of 6 mm both sides of post, must be smmothly finished to a degree of 4 , Contacting surfaces must be definitely indicated to avoid misusing of gage. Fig. 4&4 1 a 7 0.5 6 HH / 0.05R pe (MP.) =f \ Non-contacting Surface Contacting surface Unit: mm SHEET | tyco | Electronics Tyco Electronics AMP K.K. 9 oF 9 7heS NO 108-5124 , REV ; VP A ? | E3 NAME . Product Specification Dual Line Interlock Connector (D.L.1. Connector ) AMP J-523AMP J-002 BU FA on 7 Electronics & een ER ia: ee (32 GS @ 4) S49 TLepoL4R FUT oe fa Bi i 108-5124 FaFre FA ve tv R-dy Fe aK SR (D.L.1. CONNECTOR ) 1. 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