| .040 11 /.070 IHD HYBRID /O Connector Design Objectives AMP 96Pos./126Pos. | 108-5580 17NOVOO RevA DESIGN OBJECTIVES The product described in this document has not been fully tested to ensure conformance to the requirements outlined below. therefore, AMP(Japan), Ltd. makes no representation or war- ranty, express or implied, that product will comply. with these requirements. Further, AMP(Japan), Lid. may change these requirements based on the results of additional testing and evaluation. Contact AMP Engineering for further details. In case when product specification is referred to in this document, it should be read as *design objectives for all times as applicable. 1.Scope: 1,1 Contents This specification covers the requirements for product performance, test methods and quality assurance provisions of .040 11 /.070 II HD HYBRID I/O Connector 96Pos./126Pos. for WiretoBoard Termination. Applicable product description 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 draw- ing, the product drawing shall take precedence. In the event of conflict between the re- quirements of this specification and the referenced documents, this specification shall take precedence. 2.1 AMP Specifications: A. 109-5000 ;: Test Specification, General Requirements for Test Methods B. 114-5159 ; Application Specification. Crimping .040 II Series Receptacle & Tab Contact. C. 114-5160 ; Application Specification. Crimping .070 Il Series Receptacle & Tab Contact. 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 DO0203 : Method of Moisture, Rain and Spray Test for Automobile Parts E. JIS D0204 : Method of High and Low Temperature Test for Automobile Parts EF JIS D1601 : Vibration Testing Method for Automobile Parts G. JIS R5210 : Portland Cement Tyco Electronics AMP K.K. Hisamoto 3-5-8, Takatsu-ku, Kawasaki-shi, Kanagawa-ken, Japan 1of 11 AMP FAX/PRODUCT INFO 1-800-522-6752 This AMP contralled document is subject to change. For latest revision call the AMP FAX number. i T Electroni AK, i R : Copyright 2000 by Tyco Electronics AMP K.K. All Rights Reserved Released Per EG FJ00-1731-00.040 11 /.070 I|LHD HYBRID I/O Connector ANP _ $6Pos./126Pos. 108-5580 H. MIL-STD-202 : Testing Method 208 : Method of Soldering 3.Requirements: 3.1 Design and Construction: Product shall be of the design, construction and physical dimensions specified on the ap- plicable product drawing. 3.2 Material : A. Contact : a. Receptacle Contact : Pretinned brass or Pretinned Phosphor bronze b. Tab Contact : Pretinned brass B. Housing : PBT resin 3.3 Ratings: A. Temperature Rating : 30C to 105C 3.4 Performance Requirements and Test Descriptions: The product shall be designed to meet the electrical, mechanical and environmental per- formance requirements specified in Fig.2. All tests shall be performed in the room temper- ature, unless otherwise specified. 2 of 11 Rev A.040 [I /.070 Il HD HYBRID 96Pos./126Pos. 3.5 Test Requirements and Procedures Summary: VO Connector < Product shall be conforming to the | Visually,dimensionally and functional- Confirmation of requirements of applicable product | ly inspected per applicable quality in- 3.5.1 drawing and Application Specifica- | spection plan. Product Hon No.114-5159,114-5160 Electrical Requirements Termination (.040 Il} 10m Max. (Initial) Measure initial millivolt drop of con- 352 Resistance 20m 0 Max. (Final) tact test circuit in mated connectors. (Specified Cur- | (.070 11) 3mQMax. (Initial) Fig.3 rent) 10m Max. (Final) AMP Spec.1095811-2 | Subject mated contacts assembled in Termination (.040 11) 10mQMax, (Initial) housing to closed circuit current of 353 R i be 20m 2 Max. (Final) 10mA Max.at open circuit voltage of 0. (Lov Level) (.070 I!) 3mQMax. (Initial) 20mV Max. | ow nem) 10m QMax. (Final) Fig.3 AMP Spec.109-5311-1 1kV AC for 1 minute. 35.4 Dielectric No creeping discharge nor flash- Test between adjacent circuits of _ Strength over shall occur. mated connectors. Fig.4 AMP Spec. 109-5301 Impressed voltage 500V DC. Insulation . Test between adjacent circuits of 3.5. Resistance 100M Min. mated connectors. Fig.4 AMP Spec. 109-5302 . Current 12V DC impressed minute. Fig.5 3.5.6 Leakage 1mA Max AMP Spec. 109-5312 4 : Measure temperature rising by en- 3.5.7 Temperature 60 CMaxunder loaded specified gaged current. Fig.6&7. ising | current, AMP Spec. 109-5310 ' (040 1} 20m OMax. (Final) Applied Current: Fig.6&7. 35.8 C t Cyclin (.070 II} 10mQMax. (Final) 45minutesON,l5minutesOFF, re urrent yoms | No ignition is alowed during the 200cycles. test. AMP Spec. 109-5308 Fig.1(To be continued) reer enn le 3 of 11 Rev A 108-5580.040 II /.070 | HD HYBRID I/O Connector AMP 96Pos./126Pos. 108-5580 Physical Requirements Para. Test Items Requirements Procedures Vibration Frequency: 20~200 ~20Hz/3min. Accelerated Velocity : Vibrati No electrical discontinuity greater 44.1m/s* 3.5.9 (Hie , than 1 sec. shall ocour. Vibration| UP | Back | Right 5. (Hig (.040 11) 20m QMax. (Final) peration! and | and | and Frequency) | (9701) 10mQMax. (Final) "| Down | Force | Left Directions| 4hours| Z2hours| 2hours Fig.10 Vibration Frequency: 20~200 ~20Hz/3min. No electrical discontinuity greater | Accelerated Velocity: 44.1m/s than 1 zsec. shall occur. (.040 11) 20m QMax. (Final) i, Up | Back | Right (.070 Il) 10mQMax. (Final) Vibration] ona | and and Vibration+ Direction Down | Force Left 3.5.10 Current Cycle Directions| 100 50 50 hours * hours hours Test Current;(.0401D4.4A DC (.070ID10A DC Fig.10 ; Operation Speed : 100mm/min. 35.11 Contact .040 Il Series : 5.83N Max Measure the force required to mate ~ Mating Force {.070 tl Series : 5.8N Max contacts, AMP Spec.1085206 Contact Operation Speed : 100mm/min. 3.5.12 Unmating Force 040 I Series : 0.98N Min. Measure the force required to unmate aa 6 070 li Series : 0.98N Min. contacts. AMP Spec.109-5206 Operation Speed : 100mm/min. 35.18 Connector 32Pos.147N Max. Measure the force required to mate Mating Force | 30Pos.147N Max. connectors. AMP Spec.1095206 Operation Speed:100mm/min. 35.14 Connector 32Pos.147N Max. Measure the force required to unmate Unmating Force | 30Pos.147N Max. connectors. AMP Spec. 109-5206 . Measure housing locking strength. 8.5.15 Housing nth 98N Min. Operation Speed:100mm/min. 8 AMP Spec. 109-5210 Fig.1(To be continued) eee reer eee c cece ee eee eee eee eee eee eee eee ee ce eee eee 4of 11 Reva.040 tl /.070 IiHD HYBRID VO Connector ANF 96Pos./126Pos. 108-5580 Test Items Requirements Procedures | Para. Contact Inser- Measure the force required to insert 3.5.16 Hon Foree 9.8N Max. par contact. contacts into housing. yon AMP Spec. 109-5211 Contact ners axial pulloff load to 3.5.17 | Retention Force | 49N Min. 0 ion . d: . (PreLock) peration Speed: 100mm/min. AMP Spec. 109-5212 Contact Reten- Apply an axial pulloff load to 3.5.18 | tion Foree(Sec- | 78N Min. crimped wire. ondaryLock) Operation Speed: 100mm/min. 1 age Crimp Wire Size Tensile(min.) mm2 | (AWG) N Apply an axial pulloff load to Crimp Tensil crimped wire of contact secured on 3.5.19 Strength. 0.3 22 58 the tester. n 0.5 20 83 Operation Speed: 100mm/min. AMP Spec. 109-5205 085 | 18 127 pee 1.25 16 177 Durability : Operation Speed: 100mm/min. 3.5.20 | (Repeated Mate/ om f om ee eee) No. of Cycles:30 Cycles. Unmating) . . AMP Spec.109-5213 Secure one of the connectors on the . . table,and apply the bending force of 3.5.21 Resistance to O70 ' ton ee el) 98N in frontrear and rightleft ot ax directions two times.Making this a _jeycle,repeat 1LOcycle. Fig.9 Solder Temperature :230 +5C a: . Immersion Duration :3 + 0.5seconds 3.5.22 | Solderability | Wet Solder Coverage: 95%Min. Flux:Alpha 100 AMP Spec. 109-5203 Handling No abnormalities allowed in manu- 3.5.23 Ergonomics al mating/unmating handling. Manually operated Double Lock Operation Speed: 100mm/min. 3.5.24 | Plate Locking |59N Min. Measure the force required to lock the Strength double lock plate Environmental Requirements . 30C /60min.,80C/60min. 3.5.25 | Thermal Shock oo ; om eM Fey Making this a cycle, repeat Scycles. Mae NA A AMP Spec. 109-5103 Insuletion resistance (Final) Mated connector, | Humidity, ane i eae 90~95 %R.H.,60C 3.5.26 Termination resistance Steady State . 96hours (.040 11} 20m QMax, (Final) AMP Spec, 109-5105 (070 I) 10mQMax. (Final) pee. Fig.1(To be continued) ee 5 of 11 Rev A040 II/,070 II HD HYBRID W/O Connector AME 96Pos./126Pos. 408-5580 Para. Test Items Requirements | Procedures ' 9 Industrial Gas (.040 11) 20mQMax. (Final) 802 Gas : 10ppm, 95 %R.H. 3.5.27 (S02) (07011) 10mQMax. (Final) | 20 ; 24hours 2 . AMP Spec. 109-5107 ase) | (0401) 20mOMax, (Final) | 100C Duration:120hours (Heat Aging) (.070 11) 10m QMax. (Final) AMP Spec. 109-5104 3.5.29 Resistance to (.040 Il} 20m QMax. (Final) -40C +5T,120hours Cold (070 11} 20m 0 Max. (Final) AMP Spec. 109-5108 Subject JIS R 5210 cement blow of 3.5.30 Dust (040 It) 20m QMax. (Final) 1.5Kg per 10 seconds in Bombardment (.070 Il) 10m QMax. (Final) 15 minutes intervals for 90minutes. AMP Spec. 109-5110 Fig.l (End) aa eee Se 6 of 11 Rev A.040 II /.070 I1HD HYBRID I/O Connector ANP 96Pos./126Pos. 108-5580 3.6 Product. Qualification Test Sequence Test Group Para. Test Items 1{[2]3 [4] 5 | 6 7 | 8 | 9 | 10 | 11 Test Sequence (a) Confirmation of Product |} 1 1 1 1 1,9 }1,11 }1,11 1,18 $1,16]1,11[] 1 Termination Resistance 3.5.2 (Specified Current) 4 3.5.3 | Termination Resistance | 3 3,5, | 3,6, | 3,6, | 3,6, | 2,7, | 3,6, 7 (Low Level) , 7 8 8 |8,10)9,14] 8 3.5.4 Dielectric Strength 3 4,12 3.5.5 | Insulation Resistance 2 3,11 | 3.5.6 Current Leakage 4 5,10 3.5.7 Temperature Rising 5 3.5.8 Current Cycling 9 Vibration 3.5.9 (High Frequency) i ? 3.5.10 Vibration + Current | 7 Cycle 3.6.11 | Contact Mating Force 2 3.5.12 | Contact Unmating Force |} 3 3.5.13 | Connector Mating Force 2 2,10 | 2,10 | 2,12 2,10 3.5.14 Connector Unmating 6 49 14,9 |4,11 4,9 orce Housing Locking 3.5.15 Strength 2 3.5.16 | Contact Insertion Force 2 Contact Retention 8.5.17 Force(PreLock) 3 Contact Retention 3.5.18 Force(Secondary Lock) 7 3.5.19 | Crimp Tensile Strength 4 Durability 3.5.20 (Repeated Mate/ 6 Unmating) 3.5.21 | Resistance to Kojiri 5 5 5 3.5.22 Solderability 2 3.5.23 } Handling Ergonomics 8 15 Double Lock Plate 3.5.24 Locking Strength 4 3.5.25 Thermal Shock 4 Fig.2(To be continued) 7 of 11 Rev A.040 li /.070 I|HD HYBRID I/O Connector ANI 96Pos./126Pos. 108-5580 I Test Group Para. Test Items 1{2 {3 | 4 {5 | 6 7 | 8 | 9 | 10 | 11 Test Sequence (a) Humidity 3.5.26 steady State 6 8 3.5.27| Industrial Gas(SO2) || 13 Temperature Life 3.5.28 (Heat Aging) 5 3.5.29 Resistance to Cold 7 3.5.30 | Dust Bombardment ll 7 (a) Numbers indicate sequence in which tests are performed. Fig.2(End)} Imm Max. y Soldering ? Y nnn Thermocouples Mounted Here (Vv) ae 4 wa P From the measured readings, deduct the resistance of the 100mm long wire used for termina- tion. When testing for rated current measurement, apply 12 V DC,1A to the circuit. For obtaining uniformity of the current density on probing points YY apply soldering on the probing points prior testing. Fig.3 Measurement of Termination Resistance 8 of 11 Rev A.040 I! /.070 I|LHD HYBRID I/O Connector ANF 96Pos./126Pos. 108-5580 Wrap metallicfoil to cover the connector surface Measuring Apparatus Adjacent Contacts Contacts Housing Fig.4 Fig.5 Wire Size(mm Allowable Current (DC A} 0.3 9 0.5 11 0.85 16 1.25 19 Fig.6 Maximum Allowable Current (Imax.) 9of 11 Rev A.040 11/.070 IHD HYBRID I/O Connector ANF 96Pos./126Pos. 4108-5580 Number of Energized Reduction Coefficient Contacts 1 ~ 1 2~3 0.75 4~5 0.6 6~8 , 0.55 9~12 0.5 138~ 0.4 Connector with the half mate condition. 8h iy - Fixing table \\ > : WILLLLLL,. ~\ YY } Vibration table le Vi Remarks: Apply taping in the manner of halfoverlapped rounds from the position 50mm apart from the tip end the contact. Fig.10 10 of 11 RevA.040 Il /.070 | HD HYBRID I/O Connector AMF 96Pos./126Pos. 408-5580 1Hour 1Hour 80+3C 5Minutes Max. Yo Room Temperature 7 A = 3043C 1Cycle Fig.11 The applicable product descriptions and part numbers are as shown in Appendix. 1 Appendix 1 Prod. P/N | Description 353212 |.04011/.070 ll HD Hybrid I/O Connector 32Pos. Plug Hsg. Assy AType 353213 .040 Il /.070 li HD Hybrid I/O Connector 32Pos. Plug Hsg. Assy BType 353214 .040 11 /.070 Il HD Hybrid I/O Connector 32Pos. Plug Hsg. Assy CType 353217 -040 Ii /.070 Il HD Hybrid I/O Connector 30Pos. Plug Hsg. Assy 858220 .040 II /.070 Il! HD Hybrid I/O Connector 96Pos, Cap Hsg. Assy 3853222 .040 II /.070 1] HD Hybrid 1/O Connector 126Pos, Cap Hsg. Assy 175265 .040 Il S Receptacle Contact (PreTin) 175268 .070 II "S Receptacle Contact (PreTin) 175269 .070 Il "M Receptacle Contact (Pre- Tin) 11 of 11 Rev A