Application Specification 114-20079 Terminal Block Stacking Connectors NOTE i 06 AUG 08 Rev E All numerical values are in metric units [with U.S. customary units in brackets]. Dimensions are in millimeters. Unless otherwise specified, dimensions have a tolerance of +0.13 and angles have a tolerance of +2 . Figures and illustrations are for identification only and are not drawn to scale. _ 1. INTRODUCTION This specification covers the requirements for application of Terminal Block Stacking Connectors. The complete line consists of one-piece side entry, angled entry, and top entry printed circuit (pc) board terminal blocks and plug connectors with mating right-angle or vertical mount pc board headers. PC board headers are offered with either open and closed ends, and also in double-row configurations. These terminal blocks feature screw clamp contacts that accept wire sizes 0.03-4 mm2 (solid), or 0.03-2.5 mm2 (stranded). Wire entry is perpendicular to the screws. They are available in configurations of 2.54, 3.5, 3.81, 5, 5.08, 7.5, 7.62, 10, or 10.16 mm contact centerline spacings. Side entry wire, angled entry wire, and top entry wire pc board mount terminal blocks (only 5, 5.08, 7.5, and 7.62 mm pitch), as well as the pc board mating header (only 5, 5.08 mm pitch, open-ended, or unshrouded) are stackable end-to-end without loss of centerline. Ease of assembly is facilitated, in most versions, by built-in interlocks on the housing. When corresponding with Tyco Electronics Personnel, use the terminology provided on this specification to help facilitate your inquiry for information. Basic terms and features of components are provided in Figure 1. Test Facility 90 and 180 Plug Closed End 180 Header Assemblies Angled Wire Entry Unshrouded Open End Pin Header Top Wire Entry 90 Header Clamping Assembly Screw Retention Latch PC Board Mount Plug Side Wire Entry Figure 1 (cont'd) E 2008 Tyco Electronics Corporation, Harrisburg, PA All International Rights Reserved TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change. PRODUCT INFORMATION 1-800-522-6752 For latest revision and Regional Customer Service, TE logo and Tyco Electronics are trademarks. *Trademark. Other products, logos, and company names used are the property of their respective owners. visit our website at www.tycoelectronics.com 1 of 8 LOC B Terminal Block Stacking Connectors 114-20079 2nd Level 2nd and 3rd Level Wire Entries Test Facilities Three Level Interlock Feature 3rd Level 1st and 2nd Level Figure 1 (end) 2. REFERENCE MATERIAL 2.1. Revision Summary This paragraph is reserved for a revision summary covering the most recent additions and changes made to this specification which include the following: S Updated document to corporate requirements S New format 2.2. Customer Assistance Reference base part number 284093 and product code 7742 are representative numbers of Terminal Block Stacking Connectors. Use of these numbers will identify the product line and expedite your inquiries through a service network established to help you obtain product information. Such information can be obtained through a local Tyco Electronics Representative or, after purchase, by calling the Tooling Assistance Center or the Product Information Center number at the bottom of page 1. 2.3. Drawings Customer Drawings for the connectors are available from the service network. The information contained in Customer Drawings takes priority if there is a conflict with this specification or with any technical documentation supplied by Tyco Electronics. 2.4. Specifications Product Specification 108-20166 provides test and performance requirements. 2 of 8 Tyco Electronics Corporation Rev E Terminal Block Stacking Connectors 114-20079 2.5. Manuals Manual 402-40 is available upon request and can be used as a guide in soldering. This manual provides information on various flux types and characteristics along with the commercial designation and flux removal procedures. A checklist is included in the manual as a guide for information on soldering problems. 3. REQUIREMENTS 3.1. Materials Terminal Block Stacking Connectors are made of UL 94V-0 rated PA-66. 3.2. Storage A. Ultraviolet Light Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the pc board jack connector material. B. Shelf Life The jack connectors are packaged and shipped in protective anti-static tube or tray containers. To prevent damage to these connectors, they should remain in the container until ready for installation. Also, to prevent possible storage contamination, the connectors should be used on a first in, first out basis. C. Chemical Exposure Do not store jack connectors near any chemical listed below as they may cause stress corrosion cracks in the connector. Alkalies Amines Ammonia Carbonates Citrates Nitrites Phosphates Citrates Sulfur Nitrites Sulfur Compounds Tartrates 3.3. Polarization Design configuration prevents plug and receptacle connectors from being mated incorrectly. 3.4. PC Board Layout A. Single Connector Use a pc board with a nominal thickness of 1.6-2.4 mm. See Figure 2. Customer drawings provide a complete definition of pc board layout. WIRE SIZE HOLE DESCRIPTION DIAMETER (mm) SOLID STRANDED 1 mm2 0.75 mm2 1.1 +0.1/-0 1.5 mm2 1 mm2 1.1 +0.1/-0 2.5 mm2 1.5 mm2 1.4 +0.1/-0 4 mm2 2.5 mm2 1.4 +0.1/-0 Pin Header Unshrouded --- --- 1.4 +0.1/-0 Header Assembly --- --- 1.4 +0.1/-0 PC Board Mount Figure 2 Rev E Tyco Electronics Corporation 3 of 8 Terminal Block Stacking Connectors 114-20079 B. Stacked Connectors PC board mount connectors with 5, 5.08, 7.5, and 7.62 mm pitch; or headers with 5 and 5.08 mm pitch can be stacked end-to-end without loss of centerline spacing to create the required position size. Ease of assembly if facilitated in most versions by interlocking features. The 5 and 5.08 mm pitch open-ended headers are designed for stacking applications. However, those with closed ends are not. See Figure 3. 3.7 B 3.2 A A Dimension A" equals contact centerline spacing (5 or 5.08). Dimension B" equals 1/2 dimension A". Value in parenthesis refers to 5.08 pitch headers Figure 3 3.5. Wire Selection, Preparation, and Installation A. Selection The connectors will accept wires with conductors of the sizes defined in Figure 4. B. Strip Length The wire must be stripped to the proper dimension to ensure correct insertion depth in the connector. Excessive conductor will be exposed if the strip length is too long and entrapment of the insulation or improper termination will result if the strip length is too short. See Figure 4. C. Installation Two screwdrivers must be used to open and close the screw clamps. The wire must be inserted into the wire hole until the insulation is even with the housing at the wire hole opening. The screw must be hand tightened with the proper screwdriver to within the torque provided in Figure 4. Pull back on the wire to be sure it is secure and check there are no wire strands outside the terminal block. B DIM A" DIM B" PART NUMBER 1.8 0.3 785730-1 2.5 0.6 785730-2 Strip Length A Figure 4 (cont'd) 4 of 8 Tyco Electronics Corporation Rev E Terminal Block Stacking Connectors 114-20079 2 WIRE SIZE (mm ) DESCRIPTION PC Board Mount SOLID STRANDED 1 0.75 Plug (3.5-3.81 mm Pitch) STRIP LENGTH SCREW TORQUE (mm) (Nm) 4-5 0.20 5-6 0.25 0.05-1.5 1.5 1 5-6 0.5 2.5 1.5 5.5-6.5 0.5 4 2.5 6.5-7 0.5 Plug (90 & 180) 1.5 1 4-6 0.5 Plug 2.5 1.5 6-7.5 0.5-0.8 PC Board Mount SCREWDRIVER 785730-1 785730-2 Figure 4 (end) 3.6. Physical Characteristics The terminal block connectors consist of specially designed screw-activated mechanisms that are captivated inside the housing. When stripped wire is inserted into the connector and the screw is tightened, the screw activates a clamp which compresses the wire against the terminal. See Figure 5. Screw Terminal Block Clamp Terminal Stripped Wire Figure 5 3.7. Soldering NOTE Manual 402-40 provides some guidelines for establishing soldering practices. Refer to Paragraph 2.5, Manuals. i A. Fluxing The contact solder tails and, if applicable, attaching hardware must be fluxed prior to soldering with a mildly active, rosin base flux. Selection of the flux will depend on the type of pc board and other components mounted on the board. Additionally, the flux must be compatible with the wave solder line, manufacturing, health, and safety requirements. Call the Product Information number at the bottom of page 1 for consideration of other types of flux. Some fluxes that are compatible with these connectors are provided in Figure 6. COMMERCIAL DESIGNATION FLUX TYPE ACTIVITY RESIDUE KESTER Type RMA (Mildly Activated) Center (Activated) Mild Medium Noncorrosive May be Corrosive YTrademark of MacDonald & Co. U Designation of Alpha Metals Inc. Y 185/197 1544, 1545, 1547 U ALPHA 611 711, 809, 811 Figure 6 Rev E Tyco Electronics Corporation 5 of 8 Terminal Block Stacking Connectors 114-20079 B. Soldering Guidelines Eurostyle Connectors can be soldered using wave or equivalent soldering techniques. Refer to Manual 402-40 for soldering guidelines. The temperatures and exposure time shall be as specified in Figure 7. NOTE SMT High Temperature Connectors that are compatible with typical surface mount soldering techniques are also available. They can withstand a maximum temperature of 260 C [500 F] for 1 minute maximum. i D TEMPERATURE SOLDERING PROCESS TIME CELSIUS FAHRENHEIT 250 482 Wave Soldering (At Max Temp) 5 Seconds DWave Temperature (Under PC Board) Figure 7 C. Reflow Parameters Due to the many variables involved with the reflow process (ie, component density, orientation, etc), we recommend that the user conduct trial runs under actual manufacturing conditions to ensure product and process compatibility. D. Cleaning After soldering, removal of fluxes, residues, and activators is necessary. Consult with the supplier of the solder paste and flux for recommended cleaning solvents. The following is a listing of common cleaning solvents that will not affect the connectors. The connectors will be unaffected by any of these solvents for the time and temperatures listed in Figure 8. Cleaners must be free of dissolved flux and other contaminants. We recommend cleaning with the pc board on its edge. If using an aqueous cleaner, we recommend standard equipment such as a soak-tank or an automatic in-line machine. CAUTION Even when using no clean" solder paste, it is imperative that the contact interface be kept clean of flux and residue, since it acts as an insulator. Flux may migrate under certain conditions with elevated temperatures and, therefore, ! cleaning is necessary even with no clean" paste. CLEANER NAME TIME (Mi (Minutes) ) TYPE TEMPERATURES (Maximum) CELSIUS FAHRENHEIT Alpha 2110H Aqueous 1 132 270 Bioact EC-7z Solvent 5 100 212 Butyl CarbitolD Solvent 1 Isopropyl Alcohol Solvent 5 100 212 Kester 5778s Aqueous 5 100 212 Kester 5779s Aqueous 5 100 212 Loncoterge 520D Aqueous 5 100 212 Loncoterge 530D Aqueous 5 100 212 Terpene Solvent Solvent 5 100 212 H Product of Fry's Metals, Inc. z Product of Petroferm, Inc. D Product of Union Carbide Corp. Room Ambient s Product of Litton Systems, Inc. Figure 8 DANGER Consideration must be given to toxicity and other safety requirements recommended by the solvent manufacturer. Trichloroethylene and Methylene Chloride can be used with no harmful affect to the connectors; however, Tyco Electronics does not recommend them because of the harmful occupational and environmental effects. Both are carcinogenic (cancer-causing) and Trichloroethylene is harmful to the earth's ozone layer. 6 of 8 Tyco Electronics Corporation Rev E Terminal Block Stacking Connectors NOTE 114-20079 If you have a particular solvent that is not listed, contact the Product Information number at the bottom of page 1. i E. Drying Air drying of cleaned connectors is recommended. Temperature for the connectors should not exceed -40 to 105_C [-40 to 221_F]. Degradation of the housings could result from extreme temperatures. 3.8. Repair Damaged wires can be removed from screw clamp connectors and replaced. If a post in a header is damaged, it can not be repaired; the solder must be removed and the header must be replaced with a new one. 4. QUALIFICATIONS Terminal Block Stacking Connectors are Recognized by Underwriters Laboratories Inc. (UL) in File Number E66717 and certified to CSA International in File LR7189. The Istituto Italiano del Marchio di Qualita (IMQ) certificates these products to IEC 998-1 and 998-2-1. 5. TOOLING The only tooling required to attach the wire to these connectors is a flat-bladed screwdriver 785730-[ ]. Refer to Figure 4 for specific usage. Rev E Tyco Electronics Corporation 7 of 8 Terminal Block Stacking Connectors 114-20079 6. VISUAL AID Figure 9 shows typical application of Terminal Block Stacking Connectors and calls out the conditions that production personnel should check to ensure a good installation. For dimensional inspection, refer to the details in the preceding pages of this specification. THERE MAY BE SOME DISCOLORATION BUT NO CRACKS ARE PERMITTED IN THE HOUSING SCREWS MUST BE TIGHTENED AND WIRES HELD SECURELY WIRES MUST BE FULLY INSERTED AND SECURED IN CONNECTOR CONNECTORS MUST BE BOTTOMED IN HEADER HEADERS MUST BE SEATED ON PC BOARD RETENTION LATCH MUST LOCK ONTO HEADER FIGURE 9. VISUAL AID 8 of 8 Tyco Electronics Corporation Rev E