Dynamic Connector D-3000 Series 108 5349 3 3000 21NOV2006 Rev J2 1. 1. Scope : 1.1 1.1 Contents This specification covers the requirements for product performance, test methods and quality assurance provisions of D-3000 Series. Applicable product description are as shown in Fig.1 Fig.1 Description D-3000 D-3000 SERIES Fig.1 2. Applicable Documents : 2. 2.1 AMP 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 Specifications : A. 109-5000 : B. 114-5148 : C. 501-5013 : 2. 2.2 A. 109-5000 : Test Specification, General Requirements for Test Methods B. 114-5148 : Application Specification C. 501-5013 : Qualification Test Report 2.2 Commercial Standards and Specifications : MIL-STD-202 Test Methods for Electronic and MIL-STD-202 Electrical Component Parts 3. 3. Requirements 3.1 3.1 Design and Construction : Product shall be of the design, construction and physical dimensions specified on the applicable product drawing. TelFax (c)Copyright 2000 by AMP Incorporated. All Right Reserved. 1 of 12 Dynamic Connector D-3000 Series 108 5349 3 3000 3.2 A 3.2 Materials : . Contact : () Material : Copper alloy () Final : Nickel plating all over Rec : Gold plating(Contact Area) or Tin-plating(All over) Tab(Header) : Gold plating(Contact Area) and Tin-plating(Tine Area) or Tin-plating(All over) Tab(Wire) : Gold plating(Contact Area) and Tin-plating(All over) () ()() () ()() Housing : (material : G.F.Polyester,Color:Black (ORANGE and natural In Part) (Flammability : UL 94V-0 B. , UL 94V-0 Accessories and Hardware(Retention leg) () Material : Copper alloy () Finish : Tin plating C. 3.3 Ratings : AVoltage Rating : 250V AC/DC(for 3.81 mm pitch Connector) 600V AC/DC(for 5.08 mm pitch Connector) BCurrent Rating : Refer to Fig.2 and 5 for maximum allowable current to be applied. C. Temperature Rating : + 3.3 A. 250V AC/DC3.81mm 600V AC/DC5.08mm B. Fig.2Fig.5 C. 1 5 10 15 20 3.4 #14,#16 15 10.5 8.5 8 8 #18 12.25 9.5 8 7.5 7.25 #20 10 7.5 6.25 6 6 Fig. 3 2 of 12 #22 8.25 6.25 5.25 4.75 4.5 Fig.2 #24 7 5.25 4.5 4 4 #26 6 4.5 3.75 3.5 3.5 #28 5 4 3.25 3 2.75 ( : A) (UnitA 3.4 Performance Requirements and Test Descriptions : The product shall be designed to meet the electrical, mechanical and environmental performance requirements specified in Fig.3. All tests shall be performed in the room temperature, unless otherwise specified. Rev. J2 Dynamic Connector D-3000 Series 108-5349 3 3000 3.5 3.5 Test Requirements and Procedures Summary Para. Test Items Requirements Procedures 3.5.0 AMP 114-5148 3.5.0 Examination of Product Meets requirements of product drawing and AMP Specification 114- 5148 Visual inspection No physical damage 3.5.1 () 3.5.1 Termination Resistance (Low Level) 3.5.2 3.5.2 Dielectric withstanding Voltage 3.5.3 3.5.3 Insulation Resistance 3.5.4 3.5.4 Temperature Rising Electrical Requirements 5 m 10 m 50 mV 50 mA Fig. 4 AMP 109-5311-1 5 m Max. Initial Subject mated contacts assembled in 10 m Max. Final housing to 50 mV Max open circuit at 50 mA Max closed circuit. Fig. 4. AMP Spec. 109-5311-1 1 0.5 mA 3.811.5kv AC AMP 109-5301 5.082.2kv AC MIL-STD-202 301 1 minute. No creeping discharge nor flashover shall occur. Test between adjacent circuits of mated Current leakage :0.5 mA Max. connectors. 3.81 pitch1.5kv AC AMP Spec. 109-5301 5.08 pitch2.2kv AC MIL-STD-202 Method 301 1000 M 500 V DC 100 M AMP 109-5302 MIL-STD-202 302 B 1000 M Min.Initial Impressed voltage 500 V DC. 100 M Min. Final Test between adjacent circuits of mated connectors. AMP Spec. 109-5302 MIL-STD-202 Method 302 Condition B 30 C Fig. 4 AMP 109-5310 30 C Max. under loaded specified current or rating current. Measure temperature rising by energized current. Fig.4 AMP Spec. 109-5310 Fig.3 (CONT) Rev. J2 3 of 12 Dynamic Connector D-3000 Series 108 5349 3 3000 Para. Test Items Requirements Procedures Mechanical Requirements 3.5.5 49 N () : 100 mm/min AMP 109-30 3.5.5 Contact Retention Force 49 N Min. Apply an axial pull-off load to crimped (Crimp Type wire. Operation Speed : 100 mm/min. AMP Spec109-30 3.5.6 mm2 (AWG) 0.08 0.12 0.20 0.30 0.50 0.85 #28 #26 #24 #22 #20 #18 #16 #14 1.25 2.00 3.5.6 Crimp Tensile Strength Wire Size mm2 (AWG) 0.08 0.12 0.20 0.30 0.50 0.85 1.25 2.00 3.5.7 () #28 #26 #24 #22 #20 #18 #16 #14 N 11.76 19.60 29.40 44.10 73.50 117.60 186.2 186.2 100 mm/min AMP 109-5205 A Crimp Tensil (min.) Apply an axial pull-off load to crimped N 11.76 19.60 29.40 44.10 73.50 117.60 186.2 186.2 wire of contact secured on the tester, Operation Speed : 100 mm/min. AMP Spec. 109-5205 Condition A : 490 m/s2 1 s. : () : 11 m s. : X, Y, Z 3 18 AMP 109-5208 A MIL-STD-202,213, A 3.5.7 Physical Shock No electrical discontinuity Accelerated Velocity :490 m/s2 greater than 1 s. Waveform : Sinwave Shall occur. Duration : 11 m s Termination Resistance Number of Drops : 3 drops each to normal (Low Level) and reversed directions of X, Y and Z axes, totally 18 drops. AMP Spec. 109-5208 Condition A MIL-STD-202,Method213,Condition A 4 of 12 Rev. J2 Dynamic Connector D-3000 Series 108-5349 3 3000 Para. 3.5.8 Test Items Requirements Procedures 4.9 N 100 mm/min 1 AMP 109-5206 B 3.5.8 Connector Mating Force 4.9 N Max. Operation Speed : 100 mm/min. Per 1 Contact Measure the force required to mate connectors. AMP Spec. 109-5206 Condition B 3.5.9 0.49 N 100 mm/min 0.29 N AMP B 109-5206 1 3.5.9 Connector Unmating Force 0.49 N min. Operation Speed : 100 mm/min. (High Pressure and Measure the force required to unmate Tin-Plating type). connectors. 0.29 N min. AMP Spec. 109-5206, Condition B (Standard PressureGold plating type). Per 1 Contact 3.5.10 3.5.10 3.5.11 9.8 N 1 9.8 N Max. Measure the force required to insert Per 1 contact contact into housing. 1s. : 10500Hz / 15 min : 98 m/s2 : X,Y,Z : 2 Contact Insertion Force MIL-STD-202,204, A 3.5.11 Vibration Sinusoidal No electrical discontinuity High Frequency greater than 1s. Shall occur. Vibration Frequency : 10500Hz / 15 min. Accelerated Velocity : 98 m/s2 Vibration Direction : X,Y,Z Duration : 2 h each AMP Spec. 109-5202 Condition A MIL-STD-202,Method204,Condition A Fig.3 Fig.3 (CONT) Rev. J2 5 of 12 Dynamic Connector D-3000 Series 108 5349 3 3000 Para. 3.5.12 Test Items Requirements Procedures () 100mm AMP 109-27 100 500 3.5.12 Durability Termination Resistance Repeat Insertionextruction of (Low Level). connector assembly following times at 100mm/minoperation speed 100 times Tin-Plating 500 times Gold-Plating 3.5.13 N 3.5.13 3.5.14 Housing Locking Strength AMP 109-50 D-3100S 98 D-3200S 98 D-3100D 147 D-3200D 147 D-3400 196 D-3500 39.2 Series Strength Measure Housing locking strength. Nmin AMP Spec. 109-50 D-3100S 98 D-3200S 98 D-3100D 147 D-3200D 147 D-3400 196 D-3500 39.2 95 : 235 5 C % : 5 0.5 s. AMP 109-5203 MIL-STD-202 208 3.5.14 Solderability Wet Solder Coverage : Solder Temperature 2355 95 % Min. Immersion Duration : 5 0.5 s. AMP Spec. 109-5203 MIL-STD-202 208 Fig.3 Fig.3 (CONT) 6 of 12 Rev. J2 Dynamic Connector D-3000 Series 108-5349 3 3000 Para. Test Items Requirements Procedures Environmental Requirements 3.5.15 260 5C 10 1 s. AMP 109-5204 B MIL-STD-202 210A B 3.5.15 Resistance to Soldering No physical damege shall Test connector on PCB. Heat occur. Solder Temerature : 260 5C Immersion Duration : 10 1 s. AMP Spec. 109-5204 Condition B MIL-STD-202 Method 210A Condition B 3.5.16 () 55C / 30 min+85C / 30 min. 1 25 AMP 109-5103 A MIL-STD-202 107 A-1 3.5.16 Thermal Shock Termination Resistance Mated/Unmated connector (Low Level) 55C / 30 min.,+85C / 30 min. Making this a cycle, repeat 25 cycles. AMP Spec. 109-5103 Condition A MIL-STD-202 Method 107 Condition A-1 3.5.17 2565C, () 9095 % 10C AMP R. H. 10 109-5106 MIL-STD-202 106 3. 5.17 Humidity-Temperature Insulation resistance Mated connector, 2565C, Cycling Dielectric Strength 9095 % R. H. Termination resistance Cold shock 10C not performed (Low Level) AMP Spec. 109-5106 10 cycles MIL-STD-202 Method 106 Fig.3 Fig.3 (CONT) Rev. J2 7 of 12 Dynamic Connector D-3000 Series 108 5349 3 3000 Para. 3.5.18 Test Items Requirements Procedures 100 M () () 10 m () 90-95 % R. H. 40 C 96 AMP 109-5105 MIL-STD-202 103 B 3.5.18 Humidity, Steady State Insulation resistance 100 M Min.(Final) Termination resistance 10 mMax. (Final) Mated connector, 90-95 % R. H. 40 C 96h AMP Spec. 109-5105 MIL-STD-202 Method 103 3.5.19 () SO2 25C, 3.5.19 Industrial Gas (SO2) Condition B 103 ppm, 90 % R. H. 96 Termination Resistance Mated connector (Low Level) SO2 Gas : 103 ppm, 90 % R. H. 25C, 96h 3.5.20 () 105C250 AMP 109-5104-3 C MIL-STD-202 108 3.5.20 Temperature Life Termination Resistance (Heat Aging) (Low Level) Mated connector 105C, Duration :250h AMP Spec. 109-5104-3 Condition C MIL-STD-202 Method 108 3.5.21 () () 5 % 96 AMP 109-5101 B MIL-STD-202 101 3.5.21 A Salt Spray Termination Resistance Subject mated connectors to 5 % salt (Gold Plating Item only) (Low Level) concentration for 96h : AMP Spec. 109-5101 Condition B MIL-STD-202 Method 101 Condition A Fig. 3 () Fig. 3 (End) 8 of 12 Rev. J2 Dynamic Connector D-3000 Series 3 3000 108-5349 Fig.4 Fig.5 Rev. J2 9 of 12 Dynamic Connector D-3000 Series 108 5349 3 3000 3.6 3.6 Product Qualification Test Sequence /Test Group Test Examination 1 2 3 4 5 6 7 8 9 10 11 12 13 1 1 1 1 1 /Test Sequence (a) () Examination of Product Termination Resistance (Low Level) Dielectric withstanding Voltage Insulation Resistance Temperature Rising 1 1 1 1 1 1 1 1 2,8 2,5 2,6 2,4 2,4 2,4 2,4 2,4 4 3,7 3 Contact Retention Force Crimp Tensile Strength 3 2 Physical Shock Connector Mating Force Connector Unmating Force Contact Insertion Force 2,4 4 3,6 4,7 2 Vibration Durability Housing Locking Strength 3 Solderability 2 Resistance to Soldering Heat Contact Insertion Force Thermal Shock ( Humidity-Temperature Cycling Humidity (Steady State) Industrial SO2 Gas Temperature Life Salt Spray 3 5 2 3 5 3 3 3 3 Fig.6 (a) /Numbers indicate sequence in which the tests are performed. 10 of 12 Rev. J2 Dynamic Connector D-3000 Series 3 3000 108-5349 QUALITY ASSURANCE ROVISIONS: 4.1 4.1 Qualification Testing Sample Selection Connector housings and contacts shall be prepared in accordance with applicable Instruction Sheets. They shall be selected at random from current production. Test Sequence Fig.6 Qualification inspection shall be verified by Testing samples as specified in Figure 6. Test Conditions Unless otherwise specified,all the tests shall be performed in any conbination of the test condition. Temperature Relative humidity Atmospheric Pressure 4.2 Rev. J2 ..hPa 4.2 Requalification Testing If changes sighificantly affecting fromfit,or function are made to the product or to the manufacturing process,product assurance shall coordinate requalification testing,consisting of all or part of the original testing sequence as determined by envelopment product,quality, and reliability engineering. 11 of 12 Dynamic Connector D-3000 Series 3 3000 4.3 Fig.3 4.4 12 of 12 108 5349 4.3 Acceptance: Acceptance is based on verification that the product meets the requirements of Figure.3 Failures attributed to equipment,test get up, or operator deficiencies shall not disqualify the product. When product failure occurs,corrective action shall be taken and samples resubmitted for qualification. Testing to confirm corrective action is required before resubmittal. 4.4 Quality Conformance Inspection: The applicable AMP quality inspection plan will specify the sampling acceptable quality level to be used. Dimensional and functional requirements shall be in accordance with the applicable product drawing and this specification. Rev. J2