040III HIGH DENSITY CONNECTOR 72POS/86POS/94POS/108POS/122POS/125POS Product Specification 108-5673 27JUN06 Rev C2 1. Scope: 1.1 Contents This specification covers the requirements for product performance, test methods and quality assurance provisions of 040 HIGH DENSITY CONNECTOR 72pos/86Pos/94Pos/108Pos/122Pos/125Pos for Wire-to-Board 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 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 Test Specification, General Requirements for Test Methods B. 114-5217 : Crimping 040 Series Receptacle Contact C. 501-5487 : Qualification Test Report 2.2 Commercial Standards and Specifications. A. JASO D605 : Multi-pole Connector for Automobiles C. JIS C3406 : Low Voltage Wires and Cables for Automobiles E. JIS D0204 : Method of High and Low Temperature Test for Automobile Parts B. JASO D7101 D. JIS D0203 : Test Methods for Plastic Molded Parts : Method of Moisture, Rain and Spray Test for Automobile Parts F. JIS D1601 : Vibration Testing Method for Automobile Parts H. MIL-STD-202 : Testing Method 208 : Method of Soldering G. JIS R5210 : Portland Cement 213-8535 3-5-8 1 of Tyco Electronics AMP K.K. (3-5-8 Hisamoto Takatsu-ku Kawasaki, 213-8535) This document is subject to change. Call local AMP for the latest revision. (c) Copyright 2002 by Tyco Electronics AMP K.K. All rights reserved. * : Trademark 10 040III HIGH DENSITY CONNECTOR 72POS/86POS/94POS/108POS/122POS/122POS/125POS 108-5673 3. Requirements: 3.1 Design and Construction: Product shall be of the design, construction and physical dimensions specified on the applicable product drawing. 3.2 Material : A. Contact : a. Receptacle Contact : Pre-tinned Phosphor bronze b. Tab Contact B. HousingPBT resin : Pre-tinned Copper alloy 3.3 Ratings: A. Temperature Rating-30 to 105 3.4 Performance Requirements and Test Descriptions: The product shall be designed to meet the electrical, mechanical and environmental performance requirements specified in Fig.2. All tests shall be performed in the room temperature, unless otherwise specified. Rev. C2 2 of 10 040III HIGH DENSITY CONNECTOR 72POS/86POS/94POS/108POS/122POS/122POS/125POS 108-5673 3.5 Test Requirements and Procedures Summary: Para. 3.5.1 Test Items Requirements Procedures Product shall be conforming to the Visually, dimensionally and functionally Confirmation of requirements of applicable product inspected per applicable quality inspection drawing and Application plan. Product Specification.No.114-5217 Electrical Requirements 3.5.2 Termination Resistance Low Level 10mMax.Initial 20mMax.Final 3.5.3 Termination Resistance Specified Current 10mMax.Initial 20mMax.Final 3.5.5 Insulation Resistance 3.5.4 Dielectric Strength 3.5.6 Temperature Rising 3.5.7 Current Leakage 3.5.8 Handling Ergonomics 3.5.9 Contact Mating Force Measure initial mill volt drop of contact test circuit in mated connectors. Fig.3 AMP Spec.109-5311-2 Impressed voltage 500V DC. Test between adjacent circuits of mated connectors. Fig.4 AMP Spec. 109-5302 100MMin. No creeping discharge nor flashover shall occur. Represent inter relative characters between temperature rising of energized contact crimp vs. current intensity in graph. No abnormal temperature rising shall take place. 1mA Max Subject mated contacts assembled in housing to closed circuit current of 10mA Max. at open circuit voltage of 20mV Max. Fig.3 AMP Spec.109-5311-1 1kVAC for 1 minute. Test between adjacent circuits of mated connectors. Fig.4 AMP Spec. 109-5301 Measure temperature rising by engaged current.(Measure until the temperature rising reaches 80) AMP Spec. 109-5310 12V DC impressed 1min. AMP Spec. 109-5312 Fig.5 Physical Requirements No abnormalities allowed in Manually operated Manualmating/unmating handling. Operation Speed : 100mm/min. 4.9N Max Measure the force required to mate contacts. AMP Spec.109-5206 Contact 3.5.10 0.98N Min. Unmating Force Operation Speed : 100mm/min. Measure the force required to unmate contacts. AMP Spec.109-5206 Fig.1 (To be continued) Rev. C2 3 of 10 040III HIGH DENSITY CONNECTOR 72POS/86POS/94POS/108POS/122POS/122POS/125POS Para. Test Items Requirements 3.5.11 Insertion Force 29.4N Max. of Housing Unit 3.5.12 Housing Locking 98N Min. Strength 3.5.13 Connector Mating Force 3.5.14 3.5.15 Contact Insertion Force 3.5.16 Contact Retention Force 39.2N Min. (Pre-Lock) 3.5.17 Connector 58.8N Min. Retention Force 3.5.18 3.5.19 3.5.20 Reverse Insertion of Housing Reverse Insertion of Terminal Measure housing locking strength. Operation Speed:100mm/min. AMP Spec. 109-5210 Operation Speed : 100mm/min. Measure the force required to mate connectors. AMP Spec.109-5206 Operation Speed:100mm/min. Measure the force required to unmate connectors. AMP Spec. 109-5206 Measure the force required to insert contacts into housing. AMP Spec. 109-5211 Apply an axial pull-off load to crimped wire. Operation Speed: 100mm/min. AMP Spec. 109-5212 Operation Speed:100mm/min. Measure the force required to pull off the housing from the connector or to break the locking. Attempt to mate in the direction other than Shall not be inserted the other normal mating . way. attempt to load the contact in the direction Shall not be inserted the other other than normal way. way. mm2 (AWG) 0.5 20 0.3 0.85 1.25 Measure releasing force of lock. Max. Wire size 3.5.21 Operation Speed : 100mm/min. Measure the force required to mate Housing Unit. AMP Spec.109-5206 9.8N Max. par contact. Releasing Force 49.0N of Lock Crimp Tensile Strength Procedures 17Pos.147N Max. 22Pos.147N Max. 24Pos.147N Max. 31Pos.147N Max. 17Pos.147N Max. Connector 22Pos.147N Max. Unmating Force 24Pos.147N Max. 31Pos.147N Max. 108-5673 Crimp tensile(Min) N 22 58 18 127 16 88 Apply an axial pull-off load to crimped wire of contact secured on the tester. Operation Speed:100mm/min. AMP Spec. 109-5205 177 Fig.1 (To be continued) Rev. C2 4 of 10 040III HIGH DENSITY CONNECTOR 72POS/86POS/94POS/108POS/122POS/122POS/125POS Para. 3.5.22 3.5.23 3.5.24 Test Items Contact Retention Force 78N Min. (Secondary-Lock) Requirements Fitting Force of 59N Max. Double Lock Plate Solderability 108-5673 Procedures Apply an axial pull-off load to crimped wire. Operation Speed: 100mm/min. Operation Speed:100mm/min. Measure the fitting force of double lock plate. Wet Solder Coverage: 95%Min. Solder Temperature :2305 Immersion Duration :30.5seconds Flux: Alpha 100 AMP Spec. 109-5203 Environmental Requirement 3.5.25 3.5.26 3.5.27 3.5.28 3.5.29 3.5.30 Low level: Temperature 20mMax.Final Life Contact Retention Force: Heat Aging 0.98N Min. Resistance to Cold Thermal Shock Humidity, Steady State Low level: 20mMax.Final Low level: 20mMax.Final Satisfied 3.5.21 Crimp Tensile Strength Low level: 20mMax.Final Insulation resistance: 100MMin.Final 1kVAC forminuteNo creeping discharge nor flashover shall occur. Contact Retention Force: 0.98N Min. Connector Retention Force 58.8N Min. Current Leakage1mA Max. Low level: 20mMax.Final Current Cycling No ignition is allowed during the test. Temperature rise in the terminal press point area shall be 20Max. Durability Specified Current (Repeated 20mMax.Final Mate/Unmating) 120,Duration:120hours AMP Spec. 109-5104 -402, 120hours AMP Spec. 109-5108 -30/120min.,80/120min. Making this a cycle, repeat 5cycles. AMP Spec. 109-5103 Mated connector, 9095R.H.,60 96hours AMP Spec. 109-5105 45minutes"ON",15minutes"OFF", 1000cycles. Current intensity shall cause temperature rising up to 40. AMP Spec.109-5308 Operation Speed: 100mm/min. No. of Cycles:20 Cycles. AMP Spec.109-5213 Fig.1 (To be continued) Rev. C2 5 of 10 040III HIGH DENSITY CONNECTOR 72POS/86POS/94POS/108POS/122POS/122POS/125POS Para. Test Items 3.5.31 Resistance to "Kojiri" Specified Current 20mMax.Final Vibration (High Frequency) Vibration Frequency: 20400Hz/6min. No electrical discontinuity greater Accelerated Velocity: 44.1m/s2 than 1sec. shall occur. Vibration DirectionUp and Down, Back and Force, Right and Left Specified Current DirectionsEach 3hours 20mMax.Final Open circuit voltage13V Closed circuit current10.1A 3.5.32 3.5.33 Resistance Oil Requirements 108-5673 Specified Current 20mMax.Final 3.5.34 Dust Bombardment Specified Current 20mMax.Final 3.5.35 Industrial Gas SO2 Low level: 20mMax.Final 3.5.36 Resistance to Ammonia Satisfied 3.5.21 Crimp Tensile Strength Procedures Secure one of the connectors on the table, and with the half mated condition, apply the bending force of 98N in front-rear and right-left directions two times. Making this a cycle, repeat 10 cycles. Immerse the connector in the engine-oil mixture of SAE 10W or equivalent and kerosene conforming to JIS K 2203(Kerosene)K No.2 in equal quantity kept at 50 for 20 hours. Subject JIS R 5210 cement blow of 1.5Kg per 10 seconds in 15 minutes intervals for 8 cycles, which Unmate/Re-mating per 2 cycles. AMP Spec. 109-5110 SO2 Gas10ppm, 90~95R.H. 40, 24hours AMP Spec. 109-5107 The ammoniacal water solution 100ml(concentration:1%) in the sealed glass container(20~25l),which pedestal the samples leave 96hours. Fig.1 End Rev. C2 6 of 10 040III HIGH DENSITY CONNECTOR 72POS/86POS/94POS/108POS/122POS/122POS/125POS 108-5673 3.6 Product Qualification Test Sequence Test Group Para. Test Items 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 3.5.1 Confirmation of Product 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Termination Resistance Specified Current 3 Dielectric Strength 5 3.5.2 3.5.3 3.5.4 3.5.5 Termination Resistance Low Level 2 Insulation Resistance 4 3.5.6 Temperature Rising 3.5.8 Handling Ergonomics 3.5.7 3.5.9 3.5.10 3.5.11 3.5.12 Current Leakage Contact Mating Force Contact Unmating Force 2,4 3.5.17 3.5.18 7 12 6 2 3.5.19 3 2 Connector Unmating Force 3.5.22 Contact Retention Force(Secondary Lock) 2 3 Connector Retention Force 3.5.21 Crimp Tensile Strength 3 2 Contact Retention Force(Pre-Lock) 3.5.20 Releasing Force of Lock 2 2 Housing Locking Strength Reverse Insertion of Terminal 4,68 2,4 2,4 6 5 3 Insertion Force of Housing Unit Reverse Insertion of Housing 6 11 3.5.15 Contact Insertion Force 3.5.16 2,4 2,4, 7,9 10 3.5.13 Connector Mating Force 3.5.14 Test Sequence (a) 13 3 4 5 2 4 5 3 Fig.2To be continued Rev. C2 7 of 10 040III HIGH DENSITY CONNECTOR 72POS/86POS/94POS/108POS/122POS/122POS/125POS Para. Test Items 3.5.23 Double Lock Plate Locking Strength 3.5.24 3.5.25 3.5.26 3.5.27 3.5.28 3.5.29 3.5.30 3.5.31 3.5.32 3.5.33 3.5.34 3.5.35 1 2 3 4 5 6 2 7 Test Group 8 9 10 11 Test Sequence (a) 2 Solderability Temperature Life Heat Aging Resistance to Cold Humidity, Steady State 3 Current Cycling Durability(Repeated Mate/Unmating) 13 14 15 16 3 3 Thermal Shock 12 108-5673 6 8 5 3 Resistance to "Kojiri" 5 Vibration (High Frequency) 7 Resistance to Oil Dust Bombardment 3 5 Industrial Gas (SO2) 3.5.36 Resistance to Ammonia 2 (a) Numbers indicate sequence in which tests are performed. Fig.2End Rev. C2 8 of 10 040III HIGH DENSITY CONNECTOR 72POS/86POS/94POS/108POS/122POS/122POS/125POS Y 1mm Max. 108-5673 L Soldering PCB Y' X Deduct resistance of Y-Y'(wire"L")from X-Y' Fig.3 Measuring Apparatus Wrap metallic-foil to cover the connector surface Contacts-Housing Adjacent Contacts Fig.4 Rev. C2 9 of 10 040III HIGH DEHSITY CONNECTOR 72POS/86POS/94POS/108POS/122POS/125POS 108-5673 Fig.5 The applicable product descriptions and part numbers are as shown in Appendix 1. Appendix Prod.P/N 353027- 17 Position Plug-housing Assembly 353029- 24 Position Plug-housing Assembly 353028- 353826- 1318682- 353015-3 22 Position Plug-housing Assembly 31 Position Plug-housing Assembly 31 Position Plug-housing Assembly 122 Position Cap-housing Assembly 1318612-1 125 Position Cap-housing Assembly 1318614-1 86 Position Cap-housing Assembly 1318613-1 B Type C Type 108 Position Cap-housing Assembly 1123038-2 72 Position Cap-housing Assembly 316836-1 040 "S" Receptacle Contact Tin-plate 1123042-3 1123653-1 316838-1 1473181-1 Rev. C2 Description 72 Position Cap-housing Assembly without several contacts 040"MS" Receptacle Contact Tin-plate 040"M" Receptacle Contact Tin-plate 94 Position Cap-housing Assembly B Type 10 of 10