2154018-6 - TE Connectivity AMP Connectors

TE logo and Tyco Electronics are trademarks.

*Trademark. Other products, logos, and company names might be trademarks of their respective owners.

Application Specification

TOOLING ASSISTANCE CENTER 1-800-722-1111

PRODUCT INFORMATION 1-800-522-6752 This controlled document is subject to change.

For latest revision and Regional Customer Service,

visit our website at www.tycoelectronics.com

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LOC B

NEVALO* Interconnect System 114-13290

21 DEC 10 Rev A

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 ±0.20 and angles have a tolerance of ±2°. Figures and illustrations

are for identification only and are not drawn to scale.

1. INTRODUCTION

The NEVALO Interconnect System is designed to be a complete LED lighting interconnect solution. The

NEVALO surface mount clip mates to the Feed-Thru, Straight, and Right-Angle connector s which make a card

edge connection to the printed circui t (pc) board pads. These connectors are insulation displacement contact

(IDC) terminated to the NEVALO ribbon cable and a terminator connector is placed on the free end to create a

series circuit between all connectors and the driver.

When correspondin g with Tyco Electronics Personnel, use th e terminolo gy provided on this sp ecification to help

facilitate your inquiry for information. Basic terms and features of receptacles are provided in Figure 1.

Figure 1

NOTE

Feed-Thru Connector Straight Connector

Terminator

Right-Angle Connector

SMT Clip

Keying Features to

Prevent Over/Under

Powering of Light

Modules

Stripes for Proper

Orientation of

Ribbon Cable

Typical NEVALO IDC Contact

NOT the LATEST

REVISION

OBSOLETE

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2. REFERENCE MATERIAL

2.1. Revision Summary

•Initial release of document

2.2. Customer Assistance

Reference Part Number 2154234 and Product Code L895 are representative numbers of the NEVALO

Interconnect System. Use of these numbers will identify the product line and expedite your inquiries through a

service network est ablished to help you obt ain product informa tion. Such information can be obt ained 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 each connector 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 tech nical document ation

supplied by Tyco Electronics.

2.4. Specifications

Design Objective 108-2442 provides expected product performance and test information.

2.5. Instructional Material

Instruction Sh eet 408-10413 prov ides information for the NEVALO Interconnect System Hand Crimping Tool Kit

2161090-1.

3. REQUIREMENTS

3.1. Safety

Do not sta ck product shipping containers so high that the containers buckle or deform.

3.2. Storage

A. Ultraviolet Light

Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the receptacle

connector material.

B. Shelf Life

The connectors should remain in the shipping containers until ready for use to prevent deformation to the

connectors. The connectors should be used on a first in, first out basis to avoid storage contamination.

C. Chemical Exposure

Do not store connectors near any chemicals listed below as they may cause stress corrosion cracking in the

contacts.

Alkalies Ammonia Citrates Phosphates Citrates Sulfur Compounds

Amines Carbonates Nitrites Sulfur Nitrites Tartrates

3.3. Materials

The NEVALO housings are made from glass-filled PBT, while the IDC cont acts are ma de from copper alloy with

tin plate over nickel.

3.4. Limitations

The operating temperature range for the NEVALO Interconnect System is -20° to 105°C [-4° to 221°F].

3.5. Special Characteristics

NEVALO Interconnects are availab le in four colors. Housings have a molded keying feature th at corresponds to

keying features on the mating part (clip, driver, etc.) to prevent over/under powering of light modules. See

Figure 1.

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3.6. Cable Preparation

The IDC contacts in the NEVALO Interconnects are designed to accept NEVALO ribbon cable stranded tinned

copper conductors. An initial cut needs to be made using a guillotine-type cutting tool. See Figure 2. Contact

your Ty co Elec tr on ics Re pr es en tative for cur re nt t ool recommendations for cutting and notchin g of cables.

A notching procedure is required when a NEVALO Feed-Thru connector is used. Use cable notching tool 2119990-1 to

ensure proper notch size and length. Contact the Product Information Center number at the bottom of page 1 for specific

information on this process or refer to hand tool instruction sheet.

Care must be taken when aligning cable prior to termination to maintain parallelism between the end of the cable an d the

inner wall of the connector.

Figure 2

Feed-Thru connectors should not be placed closer than 25 mm [1 in.] apart (centerline-to-centerline) due to tooling

constraints. Printed Circuit Board width may effect minimum spacing.

3.7. Product Selection

All NEVALO Interconnects should b e us ed with cor respond ing color ed ri bbon ca ble, l i ght modu les, an d drivers.

Right/left, up/down orientation corresponds to connector orientation relative to NEVALO ribbon cable stripe.

Figure 3 shows proper connector orientation.

Figure 3

NOTE

CAUTION

NOTE: Use notching tool 2119990-1 to sever two

conductors. Notch striped side of ribbon cable for Feed-Thru

Left (FTL) and non-striped side for Feed-Thru Right (FTR).

Cable preparation for feed-thru connector

FTL FTR

-A-

0.25 A

Cable preparation for

straight, right-angle, and

terminator connectors

NOTE

NEVALO Driver

Straight Left (STL)

Feed-Thru Left (FTL)

Feed-Thru Right (FTR)

Straight Right (STR)

Right-Angle Down (RAD)

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3.8. PC Board

A. Material and Thickness

The pc board material shall be metal clad. There is no required thickness for the pc board.

B. Tolerance

Maximum allowable bow of the pc board shall be 0.05 mm over the length of the connector.

C. Pads

The pc board circuit pads must be solderable in accordance with Test Specification 109-11.

D. Layout

The pc board layout must be designed using the dimensions provided on the customer d rawing for the

specific connector. Reference sample of the recommended pc board layout is shown in Figure 4.

Figure 4

3.9. Soldering

Observe guidelines and procedures when soldering contact s. Solder, clean, and dry all leads to contacts

according to the following. The connectors should be soldered using vapor phase reflow (VPR), double-sided,

non-focused infrared (IR), forced air convection, or equivalent soldering techniques. All solder joints should

conform to the Workmanship Specification 101-21 and IPC-S-815.

A. Flux Selection

Contacts 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 an d other componen t s mounte d on the board. Additionally, the flux must be

compatible with the wave solder line, manufacturing, health, and safety requirements. Flux that is compati-

ble with the connectors is provided in Fig ure 5.

±0.08

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Figure 5

No flux allowable on any of the four inner pads.

B. Connectors with SMT Contacts

1. Solderability

The pc board pads must be solderable in accordance with Test Specification 109-11 (Test Method A,

non-activated rosin flux) and all other requirements for surface mount contacts specified in this document.

2. Solder Paste Characteristics

1. Alloy type shall be SAC 305; Sn 96.5/Ag 3.0/Cu 0.5.

2.Flux incorporated in the paste shall be rosin, mildly active (RMA) type.

3.Paste will be at least 80% solids by volume.

4.Mesh designation -200 to +325 (74 to 44 square micron openings, respectively).

5.Minimum viscosity of screen print shall be 5y10% cp (centipoise) .

6.Minimum viscosity of stencil print shall be 7.5y10% cp (centipoise).

3. Solder Volume

Solder volume may vary depending on solder paste composition.

Solder volume is required to be 4.27 mm3 per solder foot (calculated per 50% solid content).

4. Screen (or Stencil)

The stencil aperture shall be determined by the circuit pad size and thickness. It may be any shape as long

as it prevents solder bridg ing and maintains the given volume of solder paste.

C. Process

Connectors with surface mount contacts should be soldered using vapor phase (VPR), double-sided, non-

focused infrared reflow (I R) or equivalent soldering techniques. Due to many variables involved with the

reflow process (i.e., component density, orientation, etc.), it is recommended that trial runs be conducted

under actual manufacturing conditions to ensure product and process compatibility. These connectors will

withstand the temperature and exposure time specified in Figure 6.

Figure 6

The lead-free reflow profile is shown in Figure 7.

‡Alpha and Kester are trademarks.

FLUX TYPE ACTIVITY RESIDUE COMMERCIAL DESIGNATION

KESTER‡ ALPHA‡

Type RMA (Mildly Activated) Mild Noncorrosive 185/197 611

SOLDERING PROCESS TEMPERATURE (Max) TIME (At Max Temperature)

IR 220°C [428°F] 3 Minutes

CAUTION

NOTE

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Figure 7

3.10. Connector Placement

A. Position

Optimally, the clip solder feet should be centered on the pads; however, slight misalignment is permissible.

Refer to Figure 8.

Figure 8

B. Seating Force

It is imperative that the clip solder feet are sufficiently pressed into the solder paste.

Kester Lead-Free Reflow Profile

Alloys:Sn96.5/Ag3.0/Cu0.5 and Sn96.5/Ag3.5

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Rev A

3.11. Terminated Connector Requirements

Prepared cable shall be terminated according to the procedures given in the applicable tooling instructions. See

Section 5, TOOLING, for details on tooling options and instructional materials. Figure 9 shows criteria for

acceptable terminations.

Tyco Electronics specified tooling must be used to ensure proper termination.

Figure 9

3.12. Repair/Replacement

NEVALO Interconnects are not repairable. If a connector becomes damaged, it must be cut from the ribbon

cable and replaced with a new one.

Pre-terminated cable cannot be used with a new connector. If ribbon cable insulation has been pierced, the cable must

be replaced as well.

4. QUALIFICATIONS

The NEVALO Interconnect System has not yet been sent for agency evaluation and testing.

5. TOOLING

This section provides a selection of tools for various application requirements. Modified designs and additional

tooling concepts may be available to mee t other application requirements. For additional information, contact

one of the servic e gr ou ps at the bott om of page 1.

There are m an ua lly op er at ed an d pn eu m at ica lly ope ra t ed (auto-cycle and foot pedal actuated) arbor frame

assemblies designed for bench mounted operation. They accept standardized upper/lower tooling assemblies

that have been desig ned for the NEVALO Interconnect System. Hand crimping tools are designed for prototype

and low-volume applications. Instruction sheets covering tool setup and operation are packaged with the

tooling. See Figure 10

Figure 10

Tooling not required to unmate connectors from clip.

CONNECTOR TYPE DIE SET HAND TOOL FRAME HAND TOOL KIT (DOCUMENT)

Feed-Thru

Straight

Terminator Multi-Nest

2161080-1 PRO-CRIMPER* III

2119991-1 2161090-1

(408-10413)

Right-Angle Right-Angle

2161085-1

CAUTION

4.90

15.20

Straight Connector

Terminator

Feed-Thru Connector

Right-Angle Connector

CAUTION

NOTE

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Rev A

6. VISUAL AID

Figure 11 shows a typical application of the NEVALO Interconnect System. This illustration should be used by

production personnel to ensure a correctly applied product. Applications which DO NOT appear correct should

be inspected using the information in the preceding pages of this specif ica tio n an d in the instructional material

shipped with the product or tooling.

FIGURE 11. VISUAL AID (CONT’D)

RIBBON STRIPE AND

CONNECTOR STRIPES

SHOULD ALL BE IN

ALIGNMENT

ALL LATCHES SHOULD

BE FULLY CLOSE D

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FIGURE 11. VISUAL AID (CONT’D)

ALL LATCHES SHOULD

BE FULLY CLOSED

NOT FULLY CLOSED FULLY CLOSED

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Rev A

FIGURE 11. VISUAL AID (END)

Care must be taken when mating or

unmating connectors to/from clip.

CAUTION

CLIP LATCH MUST BE

FULLY CLOSED PAST

HOUSING BUMP