Product Specification 108-106094 28 Aug.2012 Rev.A NEXT GENERATION GRACE INERTIA CONNECTOR 3.3 W-B 1 Scope : 1.1 Contents This specification covers the requirements for product performance, test methods and quality assurance provisions of Grace Inertia Connector 3.3mm Pitch connector. 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. 501-106094 Test Report 2.1 Commercial Standards and Specifications : A. MIL-STD-202 Product Specification 3. 108-106094 Requirements : 3.1 Design and Construction : Product shall be of the design, construction and physical dimensions specified on the applicable product drawing. 3.2 Materials : A. Rec Contact (Crimp Type) Tin Copper Alloy (Tin PL 0.8μm min.) B. Plug Housing 6/6 Nylon (Glass Filled) (UL 94 V-0) Tracking Index : LEVEL 2 C. HDR Assy : HDR Hsg : 6/6 Nylon (Glass Filled) UL 94 V-0 Tracking Index : LEVEL 2 Tab Cont : Copper Alloy Tin PL (Tin PL 0.8μm min.) Rev. A 2 of 17 Product Specification 108-106094 3.3 Ratings : A. Voltage Rating : 250V AC/DC B. Current Rating : See Fig. 2 C. Temperature Rating : -30℃ to 105℃ (Include temperature rising by energized current) D. Minimum Rating :1mV, 1μA Minimum E. Applicable P.C.B : Thickness : 1.6 mm Diameter of The hole : For Tine : 0.7+0.1/-0 (Punched Hole) 0.8±0.05 (Drilled Hole) For Boss : 1.4±0.05 (Punched Hole & Drilled Hole) 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. Unit : A Rec. Contact : Contact Wire Size Pos. AWG #20 4 6 8 10 12 Rev. A 4 4 4 3.5 3.5 AWG #22 2.5 2.5 2.5 2.5 2.5 Fig. 2 AWG #24 2.2 2.2 2.2 2.2 2.2 3 of 17 Product Specification 3.5 108-106094 Test Requirements and Procedures Summary : No. Test Items Requirements Procedures No. Test Items Requirements Procedures No. Test Items Requirements Procedures 3.5.1 Examination of Product Meets requirements of product drawing and AMP Specification (114-5372) After test, no corrosion influence performance. Visual inspection No physical damage Electrical Requirements 3.5.2 Termination Resistance (Low Level) 10 mΩ Max. (Initial) 20 mΩ Max. (Final) Subject mated contacts assembled in housing to 20mV Max. open circuit at 10mA. Take the resistance of the wire only away from measurement Fig. 8. AMP Spec. 109-5311-1 3.5.3 Insulation Resistance 1000 MΩ Min. (Initial) 500 MΩ Min. (Final) Impressed voltage 500 V DC. Test between adjacent circuits and between the surface of housing and contact of mated connectors. AMP Spec. 109-5302 MIL-STD-202, Method 302 Condition B Fig. 3 Rev. A (To be Continued) 4 of 17 Product Specification No. Test Items Requirements Procedures No. Test Items Requirements Procedures No. Test Items Requirements Procedures 108-106094 3.5.4 Dielectric withstanding Voltage No creeping discharge nor flashover shall occur. Current leakage : 5 mA Max. 1.5kVAC for 1 minute. Test between adjacent circuits and between the surface of housing and contact of mated connectors. 3.5.5 Temperature Rising 30℃ Max. under loaded specified current. Measure temperature rising by energized current. Subject measurement must do at the place of no influence from convection of air. And contacts assembled in housing all of circuits. The thermocouple attach to the contact of center circuit number. Fig. 2, 8 AMP Spec. 109-5310 Mechanical Requirements 3.5.6 Vibration (Low Frequency) No electrical discontinuity greater than 1 μsec. shall occur. 20 mΩ Max. (Final) Subject mated connectors to 10-55-10 Hz traversed in 1 minute at 1.52mm amplitude 2 hours each of 3 mutually perpendicular planes. 100 mA applied. Fig. 9 AMP Spec. 109-5201 MIL-STD-202, Method 201A Fig. 3 (To be Continued) Rev. A 5 of 17 Product Specification No. Test Items Requirements Procedures No. Test Items Requirements 108-106094 3.5.7 Shock No electrical discontinuity greater than 1μ sec. shall occur. 20 mΩ Max. (Final) Mated Conn. (50 G) Waveform : Halfsign Curve Duration : 11 m sec. Number of Drops : 3 drops each to normal and reversed directions of X, Y and Z axes, totally 18 drops AMP Spec. 109-5208 See Fig. 9 MIL-STD-202, Method 213 Condition A 3.5.8 Connector Mating/Unmating Force Mating Force 5.88×Pos. N Max. (0.6×Pos.)kg Max. Unmating Force (0.58×Pos.)N Min. (1st) (60×Pos.)g Min. (1st) (0.29×Pos.)N Min. (30th) (30×Pos.)g Min. (30th) Procedures No. Test Items Requirements Procedures 3.5.9 Contact Insertion Force 8.82N (0.9 kgf) Max. per contact Measure the force required to insert contact into housing. AMP Spec. 109-5211 Fig. 3 (To be Continued) Rev. A 6 of 17 Product Specification No. Test Items Requirements Procedures No. Test Items Requirements 3.5.10 Contact Retention Force 19.8N(2kgf) Min. Apply an axial pull-off load to crimped wire. Operation Speed : 100 mm / min. AMP Spec. 109-5210 3.5.11 Contact Mate/Unmating Force Mate Unmating Procedures No. Test Items Requirements 5.88N(600g)Max.(1st～30th) 0.34N(35g)Min. (1st) 0.25N(25g)Min. (30th) Measured by gage tab (Fig. 10) and operation speed 100 mm/min AMP Spec. 109-5206 3.5.12 Crimp Tensile Strength Wire Size (AWG) mm2 0.22 24 0.31 22 0.51 20 Procedures Crimp Tensil (min.) N (kgf) 29.4(3) 49(5) 58.8 (6) Apply an axial pull-off load to crimped wire of contact secured on the tester, Operation Speed : 100 mm/min. Subject take insulation barrel away. AMP Spec. 109-5205 Fig. 3 Rev. A 108-106094 (To be Continued) 7 of 17 Product Specification No. Test Items Requirements Procedures No. Test Items Requirements Procedures No. Test Items Requirements Procedures No. Test Items Requirements Procedures 3.5.13 Durability (Repeated Mate/Unmating) 20 mΩMAX. No. of Cycles : 30 cycles 3.5.14 Housing Locking Strength 24.5 N (2.5 kgf) Min. Measure connector locking strength. Operation Speed : 100 mm/min. AMP Spec. 109-5210 3.5.15 Post Retention Force 9.8 N (1.0 kgf) Min. Measure post retention force. Operation Speed : 100 mm/min 3.5.16 Hammering Shocks 20 mΩ Max. (Final) No evidence of abnormalities Mated connectors to under 10000 cycles of repeated hammering shocks Hammering height : 80mm Hammering weight : 50g Hammering speed : 1cycle/sec. DC 10V, 1mA applied Fig.11 Fig. 3 Rev. A 108-106094 (To be Continued) 8 of 17 Product Specification No. Test Items Requirements Procedures No. Test Items Requirements Procedures No. Test Items Requirements Procedures Environmental Requirements 3.5.17 Thermal Shock 20 mΩ Max. (Final) Mated connector -55℃/30 min., 85℃/30 min. Making this a cycle, repeat 25 cycles. AMP Spec. 109-5103 Condition A MIL-STD-202 Method 107-1 Condition A-1 The measurement is held after being left indoor for 3 hours. 3.5.18 Humidity-Temperature Cycling Dielectric withstanding voltage 1.5 kV AC 1 minute. Insulation resistance (final) 500 MΩ Min. Termination resistance 20 mΩ Max. (Final) Mated connector, 25～65℃, 80～98 % R. H. 10 cycles Cold shock －10℃(not ) performed AMP Spec. 109-5106 MIL-STD-202, Method 106 Condition D The measurement is held after being left indoor for 3 hours. 1cycle=24hours 3.5.19 Salt Spray 20 mΩ Max. (Final) No corrosion influence performance Subject mated connectors to 5±1% salt concentration for 48 hours : MIL-STD-202, Method 101 Condition B The measurement is held after remove the salt and dry up at indoor. Fig. 3 Rev. A 108-106094 (To be Continued) 9 of 17 Product Specification No. Test Items Requirements Procedures No. Test Items Requirements Procedures No. Test Items Requirements Procedures No. Test Items Requirements Procedures 3.5.20 Heat Aging 20 mΩ Max. (Final) Mated Conn. 105±2℃ Duration :96 hr AMP Spec. 109-5104-3 Condition A The Measurement is held after being left indoor for 3 hours. 3.5.21 Resistance to Cold 20 mΩ Max. (Final) Mated connector -30℃±2℃, 96 hours AMP Spec. 109-5108-3 Condition D 3.5.22 H2S 20 mΩ Max. (Final) No corrosion influence performance Mated connector 3±1 ppm, 40±2℃ 96 hours 3.5.23 NH3 Gas 20 mΩ Max. (Final) No corrosion influence performance Mated conn. is put into atmosphere that rated 25 ml/l of 3% NH3 for 7hr. Fig. 3 Rev. A 108-106094 (To be Continued) 10 of 17 Product Specification No. Test Items Requirements Procedures 108-106094 3.5.24 Solderability Wet Solder Coverage : 95 % Min. Eutectic solder Solder Temperature : 230±5℃ Immersion Duration : 3±0.5 sec. Lead-Free solder （Sn-Ag-Cu） Solder Temperature : 240±5℃ Immersion Duration : 3±0.5 sec. MIL-STD-202 Method 208 No. Test Items Requirements Procedures 3.5.25 Resistance to Soldering Heat No physical damage shall occur. Test connector on PCB. Solder Temperature : 260±5℃ Immersion Duration : 10±0.5 sec. AMP Spec. 109-5204 MIL-STD-202 Condition B In case of manual soldering iron,apply it as 360±10℃, 3±0.5sec without forcing pressure to affect the tine of contact. Fig. 3 (End) * Product must be without rust, corrosion transformation, crack and discoloration. Rev. A 11 of 17 Product Specification 108-106094 3.6 Product Qualification Test Sequence Test or Examination Confirmation of Product Termination Resistance (Low Level) Dielectric withstanding Voltage Insulation Resistance Temperature Rising Vibration (Low Frequency) Physical Shock Connector Mating Force Connector Unmating Force Contact Insertion Force Contact Mating Force Contact Unmating Force Crimp Tensile strength Durability (Repeated Mating/Unmating) Housing Locking Strength NH3 Humidity-Temperature Cycling H2S Thermal Shock Salt Spray Resistance to Cold Contact Retention Force Heat Asing Post Retention Force Solderability Resistance to Soldering Heat Hammering Shocks 1 2 3 1,3 1,4 1,3 Test Group 4 5 6 Test Sequence (a) 1,3 1,3 1,4 7 8 9 1,7 2,4, 6 1,7 3,6 1,4 2,5 3 2 2 5 3 2 4 2 2 3 2 5 2 3 5 (a) Numbers indicate the sequence in which the tests are performed. Fig. 5(1/2) Rev. A 12 of 17 Product Specification Test or Examination Confirmation of Product Termination Resistance (Low Level) Dielectric withstanding Voltage Insulation Resistance Temperature Rising Vibration (Low Frequency) Physical Shock Connector Mating Force Connector Unmating Force Contact Insertion Force Contact Mating Force Contact Unmating Force Crimp Tensile strength Durability (Repeated Mating/Unmating) Housing Locking Strength NH3 Humidity-Temperature Cycling H2S Thermal Shock Salt Spray Resistance to Cold Contact Retention Force Heat Asing Post Retention Force Solderability Resistance to Soldering Heat Hammering Shocks 10 11 12 1,4 2,5 1,4 2,5 1,4 2,5 108-106094 Test Group 14 15 16 17 Test Sequence (a) 1,4 1,4 1,4 1,3 1,3 2,5 2,5 2,5 13 18 19 1,3 1,3 2,5 7 6 3 3 3 3 3 3 2 2 2 4 (a) Numbers indicate the sequence in which the tests are performed. Fig. 5(2/2) Rev. A 13 of 17 Product Specification 108-106094 4. Quality Assurance Provisions : 4.1 Test Conditions : Unless otherwise specified, all the test shall be performed in any combination of the following test conditions. Temperature : Relative Humidity : Atmospheric Pressure : 15～35℃ 45～75 % 86.6～106.6 Kpa Fig. 6 4.2 Tests : 4.2.1 Test Specimens : The test specimens to be employed for the tests shall be conforming to the requirements specified in the applicable product drawings. The crimped contacts shall be prepared in accordance with the requirements of applicable application Specification, 114-5372, Crimping of Grace Signal Connector 3.3mm Pitch on the wires specified in Fig. 7 of this specification. 4.2.2 Applicable Wires : The wires to be used for crimping the samples for performance testing shall be conforming to the requirements specified in Fig. 7. Calculated Cross-sectional Area(mm2) 0.22 0.31 0.53 AWG Diameter of a Conductor (mm) Number of Conductors Insulation Outer Diameter (mm) 24 22 20 0.16 0.16 0.18 11 17 21 1.4 1.58 1.9 Fig. 7 Rev. A 14 of 17 Product Specification 108-106094 Wire-to-Boad Termination Type : Power Source Plug housing 75mm Termination Resistance (Low Level) Header Assy Thermocouple Attached here * Take the resistance of 75 mm wire only away Fig. 8 Termination Resistance (Low Level) and Temperature Rising Vs. Current Measuring Methods TE Fig. 9 Connector Mounting Methods of Low Frequency Vibration and Physical Shock Tests Rev. A 15 of 17 Product Specification 108-106094 0.7±0.002 Fig. 10 Gage Design for Contact Meting/Unmating Force Tests Fig. 1 Rev. A 16 of 17 Product Specification Part Number 1971904 -□ □- 1971905 -□ □-1971906 -□ 1983780 -1 108-106094 Remarks TPA Plug housing Header Assembly Rec contact Appendix 1 Rev. A 17 of 17