108-151014 TE-Connectivity-Ltd

Document overview

  • Manufacturer or author: Provided By digicamel.com
  • PDF pages: 12

Technical content

1 of 12 © 2018 TE Connectivity family of companies All Rights Reserved | Indicates Change *Trademark. TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be tra demarks of their respective owners. Product Specification This controlled document is subject to change. For latest revision and Regional Customer Service, visit our website at www.te.com PRODUCT INFORMATION 1-800-522-6752 108-151014 12Sep2018 Rev B1 HD30 Series Connector System 1. SCOPE 1.1. Content This specification covers performance, tests and quality requirements for the TE Connectivity (TE) HD30 Series Connector System. 1.2. Qualification When tests are performed on the subject product line, procedures specified in Figure 2 shall be used. All inspections shall be performed using the applicable inspection plan and product drawing. 1.3. Qualification Test Results Successful qualification testing on the subject product line was completed. The Qualification Test Report number for this testing is 501-151036_DTR-HD30. This document is on file at and available from Product Engineering, Industrial Commercial Transportation (ICT). 2. APPLICABLE DOCUMENTS AND FORMS The following documents and forms constitute a part of this specification to the extent specified herein. Unless otherwise indicated, the latest edition of the document applies. 2.1. TE Connectivity (TE) Documents

  • 0425-013-1800: Arrangement of Contact Locations for size 18 HD30
  • 0425-014-2400: Arrangement of Contact Locations for size 24 HD30
  • 0425-016-0000: HD30 Series Performance and Application Characteristics
  • 109-1: General Requirements for Testing
  • 114-151000: Application Specification for DEUTSCH Size 16 S&F Pin & Socket
  • 408-151007: Instruction Guide DEUTSCH Extraction Tools
  • 501-151036: HD30 Qualification Test Report
  • Product Drawings HD34-18-XXP/SX – Size 18 Receptacles HD34-24-XXP/SX – Size 24 Receptacles HD36-18-XXP/SX – Size 18 Plugs HD36-24-XXP/SX – Size 24 Plugs
  • Product Part Numbers X refers to N, T, E seal type. XXXX refers to special modification. HD34-18-6PX-XXXX 6 pin Receptacle HD36-18-6PX-XXXX 6 pin Plug HD34-18-6SX-XXXX 6 socket Receptacle HD36-18-6SX-XXXX 6 socket Plug HD34-18-8PX-XXXX 8 pin Receptacle HD36-18-8PX-XXXX 8 pin Plug HD34-18-8SX-XXXX 8 socket Receptacle HD36-18-8SX-XXXX 8 socket Plug HD34-18-14PX-XXXX 14 pin Receptacle HD36-18-14PX-XXXX 14 pin Plug HD34-18-14SX-XXXX 14 socket Receptacle HD36-18-14SX-XXXX 14 socket Plug HD34-18-20PX-XXXX 20 pin Receptacle HD36-18-20PX-XXXX 20 pin Plug HD34-18-20SX-XXXX 20 socket Receptacle HD36-18-20SX-XXXX 20 socket Plug HD34-18-21PX-XXXX 21 pin Receptacle HD36-18-21PX-XXXX 21 pin Plug HD34-18-21SX-XXXX 21 socket Receptacle HD36-18-21SX-XXXX 21 socket Plug HD34-24-7PX-XXXX 7 pin Receptacle HD36-24-7PX-XXXX 7 pin Plug HD34-24-7SX-XXXX 7 socket Receptacle HD36-24-7SX-XXXX 7 socket Plug HD34-24-9PX-XXXX 9 pin Receptacle HD36-24-9PX-XXXX 9 pin Plug HD34-24-9SX-XXXX 9 socket Receptacle HD36-24-9SX-XXXX 9 socket Plug HD34-24-14PX-XXXX 14 pin Receptacle HD36-24-14PX-XXXX 14 pin Plug HD34-24-14SX-XXXX 14 socket Receptacle HD36-24-14SX-XXXX 14 socket Plug HD34-24-16PX-XXXX 16 pin Receptacle HD36-24-16PX-XXXX 16 pin Plug HD34-24-16SX-XXXX 16 socket Receptacle HD36-24-16SX-XXXX 16 socket Plug HD34-24-18PX-XXXX 18 pin Receptacle HD36-24-18PX-XXXX 18 pin Plug HD34-24-18SX-XXXX 18 socket Receptacle HD36-24-18SX-XXXX 18 socket Plug HD34-24-19PX-XXXX 19 pin Receptacle HD36-24-19PX-XXXX 19 pin Plug HD34-24-19SX-XXXX 19 socket Receptacle HD36-24-19SX-XXXX 19 socket Plug HD34-24-21PX-XXXX 21 pin Receptacle HD36-24-21PX-XXXX 21 pin Plug HD34-24-21SX-XXXX 21 socket Receptacle HD36-24-21SX-XXXX 21 socket Plug HD34-24-23PX-XXXX 23 pin Receptacle HD36-24-23PX-XXXX 23 pin Plug HD34-24-23SX-XXXX 23 socket Receptacle HD36-24-23SX-XXXX 23 socket Plug HD34-24-29PX-XXXX 29 pin Receptacle HD36-24-29PX-XXXX 29 pin Plug HD34-24-29SX-XXXX 29 socket Receptacle HD36-24-29SX-XXXX 29 socket Plug HD34-24-31PX-XXXX 31 pin Receptacle HD36-24-31PX-XXXX 31 pin Plug HD34-24-31SX-XXXX 31 socket Receptacle HD36-24-31SX-XXXX 31 socket Plug HD34-24-33PX-XXXX 33 pin Receptacle HD36-24-33PX-XXXX 33 pin Plug HD34-24-33SX-XXXX 33 socket Receptacle HD36-24-33SX-XXXX 33 socket Plug HD34-24-35PX-XXXX 35 pin Receptacle HD36-24-35PX-XXXX 35 pin Plug HD34-24-35SX-XXXX 35 socket Receptacle HD36-24-35SX-XXXX 35 socket Plug HD34-24-47PX-XXXX 47 pin Receptacle HD36-24-47PX-XXXX 47 pin Plug HD34-24-47SX-XXXX 47 socket Receptacle HD36-24-47SX-XXXX 47 socket Plug HD34-24-91PX-XXXX 9 pin Receptacle HD36-24-91PX-XXXX 9 pin Plug HD34-24-91SX-XXXX 9 socket Receptacle HD36-24-91SX-XXXX 9 socket Plug

2.2. Industry Documents

  • DIN 40050-9: Road Vehicles Degrees of Protection (IP Code)
  • DIN 72551-6: Road Vehicles—Low-Tension Cables—Part 6: Single-Core, Unscreened with Thin Insulation Wall; Dimensions, Materials, Marking
  • EIA-364: Electrical Connector/Socket Test Procedures Including Environmental Classifications
  • IEC-60512: Electronic Equipment - Tests and Measurements
  • IEC-60529: Degrees of Protection Provided by Enclosures (IP Code)
  • ISO 6722: Road Vehicles—60 V and 600 V Single-Core Cables—Dimensions, Test Methods and Requirements
  • SAE J1128: Low Voltage Primary Cable 3. REQUIREMENTS 3.1. Design and Construction Product shall be of the design, construction, materials and physical dimensions specified on the applicable product drawing. 3.2. Ratings
  • Voltage: 250 V AC/DC, except 24-29, 24-31, 24-47 arrangements are 200 V AC/DC
  • Current (Amp): See Figure 1 Contact Size Wire Size AWG [mm²] All Circuits Energized (A) 4 [25.0-21.0] 100 6 [16.0-13.0] 8 [10.0-8.0] 60 10 [6.0-5.0] 40 10 [6.0-5.0] 12 [4.0-2.5] 14 [2.0] 18 12 [2.5] 13 14 [2.0] 16 [1.5-1.0] 18 [0.8-0.75] 10 20 [0.5] 7.5 16 [1.5-1.0] 7.5 18 [0.8-0.75] 20 [0.5] 22 [0.35] 5 Figure 1
  • Temperature: -55°C to +125°C
  • Ingress Protection (IP) Level: IP67
  • Flammability: Not Applicable

3.3. Test Requirements and Procedures Summary Unless otherwise specified, all tests shall be performed at ambient environmental conditions. See Appendix A for additional test requirements See Appendix B for Test Procedure Comparison Chart Test Description Requirement Procedure Examination of Product The connectors shall be correctly constructed, marked and shall show good quality and workmanship EIA-364-18. Visually inspected for use of materials, proper construction, correct part number and insert markings and over-all quality of workmanship. Poor molding fabrication, loose materials, damaged or improperly manufactured contacts, galling of metal parts, nicks and burrs of metal parts, torn seals or cracked plastic were considered adequate basis for rejection. ELECTRICAL Insulation Resistance 1000 MΩ minimum at 25°C MIL-STD-1344, Method 3003.1 Using a 500 VDC megaohmmeter check each contact to all other contacts and the shell electrically connected together. Dielectric Withstanding Voltage No evidence of breakdown or flashover or current leakage in excess of 2.0 milliamps. MIL-STD-1344, Method 3001.1 Check each contact to all other contacts and the shell electrically connected together for breakdown / flashover when subjected to a 1500 VAC test potential for a period of 1 minute. Contact Resistance Maximum voltage drop across a 6 inch wire/contact assembly shall be 77 mV max for 12AWG and 89mV max for 16AWG MIL-STD-1344, Method 3004.1 23A for size 12 (12AWG) 13A for size 16 (16AWG) Low Level Contact Resistance Calculated resistance across mated contact pair shall not exceed 6 mΩ using 100 mA current. MIL-STD-1344, Method 3002.1 The resistance of an equal length of wire shall be subtracted from all readings to determine the added resistance of the terminal. MECHANICAL Maintenance Aging There shall be not visible change or damage to the contact cavities MIL-STD-1344, Method 2002.1 Subject 10% of the cavities to 10 cycles of inserting and removing its respective contact. Insert by hand, remove using removal tool. Contact Retention The contact shall remain in place MIL-STD-1344, Method 2007.1 Subject each wired contact to an applied load of 30 lbf (size 12) and 25 lbf (size 16) for a period of 15 seconds in a direction tending to push the contact or of the rear of the connector. Durability No evidence of damage to the contacts, contacting plating, connector housing or seals detrimental to reliable connector performance. Coupling torque must not increase as a result of cycling past the point where it can reasonably be done by hand. MIL-STD-1344, Method 2016 The connector shall be mated and unmated for a total of 100 complete cycles at room temperature Figure 2

Test Description Requirement Procedure Tool Abuse There shall be no visible damage to the connector seals or contact cavities. Use the applicable removal tool shall be inserted into the connector. With an axial load of 5 lbf applied, the tool shall be rotated 180° and then removed, also removing the terminal. Repeat 3 times. Vibration No discontinuity in excess of 1.0 µs at 100 mA during the last hour of each axis. Shall meet visual requirements, show no physical damage and meet requirements of additional tests as needed. MIL-STD-1344, Method 2005.1 Sine Sweep: 10 to 2000 Hz Sweep Cycle: 20 minutes Initial Displacement: .07 inch DA Maximum Max Acceleration: 20G’s Test Duration: 12 hours Time Per Axis X, Y, Z: 4 hours Test Current first 3 hours each axis: 12AWG = 23A, 16AWG = 13A Shock No discontinuity in excess of 1.0 µs at 100 mA during the last hour of each axis. Shall meet visual requirements, show no physical damage and meet requirements of additional tests as needed. MIL-STD-1344, Method 2004.1 10 cycles of ½ sine pluses, 50g±15%, 11±1 ms duration X and Z axis are to be tested. ENVIRONMENTAL Temperature Life There shall be no evidence of cracking, distortion or detrimental damage to the connector following the test. Meet 500 MΩ minimum. MIL-STD-1344, Method 1005.1 The wired mated connectors shall be subjected to 100 hours at 125°C. Insulation resistance shall be measured immediately after removing sample from oven. Salt Spray There should be no evidence of corrosion on the connector or terminals after the connector is removed from the test and cleaned with tap water. MIL-STD-1344, Method 1001.1 Connector shall be fully mated, then submerged in a fine mist of 5% by weight of salt solution for 96 hour. Altitude Immersion Standard pressure is 32.68 torr. The wire mated connectors shall be immersed in a container of tap water, placed in an altitude chamber such that the water covers the connector being tested. MIL-STD-1344, Method 1004.1 Chamber pressure reduced to 32.68 torr and maintained for 30 minutes, then returned to atmospheric pressure within 1 minute and maintained for another 30 minutes. Test repeated for three times. Fluid Immersion There shall be no evidence of cracking, distortion or detrimental damage to the connector following the test. MIL-STD-1344, Method 1016 Subject each connector to one fluid only. The wired mated connectors shall be submerged in the fluids below at ambient temperature. Each connector shall be submerged for 5 minutes, then removed from the fluid to air dry for 24 hours. This cycle is to be completed a total of 5 cycles. -Motor Oil 30 weight -Brake Fluid (disc type 1) -Gasoline -Diesel Fuel #2 -Antifreeze Solution (max protection) -Gear Oil 90 weight

Test Description Requirement Procedure Thermal Shock There shall be no evidence of cracking, distortion or detrimental damage to the connector following the test. Meet insulation resistance 500 MΩ minimum. MIL-STD-1344, Method 1003.1 Cycle mated connectors for 30 minutes at –67°F followed by 30 minutes at +257°F with 2 minute max transfer time. Repeat for 5 cycles. Insulation resistance measured during last heat cycle. External Bending Moment No discontinuity in excess of 1.0 µs at 100 mA during the test. Mount the Receptacle panel mounted in normal service to a rigid plane. Apply a 250 in-lbf bending moment at a rate of 1.0 lbf per second for 60 seconds Insert Retention The inserts shall retain their proper location inside the housing. There shall be no evidence of cracking, breaking, separation from housing or loose parts. MIL-STD-1344, 2010.1 Apply a pulling force of 100 lbf at a rate of 10 lbf per second to the wire bundle that exist the rear of the connector for a period of 30 seconds. Coupling/ Uncoupling Torque Coupling torque for mating and unmating connectors to be MIL-STD-1344, Method 2013.1 The Receptacle connector of each sample mated pair shall be mounted on a torque testing fixture and stay stationary. Figure 2 end

3.4. Product Qualification and Requalification Test Sequence Test or Examination Test Group No. (a) 1 2 3 4 5 6 Test Sequence (b) Examination of Product 1 1 1 1 1 1 Insulation Resistance 2 2 2 2 2 2 Dielectric Withstanding Voltage 3 3 3 3 3 3 Maintenance Aging 4 4 Temperature Life 4 4 4 Contact Retention 5 5 Durability 5 6 4 Tool Abuse 5 5 Salt Spray 6 7 5 Altitude Immersion 6 7 8 6 Fluid Immersion 7 8 9 7 6 6 Thermal Shock 8 7 Vibration 9 10 8 Shock 10 11 9 External Bending Moment 9 12 8 Insert Retention 11 10 7 Low Level Contact Resistance 10 13 Coupling/Uncoupling Torque 12 11 8 Contact Resistance 13 12 14 11 9 9 Final Examination 14 13 15 12 10 10 NOTE (a) Specimens shall be prepared in accordance with applicable product drawings and shall be selected at random from current production. (b) All cavities use wire gauge per SAE J1128 suitable for the terminal size and with sufficient length to accommodate testing. The wire insulation shall be within the connector wire sealing range. Crimp characteristics (i.e. crimp height, crimp width, etc.) shall be checked prior to testing. (c) Specimen shall consist of 24-19 arrangement connectors with DEUTSCH Solid Terminal System size 12 and 16 nickel plated pins and sockets on 12 AWG GXL and 16 AWG GXL wire. (d) All unsealed cavities shall be secured with sealing Plugs. To prevent capillary action on the sealed connector, all free wire ends and test points (i.e. millivolt test connection) shall be sealed with alcohol-based RTV silicone or equivalent and covered with heat shrink tubing (e) Numbers indicate sequence in which tests are performed.

3.5. Appendix A Additional Test Requirements Test Description Requirement Procedure ELECTRICAL Low Level Contact Resistance EIA-364-23 Test with applied voltage not to exceed 20 mV open circuit and the test current shall be limited to 100 mA. The resistance of an equal length of wire (reference wire) shall be subtracted from the same reel as used for the connector wiring. Contact Resistance EIA-364-06 Using test currents as defined. The resistance of an equal length wire (reference wire) shall be subtracted from the actual readings to determine the added resistance of the terminal. The reference wire shall be from the same reel as used for the connector wiring.

Test Description Requirement Procedure MECHANICAL Vibration There shall be no discontinuity in excess of one (1) μs at 20mV and 100 mA during the last hour of each axis. Shall meet visual requirements, show no physical damage and meet requirements of additional tests as needed. EIA-364-28 Sine Sweep: 10 to 2000 Hz Initial Displacement: 1.78 mm DA Maximum Acceleration: 20 G’s Test Duration: 12 hours Time Per Axis X, Y, Z: 4 hours Test Current first 3 hours each axis: Impact There shall be no evidence of cracking, distortion or detrimental damage to the connector following the test. Small chips and dents that do not adversely affect the connector shall be disregarded. Wired mated connector shall be dropped from a height of 1.2m on a cement floor. This action is to be completed a total of five (5) times. Connector Retention There shall be no evidence of cracking, distortion or detrimental damage to the connector following the test Apply a pulling force to the wire bundles that exit the rear of the connector for a period of one (1) minute. The amount of load is to be 111N, times the number of cavities, up to a maximum of 445N.

Test Description Requirement Procedure Contact Retention The contact shall remain in place. EIA-364-29 Using same cavities from for maintenance aging, subject to a direct load as specified below for 15 seconds in a direction tending to push the contact out of the rear of the connector. Either a Tension Testing Machine or equivalent weights may be used. ENVIRONMENTAL Temperature Life There shall be no evidence of cracking, distortion or detrimental damage to the connector following the test. EIA-364-17 The wired mated connectors shall be subjected to 1000 hours at +125°C without current flowing as per MIL-STD- 202, Method 108, Test Condition D. ELECTRICAL Thermal Cycle There shall be no evidence of cracking, distortion or detrimental damage to the connector following the test. Cycle mated connectors from –55°C to +125°C. Connectors to remain at each temperature extreme for one (1) hour minimum. Mated connectors are to be cycled a total of 20 complete cycles. Water Immersion Test samples must meet insulation resistance. The wired mated connectors shall be placed in an oven at +125°C for two (2) hours minimum then immediately be placed in water with a 5% salt by weight content and 0.1 g/L wetting solution to a depth of 914mm for four (4) hours minimum. The free ends of the mated connectors must remain out of the water to prevent wicking of the water through the open wires. Water temperature to be +23°C.

3.6. Appendix B Test Procedure Comparison Chart Test MIL-STD-1344 Method EIA-364 Dash No. Similar to SAE J2030 Paragraph Similar to ISO 8092-2 Paragraph Examination of Product - 18 6.1 4.2 Insulation Resistance 3003.1 21 6.3 4.12 Dielectric Withstanding Voltage 3001.1 20 - 4.13 Low Level Contact Resistance 3002.1 23 6.2 4.8 Contact Resistance 3004.1 06 6.4 4.8 Maintenance Aging 2002.1 24 6.6 - Contact Retention 2007.1 29 6.18 4.7 Durability 2016 09 6.11 4.3 Vibration 2005.1 28 6.15 - Shock 2004.1 27 6.16 - Impact - 42 6.17 4.20 Connector Retention - - 6.20 - Temperature Life 1005.1 17 6.7 4.18 Salt Spray 1001.1 26 6.12 4.16 Fluid Immersion 1016 10 6.14 4.23 Thermal Cycle - - - - Thermal Shock 1003.1 32 6.13 4.22 Moisture - - - - Water Immersion - - 6.19 4.9 Altitude Immersion 1004.1 - - - External Bending Moment - - - - Insert Retention 2010.1 - - - Coupling/Uncoupling Torque 2013.1 - - -

3.7. Revision History Rev Ltr Brief Description of Change Date Dwn Apvd A Initial Release 25-Oct-2017 PV DM B General Specification clarification to reflect actual product specification, updated Figure 1 to include 4AWG and other missing wire gage specs, updated durability requirement to match actual, added missing MIL -STD-1344 test procedures as needed, Appendix A added. 22AWG to LLCR Table, updated requirement CR Table, updated vibration test current, added missing contact retention 19-Dec-2017 VNB DM B1 Page 5, Fluid Immersion row, Procedure column; Changed Transmission Oil to Gear Oil. 12-Sep-2018 DD DM