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tyco Product Specification 108-5529 Electronics Saas O80CTO4 Rev. D1 eS | 040 Ill High Density Connector 1. Scope :

1.1 Contents

This specification covers the requirements for product performance, test methods and quality assurance provisions of .040 IIl High Density Connector. Applicable product description and part numbers are as shown in Appendix 1. 2. Applicable Documents : The following documenis 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 :

i A. 109-5000Test Specification, General Requirements for Test Methods B. 114-5217 Application Specification, Crimping of .040 II Unsealed Contact, Receptacle Cc. 501-5258Test Report 2.2 Commercial Standards and Specifications. A. JASO D605 Multi-pole Connector for Automobiles B. JASO D7101 Test Methods for Plastic Molded Parts Cc. JIS C3406 Low Voltage Wires and Cables for Automobiles D. JIS D0203 Method of Moisture, Rain and Spray Test for Automobile Parts E. JIS D0204 Method of High and Low Temperature Test for Automobile Parts F. JIS D1601 Vibration Testing Method for Automobile Parts G JIS R5210 Portland Cement H. MIL-STD-202 Testing Method 208 : Method of Soldering | BAD ILAMO=IA PLPRABH (7213-9535 MMH BRRAK 3-5-8) 1ofii | Tyco Electronics AMP K.K. (3-5-8 Hisamoto Takatsu-ku Kawasaki, 213-8535) | CONFOMROMBIZAM. RENSAVSH“<ESL. This document is subject to change. Call local AMP for the latest revision. © Copyright 2003 by Tyco Electronics AMP K.K. All rights reserved. *: (4% Trademark Revised Per EC FJA0-0598-04

| ELLA Electronics Product Specification 108-5529 | 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 Materials :

AContact : Description __ Finish Selective-Gold plating or Tin-Lead plating Tab(Male) Copper alloy lover Nickel under plating or Pre-Tinned Selective-Gold plating Receptacle(Female) Copper alloy over Nickel under plating lor Pre-Tinned Fig.1 B.Housing : PBT

3.3 Ratings :

| A.Voltage Rating : 12V DC B. Temperature Rating : —30T to 105°C

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 and Fig3. All tests shall be performed in the room temperature, unless otherwise specified. } 3.5 Test Requirements and Procedures Summary : | Para. Procedures 3.5.1 Examination of Meets requirements of product | Visually inspection. | Product drawing and AMP _ Specification | No physical damage | dt 45217. - ee ee Electrical Requirements i 3.5.2 | Termination 3mQ Max. (Initial) Subject mated contacts assembled in | Resistance 10mQ Max. (Final) housing to 20 mV Max. open circuit at 10 (Low Level) mA. Fig. 3 AMP Spec. 109-5311-1 3.5.3 | Termination Wire size Test Resistance | Measure mill volt drop of contact in Resistance (mm?) Current (mQ) mated connectors, Fig. 3. (Specified Current) (A) Max. AMP Spec. 109-5311-2 [05 | 1 | 3 (initial) 3.5.4 | Dielectric No creeping discharge nor flashover | 1 KV AC for 1 minute. | withstanding Voltage | shall occur. Mated connector. | Fig. 4. | AMP Spec. 109-5301 | Fig.2 (To be continued) Rev. D1 2 of 11

ELJLQ | Electronics Product Specification 108-5529 ——— SS ' Para. Procedures 3.5.5 | Insulation Resistance | 100 MQ Min. (Initial) Impressed voltage 500 V DC. 100 MQ Min. (Final) Mated connector. Fig. 4. AMP Spec. 109-5302 3.5.6 | Temperature Rising a c. Test ie Measure temperature rising at wire cimped. by "applod cuenta A) * positions. Fas | 24 Tay | AMPS 00010 Applied Current : Fig. 6 3.5.8 | Vibration No electrical discontinuity greater | Vibration Frequency : (High Frequency) than 1 jzsec. shall occur. 2020020 Hz /3 min. 10mQ Max. (Final) Accelerated Velocity : 44.1m/ s* Vibration Direction : X, Y, Z Duration: 1 hour Mounting: Fig. 7 3.5.9 | Physical Shock No electrical discontinuity greater | Accelerated Velocity : than 1 4 sec. shall occur. 980 m/s" Final 10 mQ Max. Waveform: Half sine wave Duration:6 m_ sec.Velocity Change: 3.75 m/s Number of Drops: 6 drops each directions of X, Y and Z axes, totally 18 | drops | AMP Spec. 109-5208 Condition D Mounting : Fig. 7 3.5.10 | Connector Mating Fig. 11 Operation Speed : 20 mm / min. Force Measure the force required to mate connectors. AMP Spec. 109-5206 Condition A 3.5.11 | Connector Unmating | Fig. 11 Operation Speed : 100 mm / min. Force Measure the force required to unmate connectors. (without housing lock) AMP Spec. 109-5206 Condition A | 3.5.12 | Connector Locking 100 N Min. Apply an axial pull-off load to one of the | Strength mated housing. | Measure locking strength. Operation Speed : 100 mm / min.

3.5.13 Measure the force required to insert

Force per contact contact into housing. 3.5.14 | Contact Retention Apply an axial pull-off load to crimped Force wire. ‘Housing Lance onl Operation Speed : 100 mm / min. 3.5.15 | Contact Retention Measure contact retention force with Force secondary lock set it effect. ‘Secondary Lock, Operation Speed : 100 mm / min. Fig.2 (To be continued) i Rev. D1 3 of 11

CULO ‘Electronics Product Specification 108-5529 ar SI ne Mechanical Requirements 3.5.16 | Crimp Tensile Wire size Tensile Strength Apply an axial pull-off load to crimped Strength (mm?) (N) Min. wire of contact secured on the tester, Operation Speed : 100 mm / min. [03 | 70" AMP Spec." 109-5205 [0s | s0 | Condon & [oes 130 ee Operation Speed : 100 mm / min 3.5.18 | Resistance to “Kojiri” | Termination Resistance : Hold one of mated connectors on bench, 10 mQ Max. (Final) apply repeated torque motions of 1.96 N- m in front-rear, and right-left directions for 30 cycles each at the every depth of 1 mm graduation. This test may be alternatively performed manually. See Fig. 8. AMP Specification, 109-5215 3.5.19 | Solderability Wet Solder Coverage : Solder Temperature :235+5°C | Plated area only Immersion Duration :5-+0.5 seconds | 95 % Min. Flux : Alpha 100 | (With substrate area) AMP Spec. 109-5203 50 % Min. | ithout substrate area) | mating / unmating handling. 3.5.21 | Resistance to No physical damage shall occur. Test connector on PCB. | Soldering Heat Post Retention Force Solder Temperature:260+ 5°C | 20 N Min. (Final) Immersion Duration :10+1 sec. AMP Spec. 109-5204 Condition B | Environmental Requirements H 3.5.22 | Thermal Shock 10mQ Max. (Final) Mated connector -40C/30 min., 100°C/30 min. Making this a cycle, repeat 1000 cycles. 3.5.23 | Humidity, Insulation resistance Mated connector, Steady State 100 MQ Min. (Final) 90~95%R.H. 60+5 Termination resistance 96 hours : 10mQ Max. (Final) 14 V applied. i Current Leakage Fig. 5 j 1.mA Max. | 3.5.24 | Salt Spray 10mQ Max. (Final) Mated connector, 5+1 % salt | concentration, 96 hours : | AMP Spec. 109-5101 Condition B | 3.5.25 | Industrial Gas (SO2) 10mQ Max. (Final) Unmated connector | SO, Gas : 25 ppm, 75 % R. H. | 25, 96 hours | 3.5.26 | Temperature Life 10mQ Max. (Final) Mated connector, | (Heat Aging) 120, 120 hours AMP Spec. 109-5104-5 Condition B Fig.2 (To be continued) i Rev. D1 4of 11

CEE Electronics Product Specification 108-5529 3.5.27 | Resistance to Cold 10m Max. (Final) Mated connector -40°C, 120 hours AMP Spec. 109-5108 Condition D 3.5.28 | Humidity- Insulation resistance Mated connector Temperature Cycling 100 MQ Min. (Final) Condition : Fig. 9 Termination resistance 10mQ Max. (Final) 3.5.29 | Dust Bombardment | 10m Max. (Final) Mated connector Subject JIS R 5210 cement blow of 1.5 kg per 10 seconds in 15 minutes intervals for 8 cycles, with Unmate/Re-mating per 2 cycles. AMP Spec. 109-5110 3.5.30 | Compound 10mQ Max. (Final) Temperature: 80°C Environment Vibration Frequency : Resistance 2020020 Hz/3 Min. (Log) Accelerated Velocity: 44.1 mis” Vibration Direction: X, Y, Z Duration: 300 hours Test Current: Fig. 10 Mounting: Fig. 7 Fig. 2 (End) Rev. D1 5 of 11

EYED ‘Electronics Product Specification 108-5529 cfc

3.6 Product Qualification Test Sequence

| Test Group TestExamination | 1 [ 27 3 [7 475 76[7]8 79 [oy] ny] 23 Examination of 1, Termination Resistance 27, 25, tonto | 2 | 2] || 2s | Ss | 2 | 26 | 20 | 6 | | a8 [ase Termination Resistance 3,8, 3,6, Dielectric withstanding 410 Voltage : remote] [TTS Pet OverCurrenttoading| 5 [| [| [| | | fT Vibration PhysicalShock | [5 [ [| | fT Connector Mating Force Connector Unmating 3 Force Connector Locking a Contact insertion Force |_| | | 2 | TT Contact Retention Force Contact Retention 4 13 Force(Double Lock) Crimp Tensile Strength PostRetention Force | [| 0 | TT Resistance to “Koji” | [| | | fT 4 TT Solderability [ [| 6 | of fT TT | Handling Ergonomics |_| | | | it TT Te a SST Pr tT \\ leat ThermalShock [| [| | | Tt Humidity (Steady State) [TTT Te Salt Spray [| Ta Industrial SO,Gas [| | TT a Temperature Life 3 5 (Heat Aging) ResistancetoCold | [| | TT Ta Humidity: Temperature 7 yeling DustBombardment | | | TT TT a Compound Envirenment 9 Resistance (a)Numbers indicates sequence in which tests are performed. | Fig. 2 Rev. D1 6 of 11 j

ELLO Electronics Product Specification 108-5529 Pa fata Y 1mm Max. - L PCB al x WY y’ Deduct resistance of Y-Y’ (wire “L”) from X-Y’ Fig. 3 Wrap metallic foil to cover the connector surface Measuring Apparatus L oo H H H H \\ H i | H H \\ Hi H H : H : H i H H t H Adjacent Contacts Contacts — Housing | Fig. 4 p @) | WS] | Fig.5 Rev. D1 Toft

ELJOO Etectronics Product Specification 4108-5529 Wie se (mm) Sequence | TestCurrent (@)_—_ [Duration ee os 9 [> ~@ 202200 ss. ee a ee Fig. 6 Over current loading | $ | ~ 6: > | ea ed 14 Ki aes | Vibration Direction <= [TL Vibration Tabl - B 50Min. ipration Table: Should not be banding Clamped | 740 *§ | Fig. 7 Rev. D1 8 of 11

ELJED | Electronics Product Specification 108-5529 z wy j 1,96N-m [1 a ry H Connector tesecbest i UY Fig. 8 Resistance to “Kojiri” 90~96% RH. oa ~ ~ Un-operated Humidity, 90~96% RH 90~96% RH roperated 90-96% RH 802°C 80+2°C | Temperature| | 2542°C th 4h 2h | 2h 4h 2h 1Cycle (24h) | Fig. 9 Humidity-Temperature Cycling i Reve Di GET

EYE Electronics Product Specification 108-5529 ] @ccceccMecce|/ecceccec@l[eccecc||ecccccceccli@Mecccec®@ @©o8 BEae® BHGHEB) |GH) | OoawH) |p) LI ___/7 C7 Symbol TestCurrent___ @ | t25mm" AAS ION B | o5mm | tA +) 15 min. OFF C | 0smm@ | om —— 300 cycles 2TEST CURRENT =2.4A (P/N:1318219) Fig. 10 Compound Environment Test Current Cap musing Connector Mating Force, Connector Unmating Force (N) Max Part No. ———_ | i7P os. 22 Pos. [24 Pos, [26 Pos,_[_siPos,_| TéPos, | 2-353015-C Beppe} pet 9-353015-0) 2-353016-0 23538240 | 70 | 80 | 90 | 100 | 100 | —— 1123038-0 ' 1123042-0 isieazo-O | 80 | 90 | to | t30 | 30 313184200 | 80 | 90 | 0 | too | 400 | = Fig. 11 Connector Mating Force, Connector Unmating Force i | Rev. D1 10 of 11

ELE | Electronics Product Specification 108-5529 ' The applicable product descriptions and part numbers are as shown in Appendix. 1. Product Part No. __Description | (0-353015-0_~— ‘| .040 Ill High Density Connector 122 Pos. Cap Housing Assy (-1318429-1) | .040 Ill High Density Connector 122 Pos. Cap Housing Assy(PRE-TIN TYPE) 0-353016-C)__| .040 Ill High Density Connector 105 Pos. Cap Housing Assy 0-353824-0) _| .040 Ill High Density Connector 105 Pos. Cap Housing Assy (Type B) 0-1123794-1 | .040 Ill High Density Connector 94 Pos. Cap Housing Assy [35383081 | 40 Ill High Density Connector 72 Pos. Cap Housing Assy 0-1123038-0 : (0-1123042-0 ‘| .040 Ill High Density Connector 72 Pos. Cap Housing Assy 0-1123043-0 (Without several contacts) 0-1747962-( | .040 Ill High Density Connector 48 Pos. Cap Housing Assy ithout several contacts) G-1318219-0 | .040 Ill High Density Connector 16 Pos. Cap Housing Assy 353027-D .040 Ill High Density Connector 17 Pos. Plug Housing Assy 353028-D) -040 III High Density Connector 22 Pos. Plug Housing Assy 353029-D .040 Ill High Density Connector 24 Pos. Plug Housing Assy 353030-0 .040 Ill High Density Connector 28 Pos. Plug Housing Assy 353031-0 .040 Ill High Density Connector 31 Pos. Plug Housing Assy 353826-0 -040 III High Density Connector 31 Pos. Plug Housing Assy (Type B) \\ 1318221-D .040 III High Density Connector 16 Pos. Plug Housing Assy 316836-1 .040 Ill Unsealed Contact, Receptacle (S) Sn 1565915-1 .040 Ill Unsealed Contact, Receptacle (S) Sn, LIF 316837-2 .040 Ill Unsealed Contact, Receptacle (S) Au 316838-1 .040 Ill Unsealed Contact, Receptacle (M) Sn 1565916-1 .040 Ili Unsealed Contact, Receptacle (M) Sn, LIF Appendix. 1 if i i Rev. D1 11 of 11