Product Specification 108-5365 製品規格 17OCT08 Rev. Ｂ1 040 Series Sealed PAIR MATE Connectors 1. Scope 1.1 Contents This specification covers the requirements for product performance, test methods, and quality assurance provisions of 040 Series Sealed PAIR MATE Connectors. 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 Specification A. 109-5000 Test Specification, General Requirements for Test Methods B. 114-5149 Application Specifications C. 501-xxxx Test Report 2.2 Commercial Standard and Specifications A. JASO D 605 Multi-Position Connectors for Automobiles B. JIS C 3406 Low Voltage Cables for Automobiles C. JIS D 1601 Vibration Testing Methods for Automobile Parts 3. Requirements 3.1 Design and Construction Product shall be of the design, construction and physical dimensions specified in the applicable product drawing. 3.2 Materials A. Contact a. Receptacle contact Phosphor Bronze b. Tab contact Brass B. Housing PBT C. Others a. Seal Ring Silicone Rubber b. Seal Rubber Silicone Rubber c. Packing Silicone Rubber 3.3 Ratings A. Temperature Rating -40℃ to 120℃ (Room temperature + temperature rising by energized current) 3.4 Performance and Test Descriptions The product shall be designed to meet the electrical, mechanical and environmental performance requirements specified in Fig.2. All test shall be performed in the room temperature, unless otherwise specified. タイコ エレクトロニクス アンプ株式会社 （〒213-8535 川崎市高津区久本 3-5-8） 1 of 11 Tyco Electronics AMP K.K. (3-5-8 Hisamoto Takatsu-ku Kawasaki, 213-8535) © Copyright 2007 Tyco Electronics AMP K.K. All international rights reserved. * : 商標 Trademark Product Specification 108-5365 Test Requirements and Procedures Summary Para Test Items Requirements Procedures 3.5.1 Confirmation of Product Product shall be conforming to the Visually, dimensionally and functionally requirements of applicable product inspected per applicable quality inspection drawing and Application plan. Specification. Electrical Requirements Wire Size Resistance 3.5.2 Termination Resistance Measure initial millivolt drop of contact Test Current 2 mm mV/A (Specified Current) test circuit in mated connectors. Fig.3. (A) (AWG) (max.) AMP Spec. 109-5311-2 0.5 (#20) 10(initial) 1 0.85(#18) 20(final) 1.25(#16) 3.5.3 Termination Resistance 10mΩ max. (initial) Subject mated contacts assembled in (Low Level) housing to closed circuit current of 10mA 20mΩ max. (final) DC at open circuit voltage of 20mV DC Fig.3 AMP Spec. 109-5311-1 3.5.4 Dielectric Strength No creeping discharge nor flashover 1kV AC for 1 minute. shall occur. Test between adjacent circuits and between contacts and housing of mated connectors. Fig.4 AMP Spec. 109-5301 3.5.5 Insulation Resistance 100MΩ min. (initial) 500V DC impressed. Test between adjacent circuits and between contacts and housing of mated connectors. Fig.4 AMP Spec. 109-5302 3.5.6 Current Leakage 0.1mA max. 14V DC impressed to mated connectors for 1 minute. Fig.4(a) AMP Spec. 109-5312 3.5.7 Temperature Rising 60℃ max. under loaded current Measure temperature rising of wire barrel of contact by energized current. specified in Fig.5 AMP Spec. 109-5310 3.5.8 Current Cycling 20mΩ max. (final) Applied current : Fig.5 45 minutes ON, 15 minutes OFF, 300 No ignition is allowed during the cycles test. AMP Spec. 109-5308 Physical Requirements 3.5.9 Vibration All contacts are connected in series Vibration frequency : (High frequency) and current of 12V (open voltage) 20-200-20 Hz/3min 2 0.1A DC applied under vibration, no Accelerated velocity : 44.1m/s electrical discontinuity greater than 1 Vibration direction and time : Up and down, back and forth, Right and μ sec. shall occur. left (3 directions) 3 hours/direction. Fig.6 20mΩ max. (final) AMP Spec. 109-5202 Fig.2 (CONT) Rev. B1 2 of 11 Product Specification 108-5365 Para Test Items Requirements Procedures 3.5.10 Contact Mating 0.49 - 2.45 N Operation speed : 100mm/min Force Measure the force required to mate contacts. 3.5.11 Contact Unmating 0.49 - 2.45 N Operation speed : 100mm/min Force Measure the force required to mate contacts. 3.5.12 Connector Mating 40 positions 98N max. Operation speed : 100mm/min Force Measure the force required to mate connectors. AMP Spec. 109-5206 Tightening Torque 80 positions 1.96N･m max. With connector in pre-locked position, of Bolt tighten bolt until fully mated while measuring the maximum torque. Operation speed : 15Rev./min 3.5.13 Connector 40 positions 98N max. Operation speed : 100mm/min Unmating Force Measure the force required to mate connectors. AMP Spec. 109-5206 Condition : without locking mechanism 3.5.14 Connector Locking 98N min. Measure connector locking strength. Strength Operation speed : 100mm/min. AMP Spec. 109-5210 40 Pos. Housing only. 3.5.15 Contact Insertion 14.7N max. per contact Measure the force required to insert Force contact into housing. AMP Spec. 109-5211 3.5.16 Contact Retention 78.4N min Measure contact retention force with Force secondary lock set in effect. (Secondary Lock) Operation speed : 100mm/min. 3.5.17 Crimp Tensile Wire Size Climp Tencile Apply an axial pull-off load to crimped 2 Strength mm (AWG) (min.) wire of contact secured on the tester. N Operation speed : 100mm/min. AMP Spec109-5205 0.5 (#20) 88 0.85(#18) 127 1.25(#16) 177 3.5.18 Durability 20mΩ max. (Final) Manually operated (Repeated (80 Pos. : To use manually torque wrench) Mate/Unmating) No. of Cycles : 30 cycles. AMP Spec. 109-5213 3.5.19 Resistence to 20mΩ max. (Final) Manually repeat “Kojiri” insertion and “Kojiri” extraction for 30 cycles. AMP Spec. 109-5215 (Only 40 Pos.) 3.5.20 Solderability Wet solder coverage : 95% min Solder Temperature : 230±5℃ Immersion Duration : 3±0.5 seconds Flux : Alpha 100 AMP Spec. 109-5203 Solder : Sn 60 : Pb 40 (wt%) Fig.2 (CONT) Rev. B1 3 of 11 Product Specification 108-5365 Para Test Items Requirements Procedures 3.5.21 Handling No abnormalities allowed in manual Manually operated. Ergonomics mating/unmating handling. Environmental Requirements 3.5.22 Thermal Shock 20mΩ max (Final) Subject mated connectors to exposure of –30±5℃ for 60 min., 80±5℃ for 60 min. AMP Spec. 109-5103 3.5.23 Humidity Steady Mated Connector, 90-95% R.H. 20mΩ max (Final) State 60℃, 96 hours AMP Spec. 109-5105 3.5.24 Salt Spray 20mΩ max (Final) Subject mated connectors to 5% salt concentration for 96 hours : MIL-STD-202, Method 101 (Mated Connector) AMP Spec. 109-5101 After rinsing with tap water, dry at room temperature for 1 hour. Then make resis. Measurements. 3.5.25 Industrial Gas 20mΩ max (Final) Subject mated connectors to exposure (SO2) of SO2 Gas : 10 ppm, 95% R.H., room temperature for 24 hours. AMP Spec. 109-5107 3.5.26 Temperature Life 20mΩ max (Final) Subject mated connectors to exposure (Heat Aging) of 120℃ for 120 hours. AMP Spec. 109-5104 3.5.27 Resistance to Cold 20mΩ max (Final) Subject mated connectors to exposure of –50±5℃ for 120 hours. AMP Spec. 109-5108 3.5.28 Water Immersion Current Leakage 0.1 mA max. Subject mated connectors with Testing mounting engine control unit (ECU) to immersion in tap water tub in accordance with the test patterns 1 and 2 as specified in Fig. 9 by using the new sample each time separately. Water immersion shall be done as shown in Fig. 10. During the test, test voltage of 14V DC is applied between the adjacent contact, and monitor the circuit for electrical current leakage. 3.5.29 Water Splash Current Leakage 0.1 mA max. Expose mated connectors under 80± 3℃ for 40 minutes, splash water for 20 minutes. 48 cycles, Test voltage : 14V AMP Spec. 109-5109 Condition JIS D 0203 R1 Seal tab holes in CAP HSG by applying epoxy to rear surface of HSG. Fig.2 (CONT) Rev. B1 4 of 11 Product Specification 108-5365 Para Test Items Requirements Procedures 3.5.30 Icing 20mΩ max. (Final) Immerse mated connectors in boiling water for 60 minutes, freeze at –30± 5℃ 3.5.31 Resistance to Oil 20mΩ max. (Final) Immerse mated connectors in oil. 50±5℃ Specified in Fig.8 3.5.32 Dust 20mΩ max. (Final) Subject JIS R5210 cement blow of Bombardment 14.7N per 10 seconds in 15 minutes intervals for 90 minutes. AMP Spec. 109-5110 (Mated Connectors) 3.5.33 Resistance to 20mΩ max. (Final) Immerse mated connectors into Liquid Detergents commercially suppliable car washer liquid detergent at 50±2℃ for 2 hours. After the durations, rinse in tap water for 5 minutes, and have it dried before subsequent measurement. (Mated Connectors) 3.5.34 Resistance to Immerse mated connectors into 20mΩ max. (Final) Coolant commercially suppliable L.L.C (long life coolant) at 50±2℃ for 2 hours. After the duration, rinse in tap water for 5 minutes, and have it dried before subsequent measurement. (Mated Connectors) Fig.2 (END) Rev. B1 5 of 11 Product Specification 108-5365 Product Qualification and Requalification Tests. Test or Examination Test Group 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Test Sequence (a) Confirmation of Product 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Termination Resistance 3,6,8 (Specified Current) Termination Resistance 3,6,8 2,4,6 2 2,4 2,4 2,4,6 2,5 (Low Level) 10,12 8,10 Dielectric Strength 4 Insulation Resistance 3 Current Leakage 2 Temperature Rising 3 Current Cycling 4 Vibration (High Frequency) 5 Contact Unmating Force 2 Contact Mating Force 3 Connector Unmating Force 2 Connector Mating Force ４ Connector Locking Strength 5 Contact Insertion Force 2 Contact Retention Force 6 (Secondery Lock) Crimp Tensile Strength 2 Durability (Repeated 3 Mate/Unmating) Resistence to “Kojiri” 5 Solderability 2 Handling Ergonomics 4 Thermal Shock 11 Humidity Steady State 9 Salt Spray 3 Industrial Gas（SO ） 3 ２ Temperature Life 5 (Heat Aging) Resistance to Cold 7 Water immersion Testing 2 Water Splash 2 Icing 7 Resistance to Oil 7 Dust Bombardment 9 Resistance to Liquid 5 Detergents Resistance to Coolant 3 (a) Numbers indicate sequence in which tests are performed. Rev. B1 6 of 11 Product Specification 108-5365 Rev. B1 7 of 11 Product Specification 108-5365 Rev. B1 8 of 11 Product Specification 108-5365 Rev. B1 9 of 11 Product Specification 108-5365 Rev. B1 10 of 11 Product Specification 108-5365 The applicable product descriptions and part numbers are as shown in Appendix 1. Appendix１ Prod. P/N Description 5178405-1 120 Position, Cap Assembly 1-178405-6 120 Position, Cap Assembly 178409-6 40 Position, Plug Assembly (B-Type) 178411-6 80 Position, Plug Assembly 178413-7 Double Lock Plate 178421-7 Cavity Plug 175197-2 040 Series, Receptacle Contact 1-177503-9 40 Position, Cap Assembly (A-Type) 6-177504-6 40 Position, Plug Assembly (A-Type) 1-179962-6 40 Position, Cap Assembly (B-Type) *Mating 40 position cap assembly and plug assembly shall have identical type. For 120 position cap assembly, B-Type of plug assembly shall be mated. Rev. B1 11 of 11