Product
Specification
108-40030
11 Mar 11 Rev A
AMPLIMITE* Shielding Hardware Connector
1.
1.1.
SCOPE
Content
This specification covers the performance, tests and quality requirements for AMPLIMITE*
connectors with shielding hardware.
1.2.
Qualification
When tests are performed on the subject product line, the procedures specified in 109-Series Test
Specifications shall be used. All inspections shall be performed using the applicable inspection plan
and product drawing.
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.
TE Connectivity (TE) Documents
A.
B.
C.
D.
E.
109-1:
General Requirements for Test Specifications
Test Specifications as indicated in Figure 1.
Connectors, AMPLIMITE HDE-20 for Overmolding
Connectors, AMPLIMITE HDP-20 for Overmolding
Test Report
109 Series:
114-40006:
114-40007:
501-83:
3.
3.1.
REQUIREMENTS
Design and Construction
Product shall be of the design, construction and physical dimensions specified on the applicable
product drawing.
3.2.
Materials
A.
Connector
1.
Shields:
2.
Shells:
Hardware
1.
Shields:
2.
Ferrules:
Thermoplastic, UL 94V-O
Steel
Steel
Copper
B.
3.3.
Ratings
A.
Current
1.
AMPLIMITE HDP-20: 7.5 amperes per contact maximum
2.
AMPLIMITE HDE-20: 5.0 amperes per contact maximum, see Para.3.5.(a)
Storage Temperature: -55 to 105° While this is the operating temperature of the connector,
C.
the operating environment used must not exceed the limits of either the connector or the cable
B.
©2011 Tyco Electronics Corporation,
a TE Connectivity Ltd. Company
All Rights Reserved
TE logo is a trademark.
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For latest revision, visit out website at www.te.com/documents
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Other products, logos, and company names might be trademarks of their respective owners.
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LOC B
108-40030
3.4.
Performance and Test Description
Connectors and hardware shall be designed to meet the electrical, mechanical and environmental
performance requirements specified in Figure 1. Since the results of many of the tests are dependent
not only on the hardware and the connectors, but also on the cable, the cable must be chosen to
meet the electrical, mechanical and environmental performance requirements in Figure 1 or the
stresses derated appropriately
3.5.
Test Requirements and Procedures Summary
Requirement
Meet requirements of product
drawing and Application
Specifications 114-40006 and 114-
40007
ELECTRICAL
1.0 kvac dielectric withstanding
voltage, one minute hold.
One milli- ampere maximum
leakage current.
Shielding shall decrease emissions
by the following minimum levels:
MHz
Shielding
30 to 216
35 dB
216 to 1000
15 dB
MECHANICAL
No discontinuities greater than 1
microsecond.
Procedure
Visual, dimensional and
functional per applicable
inspection plan.
Test Description
Examination of Product
Dielectric Withstanding
Voltage
Test between contacts and shield
of mated connector assemblies;
Test Specification 109-29-1.
Shielding Effectiveness
Measure shielding effectiveness of
double ended single braid cable;
Test Specification 109-90.
Vibration (b)
Physical Shock
No discontinuities greater than 1
microseconds.
Subject mated connectors to 10-
55-10 Hz traversed in 1 minute at
.06 inches total excursion; 2 hours
in each of 3 mutually
perpendicular planes; Test
Specification 109-21-1.
Subject mated connectors to 50
G’s half-sine in 11 milliseconds; 3
shocks in each direction applied
along the 3 mutually perpendicular
planes;
Test Specification 109-26-1.
Gradually apply 50 pounds weigh
to cable, see Figure 3, maintain
weight for 1 hour;
Test Specification 109-46, cond A.
Subject cable to 100 cycles at a
rate of 12 to 14 cycles per minute,
see Figure 4;
Test Specification 109-20.
Cable Pullout
No discontinuities greater than 1
microsecond for shield circuit.
Circular Jacket Cable Flexing
No evidence of damage, cracking
or chipping.
Figure 1 (continued)
Rev A
2 of 6
108-40030
Test Description
Thermal Shock (b) (c)
Requirement
ENVIRONMENTAL
Dielectric withstanding voltage;
insulation resistance.
Procedure
Subject mated connectors
to 5 cycles between -55°
and 105°
C;
Test Specification 109-22.
Subject mated connectors to
environmental class III for 10 days;
Test Specification 109-85-3.
Industrial Mixed Flowing Gas
Shielding effectiveness final
NOTE
(a)
(b)
(c)
Maximum rated current that can be carried by this product is limited by
maximum operating temperature of housings, which is 30°
C.Variables
which shall be considered for each application are: wire size, connector
size, contact material, and ambient temperature.
Shall remain mated and show no evidence of damage, cracking or
chipping.
The temperature range of this test must be adjusted as necessary to
assure that the temperatures of the cable assemblies are exposed to
shall not exceed the temperature rating of either the cable or the
connector.
Figure 1 (end)
3.6.
Connector and Hardware Qualification and Requalification Tests and Sequences
Test Group (a)
2
Test Sequence (b)
1
2, 4
Test or Examination
Examination of Product
Dielectric Withstanding Voltage
Shielding Effectiveness
Vibration
Physical Shock
Cable Pullout
Circular Jacket cable Flexing
Thermal Shock
Industrial Mixed Flowing Gas
NOTE
1
1
2, 8
3, 9
4
5
6
7
3
1
2, 4
3
3
(a) See Para 4.1.A.
(b) Numbers indicate sequence in which tests are performed.
Figure 2
Rev A
3 of 6
108-40030
4.
4.1.
QUALITY ASSURANCE PROVISIONS
Qualification Testing
A.
Sample Selection
Connector housings and contacts shall be prepared in accordance with applicable
Instruction Sheets. They shall be selected at random from current production. All test groups
shall consist of a minimum of 6 double ended cable assemblies of each type (HDE-20 and
HDP-20) with shielding hardware crimped on but not overmolded. The cable shall be constructed
as follows:
1.
0.032 inch maximum single jacket, 75 to 80 shore durometer
2.
Overall tinned copper braid, 90% coverage.
3.
Overall foil shield with drain wire
4.
The above items constitute approximately 88% of the cross sectional area of the cable
5.
All contacts terminated.
Each cable assembly shall have a cable length of 6 feet + .5 inch between the connector back
shells as specified in Test Specification 109-90.
B.
C.
Test Sequence
Qualification inspection shall be verified by testing samples as specified in Figure 2.
Acceptance
1.
Test results from development on pre-qualification samples will be used to determine upper
and lower one-sided statistical tolerance limits for 99% reliability at 95% confidence, as
follows. Let Xbar and s denote the sample average and standard deviation, respectively, of
the test data. Let k denote the normal distribution one-sided tolerance factor for 95%
confidence and 99% reliability. The value of k varies with sample size. Values of k are
given in various tables, for example, NBS Handbook 91, Factors for One-Sided Tolerance
Limits for Normal Distribution. Suitability of the normal distribution for representing the
data shall be verified with normal probability plots, goodness of fit tests, etc.
Then the upper one-sided tolerance limit for 99% reliability at 95% confidence is given by
Xbar + ks. The interpretation of thistolerance limit is as follows: based on the test
data, and assuming a normal distribution for the test data, we can be 95% confident that
99% of the population of values represented by the sample data will not exceed Xbar + ks.
For any test parameter for which there is specified an upper requirement which is not to be
exceeded, satisfactory performance of the product is achieved when the value of Xbar + ks
does not exceed the requirement value.
The lower one-sided tolerance limit for 95% confidence and 99% reliability is given by
Xbar - ks. This has a similar interpretation and corresponding application to lower
requirement values.
Failures attributed to equipment, test setup, or operator deficiencies shall not
disqualify the product. When product failure occurs, corrective action shall be taken
and samples resubmitted for qualification.
2.
4.2.
Requalification Testing
Requalification shall be established by the cognizant divisional engineering function and may
consist of all or any part of the overall qualification program provided that it is conducted within the
required time period.
4.3.
Quality Conformance Inspection
The applicable quality inspection plan will specify the sampling acceptable quality level to be used.
Dimensional and functional requirements shall be in accordance with the applicable product drawing
and this specification.
Rev A
4 of 6
108-40030
Figure 3
Cable Pullout
Rev A
5 of 6
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