68-Position Heavy Duty Hybrid Connector

Transcription

1 68-Poston Heavy Duty Hybrd Connector Applcaton Specfcaton MAR 12 All numercal values are n metrc unts [wth U.S. customary unts n brackets]. Dmensons are n mllmeters. Unless otherwse specfed, dmensons have a tolerance of ±0.13 and angles have a tolerance of ±2. Fgures and llustratons are for dentfcaton only and are not drawn to scale. 1. INTRODUCTION Ths specfcaton covers the requrements for applcaton of the 68-Poston Heavy Duty Hybrd Connector. Ths connector s used on engne control modules and consst of sxty 1 mm contacts and eght 1.6 mm contacts. It s a vertcal-mount wre-to-board connector system whch mounts to the exteror of modules. Refer to Applcaton Specfcatons and for all termnaton and applcaton nformaton for the contacts whch are used n the 68-Poston Heavy Duty Hybrd Connector. When correspondng wth TE Connectvty Personnel, use the termnology provded n ths specfcaton to facltate your nqures for nformaton. Basc terms and features of ths product are provded n Fgure 1. Wre Dress Cover Wre Condut Openng Latch Legs Wre Seal Socket Contact Seated 68-Poston Plug Assembly Housng Polarzng Posts Sealed 68-Poston Header Assembly Jackscrew Spacer Seal Cover Latch Slots Preset Latch Sze 20 Crcuts Case Seal O -Rng Sze 16 Crcuts Holes for Mountng Screws (6) 2. REFERENCE MATERIAL 2.1. Revson Summary Materal changed to PTFE Fgure Tyco Electroncs Corporaton, a TE Connectvty Ltd. Company TOOLING ASSISTANCE CENTER All Rghts Reserved PRODUCT INFORMATION TE logo s a trademark. *Trademark. Other products, logos, and company names mght be trademarks of ther respectve owners. Ths controlled document s subject to change. For latest revson and Regonal Customer Servce, vst our webste at 1 of 12 LOC B

2 2.2. Customer Assstance Reference Base Part Number and Product Code A243 are representatve numbers that dentfy the 68-Poston Heavy Duty Hybrd Connector product lne. These numbers are used n the customer servce network to access toolng and product applcaton nformaton. Ths servce s provded by your local TE Representatve or, after purchase, by callng the Toolng Assstance Center number at the bottom of page Drawngs Customer Drawngs for each product part number are avalable from the servce network. The nformaton contaned n the Customer Drawngs takes prorty f there s a conflct wth ths specfcaton or wth any other techncal documentaton suppled by TE Specfcatons Product Specfcaton provdes product performance requrements and test nformaton. Applcaton Specfcatons and provde nformaton for termnaton and requrements of the contacts used n ths connector assembly Manuals Manual s avalable upon request and can be used as a gude n solderng. Ths manual provdes nformaton on varous flux types and characterstcs along wth the commercal desgnaton and flux removal procedures. A checklst s ncluded n the manual as a gude for nformaton on solderng problems Instructonal Materal The followng lst ncludes avalable nstructon sheets (408-seres) that provde nformaton for the handlng of ths product lne. Document Number Document Ttle Preparng Reel of Contacts for Applcaton Toolng Desgn Recommendatons for Prnted Crcut (PC) Board Support Fxture Checkng Termnal Crmp Heght Gagng De Closure Handlng Of Reeled Products 3. REQUIREMENTS 3.1. Storage A. Ultravolet Lght Prolonged exposure to ultravolet lght may deterorate the chemcal composton used n the connectors. B. Reel Storage When usng reeled contacts, store col wound reels horzontally and traverse wound reels vertcally. C. Shelf Lfe The contacts and connectors should reman n the shppng contaners untl ready for use to prevent deformaton to the product. The contacts and connectors should be used on a frst n, frst out bass to avod storage contamnaton that could adversely affect sgnal transmssons. D. Storage Temperature Maxmum storage temperature should not exceed 150 C [302 F]. E. Chemcal Exposure Do not store contacts near any chemcals lsted below, as stress corroson crackng n the contacts may occur. Alkales Ammona Ctrates Phosphates Ctrates Sulfur Compounds Amnes Carbonates Ntrtes Sulfur Ntrtes Tartrates Where the above envronmental condtons exst, phosphor-bronze contacts are recommended f avalable. 2 of 12

3 3.2. Exposure Lmtatons The operatng temperature range of ths connector assembly s -40 to 125 C [-40 to 257 F] Specal Consderatons Sze 16 crcuts (8 larger crcuts) wll seal properly wth 14 AWG GXL, 16 AWG GXL, and 14 AWG PTFE wre, wth wre nsulaton (OD) between 2.5 and 3.18 mm. Sze 20 crcuts (60 smaller crcuts) wll seal properly wth 18 AWG GXL and 16 AWG PTFE wre, wth wre nsulaton (OD) between 2 and 2.5 mm Stran Relef Arrangement Care should be taken when attachng the wre dress cover as not to bend or crush any wres. make sure that the wres are not bent or angled comng through the wre seal. Dong so may cause the wres to open the wre seal holes too much and form leak paths. The wres should be bent after extng the wre cover, n order to ft all the wres comfortably underneath the wre dress cover Contact Termnaton Termnate the contacts n accordng to the specfc toolng nstructonal materal and crmp requrements provded n Applcaton Specfcatons and Plug Assembly Procedures CAUTION Seal cover and wre seal must not be removed or altered n any way. CAUTION The back of the connector must be completely sealed. Those cavtes that are not used must have ndvdual seal plugs. Use seal plug for sze 16 holes, and seal plug for sze 20 holes. See Fgure 2. Contact retenton fngers wll not engage f contact assembles are nserted nto plug housng cavty whle the plug spacer (TPA) s n the closed poston. Check to be sure the plug spacer s n the open, or as-shpped poston. See Fgure 2. Proceed as follows: 1. To nsert a termnated contact, push t straght nto the approprate crcut cavty as far as t wll go. See Fgure Pull back on the contact wre wth a force or 8.9 to 13.3 N [2 to 3 lbs] to be sure the retenton fnger s holdng the contact. Plug Assembly Seal Cover Sze 20 Seal Plug Retenton Fnger Termnated Contact Crcut Cavty Sze 16 Seal Plugs Back of Connector Seal Cover Socket Contact Spacer n Open Poston Fgure 2 3 of 12

4 3. After all requred contacts have been nserted, the spacer must be closed to ts locked poston. Release the lockng latches by squeezng them nward and slde the spacer forward untl t s flush wth the housng plug assembly. See Fgure 3. The spacer should seat wth a force of 56 N [12.5 lbs]. If the spacer does not seat, verfy that all contacts are fully nserted. Spacer (Unlocked) Preset Latch Plug Connector Spacer Spacer Closed to Locked Poston Fgure 3 4. Assemble the wre dress cover and dress wres as shown n Fgure Bolt the wre dress cover to the electroncs module usng customer suppled hardware. See Paragraph Wres Wre Condut Openng Plug Connector Locked n Place Wre Dress Cover Plug Connector 3.7. Plug Dsassembly Procedures Fgure 4 Refer to Fgure 5 and proceed as follows: 1. To remove the wre dress cover, loosen the two bolts holdng the wre dress cover to the electroncs module. 4 of 12

5 2. Cut the wre te around the condut, and release the four latch legs gong nto the plug assembly. See Fgure 5. Wres Wre Condut Openng Latch Leg Wre Dress Cover Plug Assembly Screwdrver Enters from Rear of Wre Dress Cover and Gently Pushes Down to Release Latch Legs Remove Plug Assembly from Wre Dress Cover Fgure 5 3. To remove the plug spacer, nsert any hooked tool nto the openng around the jackscrew. Rotate the tool to catch the underneath the spacer. Pull spacer straght out from the plug housng. See Fgure 6 CAUTION Do not pry aganst the wall of the plug housng, as damage to the connector sealng system could occur. Hooked Tool Removng Plug Spacer Plug Assembly Fgure 6 4. Insert a 1.4 mm screwdrver nto the contact cavty and deflect the retenton fnger holdng the contact. Gently pull the wre untl the contact s free from the housng. Repeat ths procedure for the remanng number of contacts to be removed as shown n Fgure 7. 5 of 12

6 Retenton Fnger Contact 1.4 mm Screwdrver 3.8. Prnted Crcut Boards Fgure 7 A. Thckness The header assembly has been desgned to accommodate a pc board thckness of 2 mm thck. Contact the Product Informaton Center or the Toolng Assstance Center at the number lsted at the bottom of page 1 for sutablty of other board thcknesses. B. Tolerance The maxmum bow of the pc board shall be 0.03 mm over the length of the header assembly. C. Layout The mountng and contact holes n the pc board must be precsely located to ensure proper placement and optmum performance of the header assembly. The X and Y symbols on the pc board layout represent customer establshed datums. They are the orgn for the basc dmenson (XXX and YYY datum), the pont from whch ALL hole postons must be located. Desgn the pc board usng the dmensons provded n Fgure 8. Fgure 8 6 of 12

7 3.9. Contact Holes The holes n the pc board for all contacts must be prepared as specfed n Fgure 9. : The drlled hole dameter must be szed so that the dameter of the fnshed hole after platng meets the dmensons as shown. Pad Dameter (As Requred) Trace Wdth (As Requred) Flm Fnshed Hole Dameter (After Platng) 2.14 ±0.10 for Sze 16 Crcuts and 1.55 ±0.10 for Sze 20 Crcuts Contact Solder Tne Drlled Hole Dameter (As Requred) Hold-Down Drlled Hole Dameter 3.35 ±0.10 (Unplated) PC Board Thckness (See Paragraph 3.8.A) Rgdzer Fgure Header Assembly Applcaton Ths connector s for a vertcal, surface mount applcaton wth pc boards. The header housng has a case seal for sealng aganst electronc module housngs Header Assembly Placement Make sure that the case seal o-rng s properly placed nsde the groove on the bottom sde of the header assembly before matng to the rgdzer. The seal should not be bunched up or poppng out of ts retenton features. 1. The header assembly contans two plastc posts on the undersde whch are meant to polarze the header through the rgdzer and pc board. 2. All sx mountng screws must be torqued through the rgdzer plate nto the header assembly. The torque shall be 2.25 ±.22 N m [20 ±2 n-lbs]. 3. Check for proper placement of the header nterface seal, whch sts nsde the header pocket. Ths seal should be flush aganst the bottom of the pocket. See Fgure 10. CAUTION The nterface seal and case seal must be n place to use the connector. Removng ether seal wll result n module falures. 7 of 12

8 Rgdzer Header Assembly Case Seal O -Rng Polarzng Post Mountng Screws (6) Polarzng Post PC Flm Solderng Header Assembly Fgure 10 The 68-Poston Heavy Duty Hybrd Connector Header Assembly may be soldered to the pc board wth an nfrared reflow process, provded the temperature and exposure tme s wthn the ranges specfed n Fgure 11. TE recommends the use of SN60 or SN62 solder for the connectors. Refer to Paragraph 2.5 for documentaton materal that s avalable for establshng solderng gudelnes. SOLDERING PROCESS CELSIUS TEMPERATURE (DEGREES) FARENHEIT TIME (At Max Temperature) Infrared Reflow Solderng Seconds Fgure 11 A. Flux Selecton The connector solder tnes must be fluxed pror to solderng wth a mldly actvated rosn base flux. Selecton of the proper flux wll depend on the type of pc board and other components mounted to the board. B. Reflow Parameters Due to the many varables nvolved wth the reflow process (e.g., component densty, orentaton, etc.), TE recommends that the user conduct tral runs under actual manufacturng condtons to ensure product and process compatblty. C. Cleanng After solderng, removal of fluxes, resdues, and actvators s necessary. Consult wth the suppler of the solder and flux for recommended cleanng solvents. For a lst of common cleanng solvents that wll not affect the connectors or assembles for the tmes and temperatures provded wthout any adverse effects on the connector assembly, refer to Fgure 12. DANGER Consderaton must be gven to toxcty and other safety requrements recommended by the solvent manufacturer. Trchloroethylene and Methylene Chlorde can be used wth no harmful affect to the connectors; however TE does not STOP recommend them because of the harmful occupatonal and envronmental effects. Both are carcnogenc (cancer-causng) and Trchloroethylene s harmful to earth ozone layer. 8 of 12

9 If you have a partcular solvent that s not lsted, contact the Toolng Assstance Center or Product Informaton number at the bottom of Page 1. CLEANER TIME TEMPERATURES, DEGREES (Maxmum) NAME TYPE (Mnutes) CELSIUS FARENHEIT Alpha 2110 Aqueous Boact EC-7 Solvent Butyl Carbtol Solvent 1 Room Ambence Isopropyl Alcohol Solvent Kester 5778 Aqueous Kester 5779 Aqueous Loncoterge 520 Aqueous Loncoterge 530 Aqueous Terpene Solvent Solvent Product of Fry s Metals, Inc. Product of Petroferm, Inc. Product of Unon Carbde Corp. Product of Ltton Systems, Inc. Fgure 12 D. Dryng CAUTION Excessve temperatures may cause housng degradaton. Do NOT solder the header assembly wth the plug connector or wre dress cover attached to t. E. Checkng Installed Connector All solder jonts should conform to those specfed n Workmanshp Specfcaton The mountng screws must be torqued to 2.25 ±0.22 N m [20 ± 2 n-lbs]. The housng wall should be almost flush aganst the rgdzer. See Fgure 13. Header Assembly Rgdzer Screw(s) Fgure 13 PC Flm 9 of 12

10 3.13. Polarzaton and Keyng Features The header assembly has key slots on the sdes of the pocket whch wll accept correspondng keyng protrusons from the plug assembly. There are four dfferent possble keyng arrangements. See Fgure Partally Blocked Latch Slots (-4 Confguraton) Partally Blocked Latch Slots (-3 Confguraton) Partally Blocked Latch Slots (-2 Confguraton) Partally Blocked Latch Slots (-1 Confguraton) Fgure 14 The plug assembly has polarzed latch holes for matng wth the wre dress cover. Two of the latch slots wll be partally blocked, allowng the wre dress cover to only be mated n one drecton. See Fgure of 12

11 Latch Leg Wre Dress Cover Polarzed Latch Hole Slots (Fully Open) (2) Plug Assembly Header Assembly Mountng Hardware Fgure 15 Sx customer suppled No screws are requred to mount the header assembly to the rgdzer. Also, to mount the wre dress cover to the electronc module, two customer suppled screws are requred. These screws must have a shaft of <7.0 mm dameter, and a head flange dameter > 9.0 mm Readng Voltage Durng Servce CAUTION Do NOT perce wre nsulaton to take voltage readngs. It has been common practce n electrcal troubleshootng to probe wres by percng the nsulaton wth a sharp pont. Ths practce must be strongly dscouraged when dealng wth the 68-Poston Heavy Duty Hybrd Connector System, or any other sealed connector system. The resultng pnholes n the nsulaton wll allow mosture to nvade the system by travelng along the wre strands. Ths nullfes the effectveness of the connector seals and may result n system falure Repar/Replacement Damaged crmped contacts or housngs must be removed, dscarded, and replaced wth new components. Damaged pc board connectors must be removed from the pc board by standard desolderng methods and replaced. CAUTION If a damaged contact s apparent before the contacts are nserted nto the housng, cut the wre n back of the contact and retermnate the wre end. If contacts or housng are damaged after nserton, the wre must be cut drectly n back of the housng and retermnated wth new contacts and housng. 4. QUALIFICATIONS The 68-Poston Heavy Duty Hybrd Connector s not requred to be agency approved. 5. TOOLING No specfc applcaton toolng s requred for the applcaton of the 68-Poston Heavy Duty Hybrd Connector. Informaton for crmp termnaton toolng for the contacts s avalable n Applcaton Specfcatons and of 12

12 6. VISUAL AID Fgure 16 shows a typcal applcaton of 68-Poston Heavy Duty Hybrd Connector. Ths llustraton should be used by producton personnel to ensure a correctly appled product. Applcatons whch DO NOT appear correct should be nspected usng the nformaton n the precedng pages of ths specfcaton and n the nstructonal materal shpped wth the product or toolng. WIRE AND INSULATION MUST BE VISIBLE IN THIS AREA OPTIONAL SEAL PLUGS MUST BE FULLY SEATED IN PLUG HOUSING WIRE BARREL SEAM MUST BE CLOSED WITH NO CONDUCTOR STRANDS SHOWING FRONT AND REAR BELLMOUTH MUST BE VISIBLE CONTACTS MUST BE FULLY SEATED IN PLUG HOUSING NO DAMAGE TO CONTACT MATING END PLUG ASSEMBLY AND WIRE DRESS COVER MUST BE LOCKED IN PLACE WITH ALL (4) LATCH LEGS ALL CAVITIES MUST BE FILLED : PC BOARD AND RIGIDIZER REMOVED FOR CLARITY ALL WIRES MUST EXIT WIRE DRESS COVER MOUNTING SCREWS MUST BE SECURELY FASTENED JACKSCREW MUST BE FIRMLY TIGHTENED HEADER ASSEMBLY MUST BE SEATED ON RIGIDIZER FIGURE 16. VISUAL AID 12 of 12