Application Specification
114-1075
Z-PACK* 2mm FB (Futurebus+)
LOC B
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E
2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.
TOOLING ASSISTANCE CENTER 1-800-722-1111
PRODUCT INFORMATION 1-800-522-6752 This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at
www.tycoelectronics.com
Receptacle and Pin Header Connectors
23 MAR 09 Rev D
All numerical values are in metric units [with U.S. customary units in brackets]. Dimensions are in millimeters. Unless
otherwise specified, dimensions have a tolerance of +0.13 and angles have a tolerance of +2
_
. Figures and
illustrations are for identification only and are not drawn to scale.
1. INTRODUCTION
This specification covers the requirements for application of the Z–PACK 2mm FB (Futurebus+) Receptacle
and Pin Header Connectors for printed circuit (pc) board applications. The connectors have in–row and
row–to–row centerline spacing of 2mm. They are available in either 4– or 5–row configurations.
The connectors use an open pin field construction (no ground planes) for high signal density and require
minimal pc board space. The receptacles are right–angle configurations and the pin headers are both vertical
and right–angle configurations; both are available with either solder tine or press–fit compliant pin contacts.
Accessories and their identifying features are described and shown in Section 3 of this specification.
When corresponding with Tyco Electronics Personnel, use the terminology provided on this specification to
help facilitate your inquiry for information. Basic terms and features of components are provided in Figure 1.
Figure 1 (cont’d)
Alignment
Rib
End
Stabilizers
Signal Pin
Contact
4-Row Right-Angle Power
Receptacle Connector
Back/Top Surface
of Housing
Press-Fit
Compliant
Pin Contact
Plastic Retention
Post
Alignment Rib Slot
with Guide-In
Standoff
4-Row Vertical Power
Pin Header Connector
Solder Tine
Contact
Contact
Shoulder
4-Row Right-Angle
Signal Receptacle
Connectors
4-Row Vertical Signal
Pin Header Connectors
Center
Stabilizer
Signal Receptacle
Contacts (Inside)
Retention Post
Seating Area
Guide Post for
Solder Type Only
Press-Fit
Compliant Pin
Contact
Power Pin
Contact
Power Receptacle
Contacts (Inside) Solder Tine
Contact
NOTE
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Figure 1 (end)
Alignment
Rib
End
Stabilizers
Signal Pin
Contact
5-Row Right-Angle Power
Receptacle Connector
Back/Top Surface
of Housing
Press-Fit
Compliant
Pin Contact
Plastic Retention
Post
Alignment Rib Slot
with Guide-In
Standoff
5-Row Vertical Power
Pin Header Connector
Solder Tine
Contact
Contact
Shoulder
5-Row Right-Angle
Signal Receptacle
Connectors
5-Row Vertical Signal
Pin Header Connectors
Center
Stabilizer
Signal Receptacle
Contacts (Inside)
Retention Post
Seating Area
Guide Post for
Solder Type Only
Power Pin
Contact
Power Receptacle
Contacts (Inside) Solder Tine
Contact
Press-Fit
Compliant Pin
Contact
2. REFERENCE MATERIAL
2.1. Revision Summary
This paragraph is reserved for a revision summary of the most recent additions and changes made to this
specification which include the following:
S
Updated document to corporate requirements
S
Deleted obsolete part numbers and documents in Paragraph 2.6 and Section 5, TOOLING
S
Changed dimension line in Figure 5
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2.2. Customer Assistance
Reference Part Number 536507 and Product Code 1830 are representative numbers of Z–PACK 2mm FB
Receptacle and Pin Header Connectors. Use of these numbers will identify the product line and expedite your
inquiries through a service network established to help you obtain product and tooling information. Such
information can be obtained through a local Tyco Electronics Representative or, after purchase, by calling the
Tooling Assistance Center or Product Information number at the bottom of page 1.
2.3. Drawings
Customer Drawings for specific products are available from the service network. The information contained in
Customer Drawings takes priority if there is a conflict with this specification or with any other technical
documentation supplied by Tyco Electronics
2.4. Manuals
Manual 402–40 is available from the service network. This manual provides information on various flux types
and characteristics along with the commercial designation and flux removal procedures. A checklist is included
in the manual as a guide for information on soldering problems.
2.5. Specifications
Product Specification 108–1441 provides test and performance requirements.
2.6. Instructional Material
The following list includes available instruction sheets (408–series) that provide assembly procedures for
product, operation, maintenance and repair of tooling, as well as setup and operation procedures of
applicators.
Document Number Document Title
408–4038 PC Board Support Fixtures 679980–1, –2 for Z–PACK 2mm FB (Futurebus) and
2mm HM Receptacle Tooling
408–4157 Vertical Power Contact Header Connector Seating Tool 58512–[ ] (4–Row)
408–4250 Vertical Signal Contact Header Connector Seating Tool 318860–[ ] (5–Row)
408–4488 Vertical Power Contact Header Connector Seating Tool 1214224–[ ] (5–Row)
408–9910 Vertical Signal Contact Header Connector Seating Tools 58511–[ ] (4–Row)
408–9979 Pin Repair Kit 354687–1
3. REQUIREMENTS
3.1. Storage and Chemical Exposure Limitations
A. Storage
Connectors are packaged and shipped in protective anti–static tubes. To prevent damage to the housing
and contact tines, connectors should remain in tubes until ready for use. They should be stored at normal
room temperatures with low humidity, and used on a first in, first out basis.
B. Chemical Exposure Limitations
Do not store connectors near any chemicals listed, as they may cause stress corrosion cracking in the
components.
Alkalies Ammonia Citrates Phosphates Citrates Sulfur Compounds
Amines Carbonates Nitrites Sulfur Nitrites Tartrates
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3.2. Connector Features
A. Materials
All Z–PACK 2mm FB Connector Housings are constructed of high–temperature thermoplastic. The signal
and power pin contacts are phosphor bronze and plated at the contact interface with gold flash over
palladium–nickel. The signal receptacle contacts are copper alloy and plated at the contact interface with a
gold flash over palladium–nickel. Power receptacle contacts are beryllium copper and plated at interface
with a gold flash over palladium–nickel. All contacts have a nickel underplate and tin or tin–lead tines.
B. Size
Connectors are available in three types: all–signal, all–power, and signal/power mix. The 4–row signal
connectors are available in a range of 12–mm–length (24 positions) to 132–mm–length (264 positions) in
increments of 12 mm. Also, the 4–row power connectors are available in 12–mm–length (8 positions) only.
The 5–row signal connectors are available in a range of 12–mm–length (30 positions) to 132–mm–length
(330 positions) in increments of 12 mm. Also, the 5–row power connectors are available in 12–mm–length
(10 positions) only. Signal/power mix connectors are available in any configuration in a range of 24 mm to
132 mm in increments of 12 mm.
The contact type and length for each connector type is provided in Figure 2.
A
B
C
A
C
Vertical Pin
Header
Connector
Right-Angle
Receptacle
Connector
Right-Angle Pin
Header
Connector
NOTE:
4-row shown, 5-row is the same for dimensioning purposes.
CONNECTOR CONTACT
TYPE
CONFIGURATION
TYPE
DIMENSION (Length)
TYPE
CONFIGURATION
TYPE
A B C
Vertical
Solder
50 575 65
3.20, 4.25
Vertical
Pin Header Compliant Pin
5
.
0
,
5
.
75
,
6
.
5
,
7.25, 8.0 4.25, 11.8, 13.6,
15.6, 17.0
---
Signal Right-Angle Solder
50
2.73
g
gg
Header Compliant Pin
5
.
0
--- 3.35
Right-Angle Solder 2.73, 3.53
gg
Receptacle Compliant Pin --- --- 3.55
Vertical Solder
65 725 80
3.20, 4.25,
Power
Pin Header Compliant Pin
6
.
5
,
7
.
25
,
8
.
0
4.25 ---
Power
Right-Angle Solder 2.73, 3.53
gg
Receptacle Compliant Pin --- --- 3.56
Figure 2
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C. Guides
The pin headers have alignment slots with a guide–in that helps position the pin and socket contacts prior
to engagement of the circuits. See Figure 1.
D. End-to-End Placement
The end contacts in the pin header and receptacle are one half the contact spacing distance from the ends
of the housing. This design feature makes it possible to mount connectors end–to–end while maintaining
the 2 mm grid pattern. When making this type of application, note that the contacts in the pin header are
closer to one side of the housing to allow space for the mating pc board. The contacts and board slots
must be aligned with each other when mating with a continuous pc board connector. Connectors can be
mounted end–to–end within the specified dimension. See Figure 3.
Figure 3
Joining
Ends
2mm
Pin Header Connectors Receptacle Connectors
1mm
2mm
1mm
NOTE:
4-row shown, 5-row is the same for dimensioning purposes.
3.3. Alignment
Proper alignment is essential to ensure full engagement of mating connectors, and to ensure that contacts are
not bent or otherwise damaged during mating and unmating. For tolerance limitations, see Figure 4.
Figure 4
Receptacle
Pin
Header
PC Board (Typ)
2.5 2.5 1.5
(2 Places)
9.2 (Min)
+2
_
+2
_
NOTE:
4-row shown, 5-row is the same for dimensioning purposes.
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3.4. Mating Dimension
Full mating of connectors is necessary to ensure a good connection. The dimension from the surface of the pc
board to which the pin header is mounted and the first row of contacts in the receptacle must be as shown in
Figure 5.
Figure 5
Standoff PC Board
Retention Post
PC Board
1.50
Right Angle-to-Vertical
Right Angle-to-Right Angle
10.00
Retention Posts 11.00
1.50
PC Board PC Board
NOTE:
4-row shown, 5-row is the same for dimensioning purposes.
3.5. PC Board Requirements
A. PC Board Thickness
Right–angle receptacle and right–angle pin header connectors with compliant pins require a pc board with
a minimum thickness of 1.30 mm. Those with solder tines will accommodate any pc board thickness that
allows the tine to protrude a minimum of 1.00 mm from the bottom surface of the pc board.
Vertical pin header connectors with compliant pin contacts require a pc board with a minimum thickness of
2.40 mm. Pin header connectors with solder tines will accommodate any pc board thickness that allows
the solder tines to protrude a minimum of 1.00 mm from the bottom surface of the pc board.
Mating pc boards for pin header connectors require a maximum allowable thickness of 2.50 mm.
B. PC Board Circuit Pattern Layout
The pc board layout patterns for the placement of Z–PACK 2mm FB Pin Header and Receptacle
Connectors are provided in Figure 6.
For applications requiring the minimum installation force for the connector, the pc board through-hole size should favor
the high end of the allowable tolerance. For applications using IR or vapor phase soldering techniques in conjunction
with solder paste, through-hole size should favor the low end of the allowable tolerance to ensure optimum solder fill.
NOTE
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Figure 6 (cont’d)
Recommended 4-Row PC Board Circuit Pattern
Layouts (Component Side)
Vertical Connectors Right-Angle Connectors
Recommended 5-Row PC Board Circuit Pattern
Layouts (Component Side)
Vertical Connectors Right-Angle Connectors
NOTE:
Vertical connector pc board layouts are the same for both solder type and press fit except press fit does not have guide
post holes. Right-angle connector pc board layouts are the same for both solder type and press-fit.
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Recommended 4-Row PC Board Circuit Pattern
Layouts (Component Side)
Right-Angle Power
Module Connectors
Vertical Power
Module Connectors
Recommended 5-Row PC Board Circuit Pattern
Layouts (Component Side)
NOTE:
Vertical connector pc board layouts are the same for both solder type and press fit except press fit does not have guide
post holes. Right-angle connector pc board layouts are the same for both solder type and press-fit.
Right-Angle Power
Module Connectors
Vertical Power
Module Connectors
Figure 6 (cont’d)
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NUMBER OF SIGNAL POSITIONS
DIMENSION B
DIMENSION C
4-ROW 5-ROW
DIMENSION B
DIMENSION C
---
630 125 250
--- 540 107 214
264 330 65 130
240 300 59 118
216 270 53 106
192 240 47 94
168 210 41 82
144 180 35 70
120 150 29 58
96 120 23 46
72 90 17 34
48 60 11 22
24 30 5 10
Figure 6 (end)
C. Contact Hole Configuration
The contact holes in the pc board for all connectors must be prepared to the dimensions specified in
Figure 7.
1.12 Min
Pad Diameter
0.025-0.050
Copper Plating
0.65-0.80 (Ref)
Diameter of Finished
Hole After Plating
FR-4
Material
ÉÉÉÉÉ
ÉÉÉÉÉ
ÉÉÉÉÉ
ÉÉÉÉÉ
ÉÉÉÉÉ
ÉÉÉÉÉ
ÉÉÉÉÉ
ÏÏ
ÏÏ
ÏÏ
ÏÏ
ÏÏ
ÏÏ
ÌÌ
ÌÌ
ÌÌ
ÌÌ
ÌÌ
ÌÌ
Ï
Ï
Ï
Ï
Ï
Ï
Ï
Ì
Ì
Ì
Ì
Ì
ÉÉÉÉÉ
ÉÉÉÉÉ
ÉÉÉÉÉ
ÉÉÉÉÉ
ÉÉÉÉÉ
ÉÉÉÉÉ
ÉÉÉÉÉ
0.81-0.86
Drilled Hole
Diameter
PC Board Thickness
(See Paragraph 3.5)
Surface Finish (See Table Below)
SURFACE FINISH
THICKNESS PLATING
0.004-0.010 Hot Air Solder Leveling (HASL) Tin-Lead (Sn Pb)
0.0005-0.004 Immersion Tin (Sn)
0.0002-0.0005 Organic Solderability Preservative (OSP)
0.0001-0.0005 Au,
0.00127-0.0076 Ni Immersion Gold (Au) Over Nickel (Ni) (ENIG)
0.0001-0.0005 Immersion Silver (Ag)
Figure 7
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3.6. Special Handling
A. Initial Positioning
Prior to positioning a connector, the pc board should be placed on an appropriate board support fixture.
Connectors should be gripped by the housing only and not by the contacts. When placing a connector into
a pc board, all contact pins should be aligned and inserted into the pc board simultaneously to prevent
twisting or bending of the contacts. If using robotic equipment, a total equipment accuracy of +0.13 mm,
including the gripper and fixture tolerance and equipment repeatability, is required.
B. Seating Connectors
Seating force must be applied evenly on the connectors to prevent deformation or other damage to the
contacts and housings. The standoffs must be within 0.13 mm of the pc board (after insertion or
soldering). Refer to Paragraph 3.8.
When installing vertical pin header connectors with compliant pins, the insertion force must be
simultaneously applied to the shoulder of each contact on the inside floor surface of the connector. When
installing right–angle connectors with compliant contact pins, the insertion force must be evenly applied to
the back/top surface of the connector housing (see Figure 1) with a force of approximately 67 N per pin.
When installing vertical pin header connectors with solder tines, the insertion force must be evenly
distributed to the inside floor surface of the connector. When installing right–angle connectors with solder
tines, the insertion force must be evenly applied to the back/top surface of the connector housing (See
Figure 1) with a force of approximately 40 N per each 12 mm of length of the connector. Connectors will
remain securely on the pc board until passed through soldering providing that they are not jarred in any
manner. Tooling recommendations are covered in Section 5.
3.7. Soldering
Connectors with solder tines must be soldered to the pc board.
A. Flux Selection
The solder tines must be fluxed prior to soldering with a rosin base flux. Selection of the proper flux will
depend on the type of pc board and other components mounted on the pc board. The flux must be
compatible with the wave solder line, and all manufacturing and safety requirements.
To avoid personal injury, strict attention must be given to the recommendations of the solvent manufacturer regarding
toxicity and other safety requirements. Request the Material Safety Data Sheet (MSDS) from the supplier.
B. Cleaning
After soldering, removal of fluxes, residues, and activators is necessary. Consult with the supplier of the
solder and flux for recommended cleaning solvents. A list of common cleaning solvents that will not affect
the connectors for the time and temperature specified is provided in Figure 8.
CLEANER TIME TEMPERATURES (Max)
NAME TYPE (Minutes) CELSIUS FAHRENHEIT
ALPHA 2110 Aqueous 1 132 270
BIOACT EC-7 Solvent 5 100 212
CARBITOL Solvent 1 Room Ambience
Isopropyl Alcohol Solvent 5 100 212
KESTER 5778 Aqueous 5 100 212
KESTER 5779 Aqueous 5 100 212
LONCOTERGE 520 Aqueous 5 100 212
LONCOTERGE 530 Aqueous 5 100 212
Terpene Solvent Solvent 5 100 212
Figure 8
C. Drying
When drying cleaned assemblies and pc boards, do not exceed the temperature limitations of –55
_
to
125
_
C [–99
_
to 225
_
F]. Excessive temperatures may cause housing degradation.
DANGER
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D. Soldering Guidelines
Refer to Paragraph 2.4 for reference Manual 402–40 that is available for establishing soldering guidelines.
3.8. Inspection
A. Solder Fillets
All solder fillets should comply to the Workmanship Standard 101–21. For a typical fillet for these
connectors, refer to Figure 9.
B. Housing Stand-Offs
The connector housing standoffs must be seated within the dimension shown in Figure 9 of the pc board
(after insertion or soldering).
Figure 9
Typical Solder
Fillet
Flush to
Within 0.13
Right-Angle
Type Connector
Vertical Pin Header
Type Connector
Flush to
Within 0.13
NOTE:
4-row shown, 5-row is the same for dimensioning purposes.
3.9. Repair
Damaged contacts can not be removed from receptacle housing connectors. The entire connector will have to
be removed and replaced with a new one.
A. Right-Angle Receptacles with Solder Tines
Before removing the connectors from the pc board, remove solder from all solder tines by heating them
and removing the solder fillet. Do NOT apply heat to the pc board, otherwise you could damage
plated–through holes. After solder is removed, grip the center of the housing with a pair of pliers and pull
the connector straight away from the pc board. Drill the holes with a 0.60 mm drill bit; then clean the holes.
Insert a new connector and solder it using standard hand soldering technique. See Figure 10.
Figure 10
PC Board
Retention Post
(Plastic Material)
Pliers
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B. Right-Angle Connectors with Compliant Pins
Place the connector in a housing support that has a slot wide enough and deep enough to receive the full
length of the housing and contacts. Make sure the tool support will not interfere with any other
components on the pc board. Apply an even force simultaneously to all compliant pins with a push bar and
press capable of applying 100 N per pin. See Figure 11.
Figure 11
Push Bar
Housing
Support
Housing
Support
Force Force
Force Force
Push Bar
Open Space
Open Space
C. Vertical Pin Headers with Solder Tines
Individual solder tine contacts can be removed by removing the solder fillet and gripping the front of the
contact with a pair of needle–nosed pliers and pulling it straight out the front of the pin header. Replace
contact with a new one.
D. Vertical Pin Headers with Compliant Pins
Individual compliant pin connector contacts can be removed and replaced with a new one without
removing the pin header module from the pc board. If the pin header housing is damaged, the entire
connector must be removed and replaced with a new one. In either case, the pc board must be firmly
supported while in–line force is applied on the contact pin. Replace contact with a new one. See Section 5
for recommended impact repair tool.
4. QUALIFICATION
These connectors meet Institute of Electrical and Electronic Engineers (IEEE), Electronic Industries
Association (EIA), and International Electrotechnical Commission (IEC) specifications for printed circuit boards.
Z–PACK 2mm FB Connectors are Component Recognized by Underwriters Laboratories Inc. (UL) in File
E28476 and Certified by CSA International in File No. LR7189.
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5. TOOLING
Tyco Electronics has existing tooling and tooling concepts for applying these connectors. Part numbers of
available tools and the applicable instructional material for each is provided in Figure 12.
S
Robotic Equipment
Robotic equipment for placement of connectors on a pc board must have a true position accuracy of
0.13 mm to ensure proper location and insertion of the contact pins. This includes gripper and fixture
tolerances as well as equipment repeatability. It must use the connector datum surface to ensure reliable
connector placement. If you need assistance in setting up prototype or production line equipment,
contact Tooling Engineering through your local Tyco Electronics Representative or call the Tooling
Assistance Center number at the bottom of page 1.
S
Seating Tool
Seating tools are designed to push evenly on the shoulders of the vertical pin contact and force the
compliant pins into the pc board. See Figure 1.
S
Push Bar
Commercially available bar stock with a flat surface large enough to cover the top surface of right–angle
connectors and capable of exerting 67 N per pin can be used as a push bar to seat the compliant pin
and solder tine connectors onto the pc board. The same type tooling can be used to remove damaged
right–angle connectors from a pc board by pressing evenly on the compliant end of the contacts.
S
PC Board Support
A pc board support must be used to prevent bowing of the pc board during insertion of the connectors. It
should have a flat surface with holes or a channel large enough to receive the pins during installation.
S
Housing Support
A housing support with sides and ends as close as possible to the receptacle housing is recommended
for removing damaged receptacle connectors from pc boards.
S
Repair Tool
A repair tool kit consisting of a spring–loaded impact tool handle assembly, a removal tip, and a
replacement tip is available for removing damaged compliant pin contacts and replacing them with new
ones. The housing must be supported and the contact must be free to back out of housing with a
suitable housing support that will not damage housing.
The tooling referenced in Figure 12 may be used for both compliant pin and solder type connectors.
Typical Seating
Tool (See Table)
PC Board Support Fixture
(Customer Supplied)
PC Board Support Fixture
679980-1 or -2 With Bottom
Support Anvil 679977-1 or -2
(408-4038)
H-Frame Power
Unit 803880-6
Figure 12 (cont’d)
NOTE
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Pin Repair Kit 354687-1
(For Removing and
Replacing Damaged
Contacts (408-9979)
Robotic
Equipment
(Typ) Push Bar
(Customer Supplied)
Housing Support
(Customer Supplied)
CONN
O
(4-ROW) (5-ROW)
MODULE
TYPE POSN SEATING TOOL
(DOCUMENT) POWER UNIT
(DOCUMENT) POSN SEATING TOOL
(DOCUMENT) POWER UNIT
24 58511-1 (408-9910) 30 318860-1 (408-4250)
48 58511-2 (408-9910) 60 318860-2 (408-4250)
72 1-58511-4 (408-9910) 90 318860-3 (408-4250)
96 58511-3 (408-9910) 120 318860-4 (408-4250)
120 58511-6 (408-9910) 150 318860-5 (408-4250)
144 58511-5 (408-9910) 180 318860-6 (408-4250)
Signal 168 58511-7 (408-9910) 803880-6 (409-5567)
814700-2
(
409-5626
)
210 318860-7 (408-4250)
192 58511-4 (408-9910)
()
240 318860-8 (408-4250)
216 58511-8 (408-9910) 270 318860-9 (408-4250)
240 58511-9 (408-9910) 300 1-318860-0 (408-4250)
330 1-318860-1 (408-4250)
803880-6
264 1-58511-0 (408-9910) 540 1-318860-3 (408-4250)
803880
-
6
630 1-318860-2 (408-4250)
Power
8 58512-1 (408-4157) 803880-6 (409-5567)
1214224-1 (408-4488)
Power
16 58512-2 (408-4157)
()
814700-2 (409-5626)
1214224
-
1 (408
-
4488)
8P-96S 1-58511-7 (408-9910)
8P-120S 1-58511-8 (408-9910)
Hybrid
S/
8P-144S 1-58511-3 (408-9910)
y
Signal/
Power 8P-192S 1-58511-1 (408-9910) 803880-6 (409-5567)
814700-2
(
409-5626
)
10P-30S 1-318860-4 (408-4250)
Mix 8P-216S 1-58511-2 (408-9910)
()
16P-192S 1-58511-6 (408-9910)
16P-216S 1-58511-5 (408-9910)
Figure 12 (end)
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6. VISUAL AID
Figure 13 shows a typical application of Z–PACK 2mm FB Connectors. This illustration should be used by
production personnel to ensure a correctly applied product. Applications which DO NOT appear correct should
be inspected using the information in the preceding pages of this specification and in the instructional material
shipped with the product or tooling.
FIGURE 13. VISUAL AID
CONNECTOR
HOUSING MUST
BE SEATED
ON PC BOARD
CONTACTS MUST BE IDENTICAL
(SIGNAL TO SIGNAL AND
POWER TO POWER)
WIDEST SECTION OF
COMPLIANT PIN MUST BE
INSIDE PC BOARD HOLE
OVERALL LENGTH OF
PIN HEADERS AND RECEPTACLES
MUST BE THE SAME
PINS MUST NOT
BE BENT
MATING CONNECTORS
(SIGNAL OR POWER)
MUST MATCH
SOLDER FILLETS MUST BE
360
_
AROUND SOLDER TINES
WITH NO SKIPS OR VOIDS