1601120-1 - Tyco Electronics

DESIGN OBJECTIVES 04Mar10

Design

Objectives 108-2244

Rev O3

Fine Range SIAMEZE* Insulation Displacement Terminals

Harrisburg, PA

All International Rights Reserved.

* Trademark

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LOC B

DESIGN OBJECTIVES

The product described in this document has not been fully tested to ensure conformance to the requirements outlined below. Therefore

Tyco Electronics makes no representation or warranty, express or implied, that the product will comply with these requirements. Further,

Tyco Electronics may change these requirements based on the results of additional testing and evaluation. Contact Tyco Electronics

Engineering for further details.

1. SCOPE

1.1. Content

This specification covers performance, tests and quality requirements for the Tyco Electronics Fine

Range SIAMEZE* Insulation Displacement Terminals designed for general use as a magnet wire to

external interface when inserted into a plastic pocket (cavity) designed to Tyco Electronics guidelines.

The terminal is compatible with Single and Double build copper magnet wire 27 through 36 AWG (0.36

through 0.13 mm). Unless otherwise specified on the Tyco Electronics Customer drawing, connection is

to be made to an individual magnet wire or solid bare wire.

1.2. Qualification

When tests are performed on the subject product line, procedures specified in Figure 1 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. Unless

otherwise specified, the latest edition of the document applies. 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. Tyco Electronics Documents

!114-13166: Application Specification (SIAMEZE Standard and Fine Range Terminals)

!501-(TBD): Qualification Test Report (Fine Range SIAMEZE* Insulation Displacement Terminals)

2.2. Industry Standard

EIA-364: Electrical Connector/Socket Test Procedures Including Environmental Classifications

2.3. Reference Document

109-197: Test Specification (AMP Test Specifications vs EIA and IEC Test Methods)

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

Materials used in the construction of this product shall be as specified on the applicable product

drawing.

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3.3. Performance and Test Description

Product is designed to meet the electrical, mechanical and environmental performance requirements

specified in Figure 1. Unless otherwise specified, all tests shall be performed at ambient environmental

conditions. All electrical and environmental tests shall be performed with the terminals inserted into a

Tyco Electronics bobbin with a connection configuration per Figure 4.

3.4. Test Requirements and Procedures Summary

Test Description Requirement Procedure

Initial examination of product. Meets requirements of product

drawing. EIA-364-18.

Visual and dimensional (C of C)

inspection per product drawing.

Final examination of product. Meets visual requirements. EIA-364-18.

Visual inspection.

ELECTRICAL

Low level contact resistance. 20% maximum increase from initial

LLCR reading.

See Figure 3.

EIA-364-23.

Subject specimens to 100

milliamperes maximum and 20

millivolts maximum open circuit

voltage.

Current cycling. See Figure 4. EIA-364-55, Test Condition A, Test

Method 2.

Subject specimens to 100% of rated

current for wire size being tested for

250 cycles of 15 minutes ON and

15 minutes OFF.

MECHANICAL

Retention force. 45 N [10 lbf] minimum for single

barb.

90 N [20 lbf] minimum for multiple

barb.

See Note 1.

65 N [15 lbf] minimum for stranded

lead wire with LEAD LOK.

See Note 2.

EIA-364-8.

Determine retention force at a

maximum rate of 25.4 mm [1 in] per

minute.

ENVIRONMENTAL

Thermal shock. See Note 3. EIA-364-32.

Subject specimens to 25 cycles

between -40 and 125EC.

Humidity/temperature cycling. See Note 3. EIA-364-31, Method III.

Subject specimens to 10 cycles (10

days) between 25 and 65EC at 80 to

100% RH.

Figure 1 (continued)

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108-2244

Test Description Requirement Procedure

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Temperature life. See Note 3. EIA-364-17.Subject specimens to

118°C for 33 days.

(1) Vertical force required to extract the terminal from a pocket (cavity) molded to Tyco

NOTE Electronics guidelines in Nylon 6/6 30% GF.

(2) Vertical force required to extract a PVC insulated stranded lead wire secured with LEAD LOK

from a pocket (cavity) molded in Nylon 6/6 30% GF that complies with Tyco Electronics

specifications.

(3) Shall meet visual requirements, show no physical damage, and meet the requirements of

additional tests as specified in the Product Qualification and Requalification Test Sequence

shown in Figure 2.

Figure 1 (end)

3.5. Product Qualification and Requalification Test Sequence

Test or Examination Test Group (a)

1234

Test Sequence (b)

Initial examination of product 1111

Low level contact resistance 2,5 2,4 2,4

Current cycling 3

Retention force 2

Thermal shock 4

Humidity-temperature cycling 3

Temperature life 3

Final examination of product 6535

(a) See paragraph 4.1.A.

NOTE (b) Numbers indicate sequence in which tests are performed.

Figure 2

LEAD-LOK is a Trademark of LEAD LOK Incorporated

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4. QUALITY ASSURANCE PROVISIONS

4.1. Qualification Testing

A. Specimen Selection

Specimens shall be prepared in accordance with applicable Instruction Sheets and shall be

selected at random from current production. Each test group shall consist of 30 terminals (15

interconnected bobbin assemblies) per magnet wire size.

B. Test Sequence

Qualification inspection shall be verified by testing specimens as specified in Figure 2.

4.2. Requalification Testing

If changes significantly affecting form, fit or function are made to the product or manufacturing process,

product assurance shall coordinate requalification testing, consisting of all or part of the original testing

sequence as determined by development/product, quality and reliability engineering.

4.3. Acceptance

Acceptance is based on verification that the product meets the requirements of Figure 1. Failures

attributed to equipment, test setup or operator deficiencies shall not disqualify the product. If product

failure occurs, corrective action shall be taken and specimens resubmitted for qualification. Testing to

confirm corrective action is required before resubmittal.

4.4. Quality Conformance Inspection

The applicable quality inspection plan shall 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.

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Figure 3

Test Configuration

Wire Size

(AWG [mm i]) Current Carrying

Capacity (amperes)

27 [0.36] 3.5

28 [0.32] 3

29 [0.29] 2.5

30 [0.25] 2

31 [0.23] 1.5

32 [0.20] 1

33 [0.18] 1

34 [0.16] .75

35 [0.14] .5

36 [0.13] .25

Figure 4