Product Specification 108-1948 27Oct09 Rev B All Paragraphs Revised CST-100 Type II .100 Inch Centerline Crimp-Snap Connectors 1. SCOPE 1.1. Content This specification covers performance, tests and quality requirements for Tyco Electronics CST-100 Type II .100 Inch Centerline Crimp-Snap Connectors. The CST-100 Type II product is a wire-to-board connection consisting of crimp-snap contacts seated in a housing that mates to .025 inch square post headers on .100 inch centerline and is designed to be terminated to 22 to 26 AWG 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. 1.3. Qualification Test Results Successful qualification testing on the subject product line was completed in May02. The Qualification Test Report number for this testing is 501-542. Additional testing was completed on 10Jul09. This documentation is on file at and available from Engineering Practices and Standards (EPS). 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 ! ! ! ! 2.2. 102-950: Quality Specification (Qualification of Separable Interface Connectors) 109 Series: Test Specifications as indicated in Figure 1 114-13036: Application Specification (CST-100 II Connectors) 501-542: Qualification Test Report (CST-100 Type II .100 Inch Centerline Crimp-Snap Connectors) 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. (c)2009 Tyco Electronics Corporation Harrisburg, PA All International Rights Reserved. * Trademark | Indicates change For latest revision, visit our website at www.tycoelectronics.com\documents. 1 of 8 For Regional Customer Service, visit our website at www.tycoelectronics.com LOC B 108-1948 3.2. Materials Materials used in the construction of this product shall be as specified on the applicable product drawing. 3.3. Ratings ! ! ! 3.4. Voltage: 250 volts AC Current: See Figure 3 Temperature: -55 to 105C 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. 3.5. Test Requirements and Procedures Summary Test Description Requirement Procedure Initial examination of product. Meets requirements of product drawing and Application Specification 114-13036. EIA-364-18. Visual and dimensional inspection per product drawing. Final examination of product. Meets visual requirements. EIA-364-18. Visual inspection. Low level contact resistance. 6 milliohms maximum initial. 10 milliohms maximum final. EIA-364-23. Subject specimens to 100 milliamperes maximum and 20 millivolts maximum open circuit voltage. Insulation resistance. 1000 megohms minimum initial. 100 megohms minimum final. EIA-364-21. Test between adjacent contacts. Withstanding voltage. One minute hold with no breakdown EIA-364-20. 1000 volts AC at sea level. or flashover. 1.3 milliamperes maximum leakage Test between adjacent contacts. current. Temperature rise vs current. 30C maximum temperature rise at specified current. ELECTRICAL EIA-364-70. Stabilize at a single current level until 3 readings at 5 minute intervals are within 1C. See Figure 3. MECHANICAL Sinusoidal vibration. No discontinuities of 1 microsecond EIA-364-28, Condition I. Subject mated specimens to 10-55or longer duration. 10 Hz traversed in 1 minute with 1.5 See Note. mm [0.06 in] maximum total excursion. 2 hours in each of 3 mutually perpendicular planes. See Figure 4. Figure 1 (continued) Rev B 2 of 8 108-1948 Test Description Requirement Procedure Mechanical shock. No discontinuities of 1 microsecond EIA-364-27, Condition A. or longer duration. Subject mated specimens to 50 G's See Note. half-sine shock pulses of 11 milliseconds duration. 3 shocks in each direction applied along 3 mutually perpendicular planes, 18 total shocks. See Figure 4. Durability. See Note. EIA-364-9. Manually mate and unmate specimens with friction lock headers for 15 cycles at a maximum rate of 10 cycles per minute. Mating force. 8.9 N [2 lbf] maximum per contact. See Figure 5. EIA-364-13, Condition A. Measure force necessary to mate specimens with friction lock headers a distance of 5.1 mm [.200 in] from point of initial contact at a maximum rate of 12.7 mm [0.5 in] per minute. Unmating force. 3.6 N [.80 lbf] minimum per contact. EIA-364-13, See Figure 5. Condition A. Measure force necessary to unmate specimens from friction lock headers at a maximum rate of 12.7 mm [0.5 in] per minute. Contact insertion force. 17.8 N [4 lbf] maximum initial per contact. AMP Spec 109-41. Measure force necessary to insert contact into housing at a maximum rate of 25 mm [.984 in] per minute. Contact extraction force. 23 N [5 lbf] minimum final per contact. AMP Spec 109-41. Measure force necessary to extract contact from housing at a maximum rate of 50 mm [1.968 in] per minute. Crimp tensile. Wire Size (AWG) 22 24 26 Crimp Tensile (N [lbf] minimum) 48.9 [11] 44.5 [10] 31.1 [7] EIA-364-8. Measure crimp tensile at a maximum rate of 25.4 mm [1 in] per minute. ENVIRONMENTAL Thermal shock. See Note. EIA-364-32. Subject specimens to 10 cycles between -55 and 105C. Humidity/temperature cycling. See Note. EIA-364-31. Subject specimens to 10, 24 hour cycles between 25 and 65C at 95% RH. Figure 1 (continued) Rev B 3 of 8 108-1948 Test Description Temperature life. NOTE Requirement Procedure See Note. EIA-364-17. Subject mated specimens to 105C for 792 hours. Shall meet visual requirements, show no physical damage, and meet requirements of additional tests as specified in the Product Qualification and Requalification Test Sequence shown in Figure 2. Figure 1 (end) 3.6. Product Qualification and Requalification Test Sequence Test Group (a) Test or Examination 1 2 3 4 5 6 1 1 Test Sequence (b) Initial examination of product 1 1 Insulation resistance 2,5 3,7 Withstanding voltage 3,6 4,8 Low level contact resistance 1 1 2,4,7 2,5,7,10 Temperature rise vs current 3,11 Sinusoidal vibration 5 8(c) Mechanical shock 6 9 Durability 3 Mating force 2 Unmating force 3 Contact insertion force 2 Contact extraction force 9 Crimp tensile 2 Thermal shock 4 Humidity/temperature cycling 4(d) Temperature life Final examination of product NOTE (a) (b) (c) (d) 5 6 8 12 6 7 10 4 3 See paragraph 4.1.A. Numbers indicate sequence in which tests are performed. Discontinuities shall not be measured. Energize at 18C level for 100% loadings per Quality Specification 102-950. Precondition specimens with 10 durability cycles. Figure 2 Rev B 4 of 8 108-1948 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. Test groups 1 and 2 shall each consist of: 6, 28 position assemblies; 60 terminals crimped to 22 AWG wire; and 60 terminals crimped to 26 AWG wire. Test groups 3 and 4 shall each consist of: 5, 28 position assemblies and 100 terminals crimped to 22 AWG wire. Test group 5 shall consist of: 5, 28 position assemblies; 5, 3 position assemblies; 5, 10 position assemblies; 5, 18 position assemblies; and 295 terminals crimped to 22 AWG wire. Test group 6 shall consist of 25 specimens of each 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. Rev B 5 of 8 108-1948 Figure 3A Current Carrying Capability Percent Connector Loading NOTE Wire Size AWG 26 24 22 Single Contact 0.821 0.902 1.000 50 0.602 0.662 0.734 100 0.450 0.495 0.548 To determine acceptable current carrying capacity for the percentage connector loading and wire gage indicated, use the Multiplication Factor (F) from the above chart and multiply it times the Base Rated Current for a single circuit at maximum ambient operating temperature as shown in Figure 3A. Figure 3B Current Rating Rev B 6 of 8 108-1948 Figure 4 Vibration & Physical Shock Mounting Fixture Rev B 7 of 8 108-1948 Specimen Size (positions) Mating Force (N [lbf] maximum per contact) Unmating Force (N [lbf] minimum per contact) 3 6.61 [1.49] 7.24 [1.63] 10 4.25 [0.96] 4.60 [1.03] 18 4.54 [1.02] 4.42 [0.99] 28 3.36 [0.98] 4.53 [1.01] NOTE Force measured using MTA .100 Friction Lock Headers. Figure 5 Mating/Unmating Force Rev B 8 of 8