Application Specification NEVALO* Interconnect System NOTE i 114-13290 21 DEC 10 Rev A 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 0.20 and angles have a tolerance of 2. Figures and illustrations are for identification only and are not drawn to scale. 1. INTRODUCTION The NEVALO Interconnect System is designed to be a complete LED lighting interconnect solution. The NEVALO surface mount clip mates to the Feed-Thru, Straight, and Right-Angle connectors which make a card edge connection to the printed circuit (pc) board pads. These connectors are insulation displacement contact (IDC) terminated to the NEVALO ribbon cable and a terminator connector is placed on the free end to create a series circuit between all connectors and the driver. 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 receptacles are provided in Figure 1. Feed-Thru Connector Straight Connector SMT Clip Keying Features to Prevent Over/Under Powering of Light Modules Typical NEVALO IDC Contact Right-Angle Connector OBSOLETE Stripes for Proper Orientation of Ribbon Cable Terminator NOT the LATEST REVISION Figure 1 (c)2010 Tyco Electronics Corporation, Berwyn, PA TOOLING ASSISTANCE CENTER 1-800-722-1111 All Rights Reserved PRODUCT INFORMATION 1-800-522-6752 TE logo and Tyco Electronics are trademarks. *Trademark. Other products, logos, and company names might be trademarks of their respective owners. This controlled document is subject to change. For latest revision and Regional Customer Service, visit our website at www.tycoelectronics.com 1 of 10 LOC B 114-13290 2. REFERENCE MATERIAL 2.1. Revision Summary * Initial release of document 2.2. Customer Assistance Reference Part Number 2154234 and Product Code L895 are representative numbers of the NEVALO Interconnect System. Use of these numbers will identify the product line and expedite your inquiries through a service network established to help you obtain product information. Such information can be obtained through a local Tyco Electronics Representative or, after purchase, by calling the Tooling Assistance Center or the Product Information Center number at the bottom of page 1. 2.3. Drawings Customer Drawings for each connector 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 technical documentation supplied by Tyco Electronics. 2.4. Specifications Design Objective 108-2442 provides expected product performance and test information. 2.5. Instructional Material Instruction Sheet 408-10413 provides information for the NEVALO Interconnect System Hand Crimping Tool Kit 2161090-1. 3. REQUIREMENTS 3.1. Safety Do not stack product shipping containers so high that the containers buckle or deform. 3.2. Storage A. Ultraviolet Light Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the receptacle connector material. B. Shelf Life The connectors should remain in the shipping containers until ready for use to prevent deformation to the connectors. The connectors should be used on a first in, first out basis to avoid storage contamination. C. Chemical Exposure Do not store connectors near any chemicals listed below as they may cause stress corrosion cracking in the contacts. Alkalies Amines Ammonia Carbonates Citrates Nitrites Phosphates Citrates Sulfur Nitrites Sulfur Compounds Tartrates 3.3. Materials The NEVALO housings are made from glass-filled PBT, while the IDC contacts are made from copper alloy with tin plate over nickel. 3.4. Limitations The operating temperature range for the NEVALO Interconnect System is -20 to 105C [-4 to 221F]. 3.5. Special Characteristics NEVALO Interconnects are available in four colors. Housings have a molded keying feature that corresponds to keying features on the mating part (clip, driver, etc.) to prevent over/under powering of light modules. See Figure 1. Rev A 2 of 10 114-13290 3.6. Cable Preparation The IDC contacts in the NEVALO Interconnects are designed to accept NEVALO ribbon cable stranded tinned copper conductors. An initial cut needs to be made using a guillotine-type cutting tool. See Figure 2. Contact your Tyco Electronics Representative for current tool recommendations for cutting and notching of cables. NOTE i A notching procedure is required when a NEVALO Feed-Thru connector is used. Use cable notching tool 2119990-1 to ensure proper notch size and length. Contact the Product Information Center number at the bottom of page 1 for specific information on this process or refer to hand tool instruction sheet. CAUTION Care must be taken when aligning cable prior to termination to maintain parallelism between the end of the cable and the inner wall of the connector. ! -A- Cable preparation for straight, right-angle, and terminator connectors 0.25 Cable preparation for feed-thru connector FTR FTL A NOTE: Use notching tool 2119990-1 to sever two conductors. Notch striped side of ribbon cable for Feed-Thru Left (FTL) and non-striped side for Feed-Thru Right (FTR). NOTE Figure 2 Feed-Thru connectors should not be placed closer than 25 mm [1 in.] apart (centerline-to-centerline) due to tooling constraints. Printed Circuit Board width may effect minimum spacing. i 3.7. Product Selection All NEVALO Interconnects should be used with corresponding colored ribbon cable, light modules, and drivers. Right/left, up/down orientation corresponds to connector orientation relative to NEVALO ribbon cable stripe. Figure 3 shows proper connector orientation. Right-Angle Down (RAD) NEVALO Driver Feed-Thru Left (FTL) Straight Right (STR) Straight Left (STL) Feed-Thru Right (FTR) Figure 3 Rev A 3 of 10 114-13290 3.8. PC Board A. Material and Thickness The pc board material shall be metal clad. There is no required thickness for the pc board. B. Tolerance Maximum allowable bow of the pc board shall be 0.05 mm over the length of the connector. C. Pads The pc board circuit pads must be solderable in accordance with Test Specification 109-11. D. Layout The pc board layout must be designed using the dimensions provided on the customer drawing for the specific connector. Reference sample of the recommended pc board layout is shown in Figure 4. 0.08 Figure 4 3.9. Soldering Observe guidelines and procedures when soldering contacts. Solder, clean, and dry all leads to contacts according to the following. The connectors should be soldered using vapor phase reflow (VPR), double-sided, non-focused infrared (IR), forced air convection, or equivalent soldering techniques. All solder joints should conform to the Workmanship Specification 101-21 and IPC-S-815. A. Flux Selection Contacts must be fluxed prior to soldering with a mildly active, rosin base flux. Selection of the flux will depend on the type of pc board and other components mounted on the board. Additionally, the flux must be compatible with the wave solder line, manufacturing, health, and safety requirements. Flux that is compatible with the connectors is provided in Figure 5. Rev A 4 of 10 114-13290 FLUX TYPE ACTIVITY RESIDUE Type RMA (Mildly Activated) Mild Noncorrosive COMMERCIAL DESIGNATION KESTER ALPHA 185/197 611 Figure 5 CAUTION No flux allowable on any of the four inner pads. ! B. Connectors with SMT Contacts 1. Solderability The pc board pads must be solderable in accordance with Test Specification 109-11 (Test Method A, non-activated rosin flux) and all other requirements for surface mount contacts specified in this document. 2. Solder Paste Characteristics 1. Alloy type shall be SAC 305; Sn 96.5/Ag 3.0/Cu 0.5. 2.Flux incorporated in the paste shall be rosin, mildly active (RMA) type. 3.Paste will be at least 80% solids by volume. 4.Mesh designation -200 to +325 (74 to 44 square micron openings, respectively). 5.Minimum viscosity of screen print shall be 5y10% cp (centipoise). 6.Minimum viscosity of stencil print shall be 7.5y10% cp (centipoise). 3. Solder Volume NOTE Solder volume may vary depending on solder paste composition. i Solder volume is required to be 4.27 mm3 per solder foot (calculated per 50% solid content). 4. Screen (or Stencil) The stencil aperture shall be determined by the circuit pad size and thickness. It may be any shape as long as it prevents solder bridging and maintains the given volume of solder paste. C. Process Connectors with surface mount contacts should be soldered using vapor phase (VPR), double-sided, nonfocused infrared reflow (IR) or equivalent soldering techniques. Due to many variables involved with the reflow process (i.e., component density, orientation, etc.), it is recommended that trial runs be conducted under actual manufacturing conditions to ensure product and process compatibility. These connectors will withstand the temperature and exposure time specified in Figure 6. SOLDERING PROCESS TEMPERATURE (Max) TIME (At Max Temperature) IR 220C [428F] 3 Minutes Figure 6 The lead-free reflow profile is shown in Figure 7. Alpha and Kester are trademarks. Rev A 5 of 10 114-13290 Kester Lead-Free Reflow Profile Alloys:Sn96.5/Ag3.0/Cu0.5 and Sn96.5/Ag3.5 Figure 7 3.10. Connector Placement A. Position Optimally, the clip solder feet should be centered on the pads; however, slight misalignment is permissible. Refer to Figure 8. Figure 8 B. Seating Force It is imperative that the clip solder feet are sufficiently pressed into the solder paste. Rev A 6 of 10 114-13290 3.11. Terminated Connector Requirements Prepared cable shall be terminated according to the procedures given in the applicable tooling instructions. See Section 5, TOOLING, for details on tooling options and instructional materials. Figure 9 shows criteria for acceptable terminations. CAUTION Tyco Electronics specified tooling must be used to ensure proper termination. ! 4.90 4.90 Feed-Thru Connector Straight Connector 15.20 4.90 Terminator Right-Angle Connector Figure 9 3.12. Repair/Replacement NEVALO Interconnects are not repairable. If a connector becomes damaged, it must be cut from the ribbon cable and replaced with a new one. CAUTION Pre-terminated cable cannot be used with a new connector. If ribbon cable insulation has been pierced, the cable must be replaced as well. ! 4. QUALIFICATIONS The NEVALO Interconnect System has not yet been sent for agency evaluation and testing. 5. TOOLING This section provides a selection of tools for various application requirements. Modified designs and additional tooling concepts may be available to meet other application requirements. For additional information, contact one of the service groups at the bottom of page 1. There are manually operated and pneumatically operated (auto-cycle and foot pedal actuated) arbor frame assemblies designed for bench mounted operation. They accept standardized upper/lower tooling assemblies that have been designed for the NEVALO Interconnect System. Hand crimping tools are designed for prototype and low-volume applications. Instruction sheets covering tool setup and operation are packaged with the tooling. See Figure 10 CONNECTOR TYPE DIE SET Feed-Thru Straight Terminator Multi-Nest 2161080-1 Right-Angle Right-Angle 2161085-1 NOTE HAND TOOL FRAME HAND TOOL KIT (DOCUMENT) PRO-CRIMPER* III 2119991-1 2161090-1 (408-10413) Figure 10 Tooling not required to unmate connectors from clip. i Rev A 7 of 10 114-13290 6. VISUAL AID Figure 11 shows a typical application of the NEVALO Interconnect System. 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. ALL LATCHES SHOULD BE FULLY CLOSED RIBBON STRIPE AND CONNECTOR STRIPES SHOULD ALL BE IN ALIGNMENT FIGURE 11. VISUAL AID (CONT'D) Rev A 8 of 10 114-13290 ALL LATCHES SHOULD BE FULLY CLOSED NOT FULLY CLOSED FULLY CLOSED FIGURE 11. VISUAL AID (CONT'D) Rev A 9 of 10 114-13290 CAUTION Care must be taken when mating or unmating connectors to/from clip. ! CLIP LATCH MUST BE FULLY CLOSED PAST HOUSING BUMP FIGURE 11. VISUAL AID (END) Rev A 10 of 10