NUMBER
TYPE
GS-12-452
TITLE
PRODUCT SPECIFCATION
PAGE
REVISION
ZipLine
TM
Connector System
1 of 13
AUTHORIZED BY
DATE
C
2009-10-05
M. Gray
CLASSIFICATION
UNRESTRICTED
ZipLine™ Connector System
Orthogonal
Backpanel
Coplanar
TABLE OF CONTENTS:
Copyright FCI
Form E-3334
Rev F
GS-01-001
PDM: Rev:C
STATUS:
Released
Printed: Nov 28, 2010
.
NUMBER
TYPE
GS-12-452
TITLE
PRODUCT SPECIFCATION
PAGE
REVISION
ZipLine
TM
Connector System
2 of 13
AUTHORIZED BY
DATE
C
2009-10-05
M. Gray
CLASSIFICATION
UNRESTRICTED
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
OBJECTIVE.................................................................................................................................... 3
SCOPE............................................................................................................................................ 3
APPLICABLE DOCUMENTS......................................................................................................... 3
3.1
FCI Specifications ....................................................................................................................... 3
3.2
Other Standards and Specifications ........................................................................................... 3
3.3
FCI Product Qualification Test reports ....................................................................................... 3
3.4
Safety Agency Approvals............................................................................................................ 3
REQUIREMENTS ........................................................................................................................... 3
4.1
Materials ..................................................................................................................................... 3
4.2
Visual Examination of Product.................................................................................................... 3
ELECTRICAL CHARACTERISTICS.............................................................................................. 4
5.1 Contact Resistance....................................................................................................................... 4
5.1.1 Low Level (LLCR) ......................................................................................................................... 4
5.1.2 At Specified Current (power contacts only) .................................................................................. 4
5.2 Insulation Resistance.................................................................................................................... 4
5.3 Dielectric Withstanding Voltage .................................................................................................... 4
5.4 Current Rating
(signal and power IMLA’s to be tested separately)
.............................................. 5
5.4.1 General Criteria............................................................................................................................. 5
5.4.2 Signal Contacts............................................................................................................................. 5
5.4.3 Power Contacts............................................................................................................................. 5
MECHANICAL CHARACTERISTICS ............................................................................................ 6
6.1
Mating / Un-mating Force ........................................................................................................... 6
6.2
Compliant pin insertion force ...................................................................................................... 6
6.3
Compliant pin retention force...................................................................................................... 6
6.4
PCB Hole Deformation Radius ................................................................................................... 6
6.5
PCB Hole Wall Damage ............................................................................................................ 6
ENVIRONMENTAL CONDITIONS ................................................................................................. 7
7.1
Thermal Shock:........................................................................................................................... 7
7.2
Cyclical Humidity and Temperature:........................................................................................... 7
7.3
Temperature Life:........................................................................................................................ 7
7.4
Industrial Mixed Flowing Gas (Class IIA, 4-gas): ....................................................................... 7
7.5
Vibration...................................................................................................................................... 8
7.6
Mechanical Shock....................................................................................................................... 8
7.7
Durability ..................................................................................................................................... 8
7.8
Dust Contamination .................................................................................................................... 8
7.9
Disturb......................................................................................................................................... 8
QUALITY ASSURANCE PROVISIONS ......................................................................................... 9
8.1
Equipment Calibration ................................................................................................................ 9
8.2
Inspection Conditions ................................................................................................................. 9
8.3
Sample Quantity and Description ............................................................................................... 9
8.4
Acceptance ................................................................................................................................. 9
8.5
Qualification Testing ................................................................................................................... 9
8.6
Re-Qualification Testing ............................................................................................................. 9
Table 1: Qualification Test Matrix, Signal Connectors......................................................................... 10
Table 2: Qualification Test Matrix, Power IMLAs................................................................................. 11
Table 3: Qualification Sample Requirements, Signal Connectors....................................................... 12
Table 4: Qualification Sample Requirements, Power IMLA Connectors ............................................. 12
REVISION RECORD ..................................................................................................................... 13
Copyright FCI
Form E-3334
Rev F
GS-01-001
PDM: Rev:C
STATUS:
Released
Printed: Nov 28, 2010
.
NUMBER
TYPE
GS-12-452
TITLE
PRODUCT SPECIFCATION
PAGE
REVISION
ZipLine
TM
Connector System
3 of 13
AUTHORIZED BY
DATE
C
2009-10-05
M. Gray
CLASSIFICATION
UNRESTRICTED
1.0
OBJECTIVE
This specification defines the quality and reliability, performance, and test requirements of the ZipLine™
connector system. This specification applies to all press-fit versions including standard backpanel, orthogonal,
coplanar, and power configurations. The test sequences defined in this specification meet the intent of Telcordia
GR-1217-CORE requirements.
2.0
SCOPE
This specification is applicable to the press-fit ZipLine™ connector system which provides a high speed
differential board-to-board interconnect.
3.0
APPLICABLE DOCUMENTS
3.1
FCI Specifications
- Applicable FCI product customer drawings
- FCI Application Specification GS-20-094 (ZipLine™ Connector System)
Other Standards and Specifications
- UL94V-O: Test for Flammability of Plastic Materials in Devices and Appliances
- EIA 364: Electrical Connector/Socket Test Procedures Including Environmental Classifications
- GR-1217-CORE, Issue 2, December 2008: Telcordia Specification “Generic Requirements for Separable
Electrical Connectors”
FCI Product Qualification Test reports
- EL 2009-02-002A: ZipLine™ Connector System, backpanel and orthogonal signal products
- EL 2008-08-029:
ZipLine
TM
Connector System, power products
- EL 2009-08-032:
ZipLine
TM
Connector System, coplanar products
Safety Agency Approvals
- UL File Number: E66906
3.2
3.3
3.4
4.0
REQUIREMENTS
4.1
Materials
The material for each component shall be as specified herein or equivalent.
- Contacts: copper alloy
- Plating:
Contact Areas: Performance-based plating, qualified to meet the requirements of this specification,
including the Telcordia GR-1217-CORE Central Office test sequence.
Press-fit Tails: Tin or tin-lead over nickel
- Housings: high temperature thermoplastic; UL 94V-0 compliant
Visual Examination of Product
Visual examinations shall be performed using 10x magnification. Parts should be free from blistering,
cracks, discoloration, etc.
4.2
Copyright FCI
Form E-3334
Rev F
GS-01-001
PDM: Rev:C
STATUS:
Released
Printed: Nov 28, 2010
.
NUMBER
TYPE
GS-12-452
TITLE
PRODUCT SPECIFCATION
PAGE
REVISION
ZipLine
TM
Connector System
4 of 13
AUTHORIZED BY
DATE
C
2009-10-05
M. Gray
CLASSIFICATION
UNRESTRICTED
5.0
ELECTRICAL CHARACTERISTICS
5.1
Contact Resistance
5.1.1
Low Level (LLCR)
Measurements shall be performed using a four-wire method per EIA 364-23. The maximum initial
contact resistance is 150 mΩ for backpanel and orthogonal configurations, and 255 mΩ for
coplanar configurations. The increase in resistance for any position shall not exceed 10 mΩ.
Make sure metal organizer has been removed for all signal contact measurements because
several positions are shorted together by the organizer.
The following details apply:
a.
b.
c.
5.1.2
Test voltage: 20 mV maximum open circuit
Test current: 100 mA maximum
Number of readings: 500 minimum
At Specified Current (power contacts only)
The contact resistance at a specified current shall not exceed 5.00mΩ initially or after mating
cycles and environmental exposure when measured in accordance with EIA 364-06. The test
current is as follows:
1 Column Fully Powered
6.00A
2 Adjacent Columns Fully Powered
4.50A
All Columns Fully Powered
2.25A
The metal organizer is to remain assembled for power contact evaluation. There is no
shorting between power contacts and the metal organizer.
5.2
Insulation Resistance
The insulation resistance of mated connectors shall not be less than 1000 MΩ after environmental
exposure when measured in accordance with EIA 364-21.
Make sure metal organizer has been
removed for all signal contact measurements because several positions are shorted together by
the organizer.
The following details shall apply:
a.
b.
c.
d.
Test voltage: 500 VDC
Electrification time: 60 seconds
Points of measurement: between closest adjacent contacts
Number of readings: 30 (10 readings per loose-piece connector set)
5.3
Dielectric Withstanding Voltage
There shall be no evidence of arc-over, insulation breakdown, or excessive leakage current (> 0.5 mA)
when the mated connectors are tested in accordance with EIA 364-20.
Make sure metal organizer has
been removed for all signal contact measurements because several positions are shorted together
by the organizer.
The following details shall apply:
a.
b.
c.
d.
e.
Test voltage: 500 VAC, 60Hz
Test duration: 60 seconds
Voltage application rate: 500 V per second
Points of Measurement: between closest adjacent contacts
Number of readings: 30 (10 readings per loose-piece connector set)
Copyright FCI
Form E-3334
Rev F
GS-01-001
PDM: Rev:C
STATUS:
Released
Printed: Nov 28, 2010
.
NUMBER
TYPE
GS-12-452
TITLE
PRODUCT SPECIFCATION
PAGE
REVISION
ZipLine
TM
Connector System
5 of 13
AUTHORIZED BY
DATE
C
2009-10-05
M. Gray
CLASSIFICATION
UNRESTRICTED
5.4
Current Rating
(signal and power IMLA’s to be tested separately)
5.4.1
General Criteria
•
•
•
5.4.2
Test Specification: EIA 364-70
Ambient Temperature: 25˚C
Airflow: None (still-air)
Signal Contacts
•
•
•
•
•
•
•
The metal organizer must be removed for all signal contact measurements because
several positions are shorted together by the metal organizer.
Measure temperature versus applied current
All contacts powered
Thermocouple attachment: Mechanically attached to the base of the receptacle mating beams.
Thermocouple location: One thermocouple on a central position on each of the two middle
columns (two thermocouples per tested assembly)
Copper trace weight: 1oz on one external layer, connector side.
The temperature-rise above ambient shall not exceed 30˚C at 0.25A per contact for backpanel
and orthogonal configurations, and 0.20A per contact for coplanar configurations.
5.4.3
Power Contacts
•
•
•
•
•
•
•
The metal organizer is to remain assembled for power contact evaluation. There is no
shorting between power contacts and the metal organizer.
Measure temperature versus applied current
Powered contact configurations to be qualified are represented in the supporting table.
Thermocouple attachment: Mechanically attached to the base of the receptacle mating beams.
Thermocouple location: One thermocouple on a central position of each column tested.
Columns with thermocouples are noted in the supporting table
Copper trace weight: 2oz on one external layer, opposite connector side.
The temperature-rise above ambient shall not exceed 30˚C at the current levels noted in the
supporting table. Actual output curves shall be plotted up to 50˚C T-rise.
TEST CONFIGURATIONS
IMLA Columns
Fully Powered
#1
#1, #2
All
Columns with
Thermocouples
#1
#1, #2
#6, #7
Total number of columns in test sample: 12
Number of power contacts within each column: 6
Current Rating Per
Contact
6.00A
4.50A
2.25A
Current Rating Per
Column
36.0A
27.0A
13.5A
Current-rating per column drops as the number of adjacent powered columns increases. This is
due to the cumulative heating effect of multiple columns powered in still-air test conditions.
Copyright FCI
Form E-3334
Rev F
GS-01-001
PDM: Rev:C
STATUS:
Released
Printed: Nov 28, 2010
.
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