Product
Specification
Connector, Power Lock, Series I
1.
1.1.
SCOPE
Content
108-11026
11Mar11 Rev B
This specification covers perform ance, tests and quality requirem ents for TE Connectivity (TE) Power
Lock connectors. These connectors are com prised of an assem bled insulating housing and electrical
contacts and are intended to provide connect/disconnect capabilities for com m ercial power handling
applications. They are designed to accom m odate wire sizes 18 through 12 AW G.
1.2.
Qualification
W hen tests are perform ed on subject product line, procedures specified in 109 Series Test
Specifications shall be used. All inspections shall be perform ed using applicable inspection plan and
product drawing.
2.
APPLICABLE DOCUM ENTS
The following docum ents form a part of this specification to the extent specified herein. Unless
otherwise specified, latest edition of the docum ent applies. In the event of conflict between
requirem ents of this specification and product drawing, product drawing shall take precedence. In the
event of conflict between requirem ents of this specification and referenced docum ents, this specification
shall take precedence.
2.1.
TE Docum ents
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3.
3.1.
109-1: General Requirem ents for Test Specifications
109 Series: Test Specifications as indicated in Figure 1
501-315: Qualification Test Report
REQUIREM ENTS
Design and Construction
Product shall be of design, construction and physical dim ensions specified on applicable product
drawing.
3.2.
Materials
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Contact: Copper, silver plating
Housing: Polycarbonate or nylon, UL94V-0
3.3.
Ratings
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Voltage: 600 volts AC
Current: 31 am peres m axim um , See Figure 5
Maximum rated current that can be carried by this product is limited by maximum
operating temperature of the housings (75°C), and temperature rise of the contacts
(30°C). Variables which shall be considered for each application are wire size, connector
size, contact material and ambient temperature.
Tem perature: -40 to 75°C
NOTE
!
©2011 Tyco Electronics Corporation, | Indicates change
a TE Connectivity Ltd. Company
*Trademark
All Rights Reserved
TE logo is a trademark.
For latest revision, visit our website at www.te.com/documents.
For Regional Customer Service, visit our website at www.te.com
Other products, logos, and company names might be trademarks of their respective owners.
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LOC B
108-11026
3.4.
Perform ance and Test Description
Product is designed to m eet electrical, m echanical and environm ental perform ance requirem ents
specified in Figure 1. Unless otherwise specified, all tests shall be perform ed at am bient environm ental
conditions per Test Specification 109-1.
3.5.
Test Requirem ents and Procedures Sum m ary
Test Description
Exam ination of product.
Requirem ent
Meets requirem ents of product
drawing.
Procedure
Visual, dim ensional and functional
per applicable quality inspection
plan and Certificate of
Conform ance.
ELECTRICAL
Term ination resistance.
2.5 m illiohm s m axim um .
TE 109-6-7.
Subject m ated contacts assem bled
in housing to 50 m v m axim um open
circuit at 1 am pere m axim um .
See Figure 3.
TE Spec 109-28-4.
Test between adjacent contacts of
m ated sam ples ganged together.
TE Spec 109-29-1.
Test between adjacent contacts of
m ated sam ples ganged together
and a m etal plate.
See Figure 4.
Insulation resistance.
1000 m egohm s m inim um .
Dielectric withstanding voltage.
1500 vac at sea level.
Tem perature rise vs current.
30EC m axim um tem perature rise at TE Spec 109-45-1 and 109-151.
specified current of 31 am peres ac. Measure tem perature rise vs
current.
See Figures 5 and 6.
MECHANICAL
Solderability.
Crim p tensile.
Solderable area shall have
m inim um of 95% solder coverage.
W ire Size
( AW G)
18
16
14
12
Crim p Tensile
(Lbs m axim um )
20
30
50
50
TE Spec 109-11-2.
Subject contacts to solderability.
TE Spec 109-16.
Determ ine crim p tensile at
m axim um rate of 1 inch per m inute.
Vibration, sinusoidal.
No discontinuities of 1
m icrosecond or longer duration.
See Note.
TE Spec 109-21-1.
Subject m ated sam ples to 10-55-10
Hz traversed in 1 m inute at .06 inch
total excursion. 1.3 hours in each of
3 m utually perpendicular planes.
See Figure 7.
Figure 1 (continued)
Rev B
2 of 9
108-11026
Test Description
Physical shock.
Requirem ent
Procedure
No discontinuities of 1 m icrosecond TE Spec 109-26-2.
or longer duration.
Subject m ated sam ples to 75 G's
See Note.
half-sine shock pulses of 6
m illiseconds duration. 3 shocks in
each direction applied along 3
m utually perpendicular planes, 18
total shocks.
See Note.
TE Spec 109-27.
Mate and unm ate sam ples for 20
cycles at m axim um rate of 600
cycles per hour.
Retention Force
(Lbs m axim um )
10
15
20
20
TE Spec 109-30.
Apply axial load to contacts by
gripping wire and hold for 10
seconds.
Durability.
Contact retention.
W ire Size
( AW G)
18
16
14
12
Mating force.
10 pounds m axim um per contact
pair.
TE Spec 109-42, Condition A.
Measure force necessary to m ate
sam ples at m axim um rate of .5 inch
per m inute.
TE Spec 109-42, Condition A.
Measure force necessary to
unm ate sam ples at m axim um rate
of .5 inch per m inute.
Unm ating force.
1.75 pounds m inim um per contact
pair.
ENVIRONMENTAL
Therm al shock.
See Note.
TE Spec 109-22.
Subject m ated sam ples to 5 cycles
between -55 and 85°C.
TE Spec 109-23-3,
Condition B.
Subject m ated sam ples to 10
cycles between 25 and 65°C at
95% RH.
TE Spec 109-43.
Subject m ated sam ples to
tem perature life at 85°C for 1000
hours.
TE Spec 109-85-2.
Subject m ated sam ples to
environm ental class II for 14 days.
Hum idity-tem perature cycling.
See Note.
Tem perature life.
See Note.
Mixed flowing gas.
See Note.
NOTE
Shall meet visual requirements, show no physical damage and shall meet requirements of
additional tests as specified in Test Sequence in Figure 2.
Figure 1 (end)
Rev B
3 of 9
108-11026
3.6.
Product Qualification and Requalification Test Sequence
Test Group (a)
Test or Exam ination
1
2
3
4
Test Sequence (b)
Exam ination of product
Term ination resistance
Insulation resistance
Dielectric withstanding voltage
Tem perature rise vs current
Solderability
Crim p tensile
Vibration
Physical shock
Contact retention
Durability
Mating force
Unm ating force
Therm al shock
Hum idity-tem perature cycling
Tem perature life
Mixed flowing gas
NOTE
(a)
(b)
(c)
5
4
11
5
6
9
4
2
8
4
5
6(c)
3,8
2
1,10
3,7
1,9
2,7
2,6
3,7
1,8
1,3
See paragraph 4.1.A.
Numbers indicate sequence in which tests are performed.
Discontinuities shall not be measured. Energize at 18°C level for 100% loadings per Test
Specification 109-151.
Figure 2
Rev B
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108-11026
4.
4.1.
QUALITY ASSURANCE PROVISIONS
Qualification Testing
A.
Sam ple Selection
Sam ples shall be prepared in accordance with applicable Instruction Sheets and shall be selected
at random from current production. Test group 1 shall consist of 5 contact pairs, each crim ped to 4
appropriate wire sizes for single connector assem bly. Test group 2 shall consist of 2 connector
assem blies, each crim ped to 4 appropriate wire sizes for m ultiple (5 position) connector
assem blies. Test group 3 shall consist of 2 assem blies, each m ounted on printed circuit boards
with m ating connectors crim ped to 4 appropriate wire sizes. Each contact shall be attached to 1
end of a 24 inch length of wire with a suitable term inal applied to the other for series circuit wiring.
Test group 4 shall consist of contacts only.
B.
Test Sequence
Qualification inspection shall be verified by testing sam ples as specified in Figure 2.
4.2.
Requalification Testing
If changes significantly affecting form , fit or function are m ade to product or m anufacturing process,
product assurance shall coordinate requalification testing, consisting of all or part of original testing
sequence as determ ined by developm ent/product, quality and reliability engineering.
4.3.
Acceptance
Acceptance is based on verification that product m eets requirem ents of Figure 1. Failures attributed to
equipm ent, test setup or operator deficiencies shall not disqualify product. W hen product failure occurs,
corrective action shall be taken and sam ples resubm itted for qualification. Testing to confirm corrective
action is required before resubm ittal.
4.4.
Quality Conform ance Inspection
The applicable quality inspection plan will specify sam pling acceptable quality level to be used.
Dim ensional and functional requirem ents shall be in accordance with applicable product drawing and
this specification.
Rev B
5 of 9
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