NUMBER
TYPE
PRODUCT SPECIFICATION
GS-12-1176
TITLE
PAGE
REVISION
1 of 10
®
PwrBlade ULTRA Connector System
AUTHORIZED BY
Kaka Zhang
B
DATE
04/13/2017
CLASSIFICATION
UNRESTRICTED
1.0
Objective
This specification defines the performance, test, quality and reliability requirements of the PwrBlade ULTRA®
product.
2.0
Scope
This specification is applicable to the termination characteristics of the PwrBlade ULTRA® family of products
which provides separable right angle plugs that mate to right angle and vertical receptacles.
3.0
Ratings
3.1
Operating Voltage Rating = 182VAC/5.00mm Pitch-407VAC/7.25mm Pitch
(Refer to section 6.6, Table 2)
3.2
Operating Current Rating = 85A/Single Power Contact – 58A/10 Power Contacts
(Refer to section 6.5, Table 1a & Table 1b)
3.3
Operating Temperature Range = -40oC ~ 125oC
4.0
Applicable Documents
4.1
AFCI Specifications
4.1.1
Applicable AFCI PwrBlade ULTRA® product drawing
4.1.2
GS-14-2354 Packaging Specification
4.1.3
GS-20-0389 Application specification
4.2
National or International Standards
4.2.1
UL94: Flammability
4.2.2
EIA 364: Electrical Connector/Socket Test Procedures Including Environmental Classifications.
4.2.3
MIL-STD-1344A: Federal Specifications, Test Methods for Electrical Connectors.
4.2.4
J-STD-002: Solderability Tests for Component Leads, Terminations, Lugs, Terminals and Wires.
4.3
5.0
AFCI Laboratory Reports - Supporting Data
4.3.1
EL-2015-04-022
4.3.2
DG-2015-05-025
Requirements
5.1
Qualification
Connectors furnished under this specification shall be capable of meeting the qualification test
requirements specified herein.
5.2
Material
The material for each component shall be as specified herein or equivalent.
High/Low Power Contacts – High Conductivity Copper Alloy
© 2016 AFCI
Form E-3701 – Revision D
GS-01-029
PDS: Rev :B
STATUS:Released
Printed: Apr 14, 2017
NUMBER
TYPE
PRODUCT SPECIFICATION
GS-12-1176
TITLE
PAGE
REVISION
2 of 10
®
B
AUTHORIZED BY
PwrBlade ULTRA Connector System
DATE
Kaka Zhang
04/13/2017
CLASSIFICATION
UNRESTRICTED
Signal Contacts – Copper Alloy
Housing Resin – Glass filled, halogen free polyamide or other high performance resin rated flame
retardant 94V-0 in accordance with UL-94.
5.3
Finish
The finish for applicable components shall be as specified herein or equivalent.
Standard PwrBlade ULTRA® contact plating refer to AFCI 10135186.
5.4
Design and Construction
Connectors shall be of the design, construction, and physical dimensions specified on the applicable
product drawing.
5.5
Workmanship
This includes freedom from blistering, cracks, discoloration, etc.
5.6
Examination
Visual and dimensional inspection per product drawings, must meet requirements of product drawing in
accordance with EIA-364-18.
6.0
Electrical Characteristics
6.1
Contact Resistance, Low Level (LLCR)
For Signal Contacts, the low level contact resistance shall also not exceed 20 milliohms after any
treatment and/or environmental exposure.
Measurements shall be in accordance with EIA 364-23.
The following details shall apply:
a. Test Voltage - 20 millivolts DC max open circuit.
b. Test Current - Not to exceed 100 milliamperes.
6.2
Contact Resistance, Specified Current
The High Power Contact resistance at rated current shall not exceed the specified mOhms in table initially
and after any treatment and/or environmental exposure.
The Low Power Contact resistance at rated current shall not exceed the specified mOhms in table initially
and after any treatment and/or environmental exposure.
Type
Initial Contact Resistance Max.
(mOhms)
Post Environmental Contact
Resistance Max. (mOhms)
High Power
0.3
0.4
Low Power
0.6
1.2
Measurements shall be in accordance with EIA 364-06.
The following details shall apply:
a. Test Current – Shown in Tables 1a and 1b.
© 2016 AFCI
Form E-3701 – Revision D
GS-01-029
PDS: Rev :B
STATUS:Released
Printed: Apr 14, 2017
NUMBER
TYPE
PRODUCT SPECIFICATION
GS-12-1176
TITLE
PAGE
REVISION
3 of 10
®
PwrBlade ULTRA Connector System
B
AUTHORIZED BY
DATE
Kaka Zhang
04/13/2017
CLASSIFICATION
UNRESTRICTED
6.3
Insulation Resistance
The insulation resistance of mated connectors shall not be less than 1,000 megohms initially and 1,000
megohms after environmental exposure for power contacts. The insulation resistance of mated
connectors shall not be less than 500 megohms initially and 500 megohms after environmental exposure
for signal contacts.
Measurements shall be in accordance with EIA 364-21.
The following details shall apply:
a. Test Voltage – 500 volts DC.
b. Electrification Time - 2 minutes, unless otherwise specified.
c.
6.4
Points of Measurement - Between all adjacent power contacts and 5 adjacent signal contacts.
Dielectric Withstanding Voltage
There shall be no evidence of arc-over, insulation breakdown, or excessive leakage current > 1
milliamperes when mated connectors are tested in accordance with EIA 364-20.
The following details shall apply:
a. Test Voltage - 1000 volts DC for Signal Contacts.
b. Test Voltage – 2500 volts DC for High/Low Power Contacts.
c.
Test Duration - 60 seconds.
d. Test Condition - 760 Torr - sea level.
e. Points of Measurement - Between all adjacent power contacts and 5 adjacent signal contacts.
6.5
Current Rating
The temperature rise above ambient shall not exceed 30 deg C at any point in the system when contacts
are powered at specified amperes in Tables 1a and 1b.
The following details shall apply:
a. Ambient Conditions – Still air at 25oC
b. Stabilize at a single current level until 3 readings at 5 minute intervals are within 1oC.
c.
Test with single energized contact and with all adjacent contacts energized.
d. Reference - EIA 364-70, method 1.
Table 1a: Rated current table (amperes),
Note: Connectors are applied to test boards with 10 layers X 2 ounce copper power planes
Type
High Power
C Power
High
C Power
Low
C
Pitch
(mm)
7.00
5.00
3.50
Single
Contact
85
85
51
4 adjacent
Contacts
N/A
75
45
8 adjacent
Contacts
N/A
63
38
10 adjacent
Contacts
N/A
58
35
© 2016 AFCI
Form E-3701 – Revision D
GS-01-029
PDS: Rev :B
STATUS:Released
Printed: Apr 14, 2017
NUMBER
TYPE
PRODUCT SPECIFICATION
GS-12-1176
TITLE
PAGE
REVISION
4 of 10
®
PwrBlade ULTRA Connector System
B
AUTHORIZED BY
DATE
Kaka Zhang
04/13/2017
CLASSIFICATION
UNRESTRICTED
Types
Signal Contact
Pitch
(mm)
2.54
Single
Contact
3
24 adjacent
Contacts
1.5
48 adjacent
Contacts
1
NOTE: Schematic of 10 layer PCB
Layer 1,2,3 and 8,9,10 aren’t commoned.
Table 1b: Rated current table (amperes),
Note: Connectors are applied to test boards with 2 layers x 2 ounce copper power planes
Type
High Power
C Power
High
C Power
Low
C
Pitch
(mm)
7.00
5.00
3.50
Single
Contact
52
52
31
4 adjacent
Contacts
N/A
43
26
8 adjacent
Contacts
N/A
36
22
10 adjacent
Contacts
N/A
33
20
NOTE: Schematic of 2 layer PCB
Top and bottom layers are commoned.
© 2016 AFCI
Form E-3701 – Revision D
GS-01-029
PDS: Rev :B
STATUS:Released
Printed: Apr 14, 2017
NUMBER
TYPE
PRODUCT SPECIFICATION
GS-12-1176
TITLE
PAGE
REVISION
5 of 10
®
AUTHORIZED BY
PwrBlade ULTRA Connector System
Kaka Zhang
B
DATE
04/13/2017
CLASSIFICATION
UNRESTRICTED
6.6
Voltage Rating
The voltage ratings are based on the Minium Creepage Distances when the connector is installed in the
pc board. It’s related to the real application.
Table 2: Rated voltage table,
Note: MCD determined using Ø1.02mm finished hole with 0.24mm annular ring (nominal). Resulting in a
Ø1.50mm Pad (nominal).
PwrBlade ULTRA® Maximum Working Voltage Vs. Minimum Creep Distance
Table 2
Type
Signal
High Power
Low Power
Signal
High Power
Low Power
7.0
(Reference UL 60950-1 Second Edition Table 2N)
Contact
Pitch
(mm / inch)
Pollution
Degree
(office
Environment)
2.54 [.100’’]
5.00 [.197’’]
7.00 [.276’’]
7.25 [.285’’]
3.50 [.138’’]
5.50 [.217’’]
2.54 [.100’’]
5.00 [.197’’]
7.00 [.276’’]
7.25 [.285’’]
3.50 [.138’’]
5.50 [.217’’]
Material
Group (Base
on UL
Rating)
2
II
2
IIIb
MCD Of
PCB
(mm)
Maximum
Working
Voltage
(AC RMS)
1.04
1.82
3.82
4.07
2.00
4.00
1.04
1.82
3.82
4.07
2.00
4.00
120
253
531
567
285
557
39
182
382
407
200
400
Maximum
Working
Voltage
(DC/AC
Peak)
170
358
751
802
403
788
55
257
540
575
282
565
Mechanical Characteristics
7.1
Mating/Unmating Force
The force to mate/unmate a receptacle connector and compatible plug.
Contact types
Per High Power Contacts
Per Low Power Contacts
Per Signal Contacts
Mating force
7N [25 ounce] Maximum
3.5N [12.5 ounce] Maximum
1N [3.6 ounce] Maximum
Unmating Force
2.2N [8 ounce] Minimum
1.1N [4 ounce] Minimum
0.2N [0.7 ounce] Minimum
The following details shall apply:
a. Cross Head Speed – 12.7mm [0.5 in.] per minute.
b. Utilize free floating fixtures.
c.
Reference – EIA 364-13.
© 2016 AFCI
Form E-3701 – Revision D
GS-01-029
PDS: Rev :B
STATUS:Released
Printed: Apr 14, 2017
NUMBER
TYPE
PRODUCT SPECIFICATION
GS-12-1176
TITLE
PAGE
REVISION
6 of 10
®
PwrBlade ULTRA Connector System
AUTHORIZED BY
Kaka Zhang
B
DATE
04/13/2017
CLASSIFICATION
UNRESTRICTED
7.2
Compliant Pin Insertion
The force necessary to correctly apply a specimen to a printed circuit board.
Contact types
Plug/Receptacle Power Contacts
Plug Signal Contacts
Receptacle Signal Contacts
Insertion force per compliant EON
90N[20.2lbs] maximum
93.4N[21lbs] maximum
27N[6lbs] maximum
a. Cross Head Speed – 12.7mm [0.5 in.] per minute max.
b. Reference – EIA 364-5.
7.3
Radial Hole Distortion and PTH Wall Damage
0.070mm [0.00276in] maximum radial distortion.
0.008mm [0.00032in] minimum copper hole wall remaining.
There shall be no copper cracks, separation between conductive interfaces, or laminate to copper
separations.
The following details shall apply:
a. Measure at 0.2 to 0.5mm [0.008 to 0.020in] depth.
b. Reference – EIA 364-96.
7.4
Retention force per compliant pin
The force necessary to remove a specimen from a printed circuit board.
Contact types
Plug/Receptacle Power Contacts
Plug Signal Contacts
Receptacle Signal Contacts
Retention force per compliant EON
10N[2.25lbs] minimum
6.7N[1.5lbs] minimum
6.7N[1.5lbs] minimum
a. Cross Head Speed – 12.7mm [0.5 in.] per minute max.
b. Reference – EIA 364-5.
7.5
Component Heat Resistance to Wave Soldering
Shall meet visual requirements, show no physical damage, and meet requirements of additional test as
specified in Table 3.
The following details shall apply:
a) Reference – EIA 364-56, Procedure 3, Test Condition H
b) Samples are to be loose piece connectors (not mounted to PCB)
7.6
Solderability Dip Test
Solderable area shall have a minimum of 95% solder coverage.
The following details shall apply:
a. Reference – J-STD-002.
© 2016 AFCI
Form E-3701 – Revision D
GS-01-029
PDS: Rev :B
STATUS:Released
Printed: Apr 14, 2017
NUMBER
TYPE
PRODUCT SPECIFICATION
GS-12-1176
TITLE
PAGE
REVISION
7 of 10
®
PwrBlade ULTRA Connector System
B
AUTHORIZED BY
DATE
Kaka Zhang
04/13/2017
CLASSIFICATION
UNRESTRICTED
7.7
Vibration (Random) – EIA 364-28
a. Test Condition – VII, test condition E.
b. Subject mated specimens to 4.90G’s rms between 20~500Hz.
c.
Mounting – To eliminate relative motion, both mating halves should be rigidly fixed.
d. Duration – 15 minutes in each of 3 mutually perpendicular planes.
e. No evidence of physical damage.
f.
7.8
No discontinuities greater than 1microsecond.
Mechanical Shock – EIA 364-27
a. Condition - A (50G, 11millisecond, half-sine wave)
b. Shocks – 3 shocks in both directions along each of three orthogonal axes (18 shocks total)
c.
Mounting - Rigidly mount assemblies.
d. No discontinuities greater than 1.0microseconds.
7.9
Durability - EIA 364-09
a. Number Cycles - 200 cycles
b. Cycling Rate – 500 cycles/hour max.
8.0
Environmental Conditions
After exposure to the following environmental conditions in accordance with the specified test procedure
and/or details, the product shall show no physical damage and shall meet the electrical and mechanical
requirements per paragraphs 6.0 and 7.0 as specified in the Table 3 test sequences. Unless specified
otherwise, assemblies shall be mated during exposure.
8.1
Thermal Shock – EIA 364-32.
a. Number of Cycles – 36 mated
b. Temperature Range - Between -40oC and 125oC
c.
Time at Each Temperature - 30 minutes minimum
d. Transfer Time - 5 minutes, maximum
8.2
Humidity – EIA 364-31 method III (cyclic temperature)
a. Relative Humidity – 80%~100%
b. Temperature – 25oC~40oC
c.
8.3
Duration – 10 cycles, 10 days, omit step 7b
High Temperature Life – EIA 364-17, Method A.
a. Test Condition - 5
b. Test Temperature - 105oC
c.
Test Duration - 504 hours
© 2016 AFCI
Form E-3701 – Revision D
GS-01-029
PDS: Rev :B
STATUS:Released
Printed: Apr 14, 2017
NUMBER
TYPE
PRODUCT SPECIFICATION
GS-12-1176
TITLE
PAGE
REVISION
8 of 10
®
PwrBlade ULTRA Connector System
AUTHORIZED BY
Kaka Zhang
B
DATE
04/13/2017
CLASSIFICATION
UNRESTRICTED
8.4
Mixed Flowing Gas corrosion (MFG) – EIA 364-65
a. Class - IIA
b. Duration - 14 days
c.
9.0
1st 7 days unmated (both halves), 2nd 7 days mated
Quality Assurance Provisions
9.1
Equipment Calibration
All test equipment and inspection facilities used in the performance of any test shall be maintained in a
calibration system in accordance with ANSI Z-540 and ISO 9000.
9.2
Inspection Conditions
Unless otherwise specified herein, all inspections shall be performed under the following conditions:
a. Temperature: 25+/- 5oC
b. Relative Humidity: 30% to 60%
c.
9.3
Barometric Pressure: Local ambient
Acceptance
9.3.1
Electrical and mechanical requirements placed on test samples as indicated in paragraphs 6.0 and
7.0 shall be established from test data using appropriate statistical techniques or shall otherwise be
customer specified, and all samples tested in accordance with this product specification shall meet
the stated requirements.
9.3.2
Failures attributed to equipment, test setup, or operator error shall not disqualify the product. If
product failure occurs, corrective action shall be taken and samples resubmitted for qualification.
9.4
Qualification Testing
9.4.1
Qualification testing shall be performed on randomly selected sample units produced with equipment
and procedures normally used in production.
9.4.2
Test Sequence – as specified in Table 3.
9.5
Re-Qualification Testing
If any of the following conditions occur, the responsible product engineer shall initiate requalification
testing consisting of all applicable parts of the qualification test matrix, Table 3.
a. A significant design change is made to the existing product that impacts the product form, fit or
function. Example of significant changes shall include, but not be limited to, changes in the plating
material composition or thickness, contact force or contact surface geometry, insulator design, contact
base material or contact lubrication requirements.
b. A significant event occurs during production or end use requiring corrective action to be taken relative
to the product design or manufacturing process.
c.
A significant change is made to the manufacturing process that impacts the product form, fit or
function.
© 2016 AFCI
Form E-3701 – Revision D
GS-01-029
PDS: Rev :B
STATUS:Released
Printed: Apr 14, 2017
NUMBER
TYPE
PRODUCT SPECIFICATION
GS-12-1176
TITLE
PAGE
REVISION
9 of 10
®
B
AUTHORIZED BY
PwrBlade ULTRA Connector System
DATE
Kaka Zhang
04/13/2017
CLASSIFICATION
UNRESTRICTED
Table 3: Qualification Test Table
TEST
PARA
1
2
3a
Examination of Product
Low level contact resistance,
Signal Contacts only
Contact Resistance at rated current,
High/Low Power Contacts only
Insulation resistance
Dielectric Withstanding Voltage
Current Rating
Vibration, Random
Mechanical Shock
Durability
5.6
6.1
1,8
2,6
1,8
6.2
3,7
1,15
3,6,9,
12
4,7,
10,13
Mating Force
Un-Mating Force
Compliant Pin Insertion
Radial hole distortion
Compliant pin retention
Component heat resistance to
wave soldering
Solderability dip test
Thermal Shock
Humidity-temperature cycling
Temperature Life
Mixed Flowing Gas
7.1
7.1
7.2
7.3
7.4
7.5
6.3
6.4
6.5
7.7
7.8
7.9
7.6
8.1
8.2
8.3
8.4
Test Group (a,b)
3b
4
5
6
Test Sequence (c)
1,10 1,7
1,13
1,4
2,5,
2,5
8
3,6,
3,6 2,5,7,
9
9,11
7
8
P(g)
1,4
1,5
1,9
6,8
2,6
3,7
4(e)
8
11
5
4,12
10(d)
5
3(f)
2(f),
7(h)
3
4
2
14
2
3
2
4
2
3
4
5
4
7
4
5
8
6
3
NOTE:
(a) See paragraph 9.4.
(b) 3 mated pair per test group (Groups 1, 2, 3b, 4, 5 and Group P).
Need un-mounted samples (Groups 3a and 6)
Need a minimum of 10 loose piece contacts with a minimum of 20 Press-Fit EONs (Group 7).
Need a minimum of 10 loose piece contacts (Group 8).
(c) Numbers indicate sequence in which tests are performed.
(d) Energize at current for 18oC temperature rise.
(e) Precondition specimens with 5 durability cycles.
(f) Precondition specimens with 25 durability cycles.
(g) Group P is for preliminary testing and process verification.
(h) Perform remaining durability cycles to meet the paragraph 7.9 requirement.
© 2016 AFCI
Form E-3701 – Revision D
GS-01-029
PDS: Rev :B
STATUS:Released
Printed: Apr 14, 2017
NUMBER
TYPE
PRODUCT SPECIFICATION
GS-12-1176
TITLE
PAGE
REVISION
10 of 10
®
PwrBlade ULTRA Connector System
B
AUTHORIZED BY
DATE
Kaka Zhang
04/13/2017
CLASSIFICATION
UNRESTRICTED
REVISION RECORD
Rev
Page
A
B
All
4
Description
Initial Release
Add multilayer PCB schematic
EC#
Date
ELX-DG-26654-1
06/17/2016
04/13/2017
© 2016 AFCI
Form E-3701 – Revision D
GS-01-029
PDS: Rev :B
STATUS:Released
Printed: Apr 14, 2017
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