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114-18049-1 Application Specification 12.08.2011 Rev. F DCR - D20110912024925_713948 3-20pos. AMP DUOPLUG 2.5 TM Connector System APPLICATION SPECIFICATION 3-20 pos. AMP DUOPLUG 2.5TM Connector System 1. SCOPE The AMP DUOPLUG 2.5 Connectors * can be used as direct or indirect connectors for wire to board applications. For the indirect application the pair of flat spring contacts the small side of the tab contacts. The tab contacts are assembled in a housing and soldered to the PCB. The direct application connects directly specified pads of the PCB edge which can be lamination coated on single or both sides. The female connectors are available in two wire ranges (DGB I and DGB II) and are fully or selectively loaded. 1.1 Contents This specification contains criteria which guarantee a quality level acc. to prod. spec. 108-18056, if the AMP DUOPLUG 2.5 Connector System female connector has been terminated in accordance with AMP-technology. The instructions are valid for the use on any kind of AMP application tools. 1.2 Applicable Instructions DIN 41 611 part 6 TE connectivity Harrisburg, PA 17105 * Trademark | Indicates change This specification is a controlled document.  Copyright 2000 by TE connectivity. All rights reserved 1 of 9 114-18049-1 2. SYSTEM FEATURES AMP DUOPLUG 2.5 Connector System Female Connector AMP DUOPLUG 2.5 Connector System Direct connection Incl. frame for keying and positioning features Cover Wire exit Frontside Keying ribs Fig. 1 Fig. 2 AMP DUOPLUG 2.5 Connector System Indirect connection Male connector, closed-end version AMP DUOPLUG 2.5 Connector System Indirect connection Male connector, feed-through version (optional) Slot for keying Fig. 3 Rev. F Fig. 4 2 of 9 114-18049-1 3. 3. SPECIFIC REQUIREMENTS Dimensions, function and appearance of the AMP DUOPLUG 2.5 connectors have to adhere to the following requirements: 3.1 Visible check of connectors before application Visible inspection is sufficient, and in case of uncertainty, a dimensional check is necessary. 3.1.1 Coordination wire – contact Prerequisite for a perfect wire connection of AMP DUOPLUG 2.5 connectors is: a) wire performance acc. to par. 4.3 b) contact performance Wire section (par. 4.3.1) and contact to be applied have to be coordinated. Wire range identification is marked on ID contact. For visible inspection the contact has to be removed from the housing. DGB I: Contact with coined number ”0.22” suitable for wire acc. to par. 4.3.1 a DGB II: Contact with coined number ”0.35” suitable for wire acc. to par. 4.3.1 b 3.1.2 Contact Contact may not show any damage which would endanger correct function. Scratches which do not reach the basis material are allowed and do not endanger function. 3.1.3 Position of IDC slot Position of IDC slot has to be acc. to respective symmetry tolerances. Fig. 5 Rev. F 3 of 9 114-18049-1 3.1.4 Housing Housings must be free of damage originating from machine or tool failures. 3.1.5 Wire Wire may not show any damages. 3.2 Visible check of terminated connectors For the following, a visible check is sufficient and only in the case of uncertainty a dimensional inspection is necessary. 3.2.1 Contact The contact may not have any damages which could endanger correct function. Especially damages of the contact caused by insertion tool or incorrect handling have to be avoided. Slight scratches which do not touch the basic material are not relevant to the function and do not endanger function. 3.2.2 Control of wire depth For a correct function of IDC, the wire depth is important. A check of the wire depth is only possible before fixing the cover. Depending on the kind of insulation material of the wire, the funnel entry of the contact slot should be visible from the top. This should be adhered as proof of quality. Should this feature not be visible with the bare eye, (e.g. remaining parts of insulation), procedure 4.4 applies. Fig. 6 3.2.3 Contact position in housing After completion of working process, the contact has still to be in correct position in housing. (Fig. 7, see also point 4.6) Fig. 7 Rev. F 4 of 9 114-18049-1 3.2.4 Position of wire in the housing The wire may only be inserted max. 0.5 mm recede from end of cavity. It is not allowed that the wire overlaps the housing (Fig. 8, see also item 4.5). Fig. 8 3.2.5 Housing The processed housing may not show any damages which refer to incorrect machine adjustment or tool breakage. 3.2.6 Cutting of the keying ribs After cutting of the keying ribs the housings must be burr-free respectively acc. to tolerances shown in fig. 9. If, caused by the cutting process the housing breaks slightly, this has no effect on the function and is allowed. Don’t cut all keying ribs. At least one keying rib has to remain (position is unimportant). Fig. 9 3.2.7 Cutting of cover Remaining parts of cover / housing caused by the cutting process has to be within tolerances shown in fig. 10. Slight breakage of housing is allowed and does not effect function. Fig. 10 3.2.8 Cover locking After inserting the wire, contact and wire are protected by fixing the cover. The cover will function if all locking latches (front and back) are properly fixed (fig. 11). Slight deformation of locking latches is allowed and does not effect function. The overall hight of the terminated connector can be seen from picture 9. Fig. 11 Rev. F 5 of 9 114-18049-1 4. Quality precautions The actions listed below serve as quality assurance of the AMP DUOPLUG 2.5 Connector System as to the prod.-spec. 108-18056 and apply when changing the Following parameters: a) Product introduction b) Change of wire c) Tooling change QUALITY FEATURES a) width of IDC slot b) position of IDC slot c) wire quality d) wire insertion depth e) position of wire 4.1 (4.1) (4.2) (4.3) (4.4) (4.5) f) contact position g) cutting of the keying ribs h) cutting of the cover j) cover locking (4.6) (4.7) (4.8) (4.9) Slot dimension / width of IDC slot Tyco guarantees the slot dimension which is decisive to obtain an optimal connection. 4.2 Position of IDC slot See item 3.1.3 Visible inspection is sufficient, and in the case of uncertainty, a dimensional check is necessary. 4.3 Wire quality The wire specification (see sheet 9) must be kept. Should deviations of wire occur, an AMP approval is necessary. 4.3.1 Wire AMP DUOPLUG 2.5 female parts are produced to fit the following wire ranges (DGB): a.) DGB I solid wire  0.4 mm and  0.5 mm bonded wire 7 x  0.15 = 0.12 mm² bonded wire 7 x  0.16 = 0.14 mm² stranded wire 7 x  0.20 = 0.22 mm² stranded wire 12 x  0.21 mm = 0.35 mm² b.) DGB II c.) Rev. F stranded wire 7 x  0.25 mm = 0.35 mm² Ribbon cable in the same wire ranges as item a and b 6 of 9 114-18049-1 Remarks: The wire listed under item 4.3.1 and the wire specification (sheet 9) give only basic information. Upon request, a list of approved wires and its producers can be obtained. 4.3.2 Insulation The AMP DUOPLUG 2.5 System female parts are designed to fit wires with an insulation diameter of 1.3 mm  0.1. The usable wire should have a semi-rigid * PVC insulation with a shore A hardness 92  3 according to DIN 53 505, for example YJ3 per VDE 0209 Remarks: 4.4 If deviations regarding description as per item 4.3.2 occur, please contact AMP, because AMP approval is necessary ! Wire insertion depth The wire depth determinates the position of the single wires in the insulation displacement slot. It has to be guaranteed, that the conductor compound is deep enough in the slot area. This can be guaranteed when, with the wire conductor with an isolation diameter of 1.2 – 1.4 mm the wire is inserted according to picture 12 (see also par. 3.2.2) Fig. 12 4.5 Position of wire The wire must be inserted into the housing at the end or max. 0.5 mm away from the end of the cavity (fig. 13). It is not allowed to insert the wire exceeding the end of the cavity. Fig. 13 4.6 Contact position The symmetric tolerance between contact and housing has to be according to dimensions in fig. 14. Contact edges may not be visible in the mating area. Fig. 14 4.7 Cutting of keying ribs Cutting of keying ribs must be acc. to item 3.2.6 Rev. F 7 of 9 114-18049-1 4.8 Cover cutting area The cutting area of the cover must be according to item 3.2.7 4.9 Cover locking The locking of the cover must be acc. to item 3.2.8 5. QUALITY APPROVAL 5.1 Tensile strength of the applicated wire The tensile strength of the connected wire must have the result as shown in the following table (fig. 15). Wire version Solid wire  0.5 mm Stranded wire 7x  0.2 mm = 0.22 mm² AWG 24 Stranded wire 7x  0.2 mm = 0.35 mm² AWG 22 Horizontal direction fig. 15 30 N 30 N 30 N Fig. 15 5.2 Cross section pictures The embedding of the grinding parts should be done in vacuum in order to assure exact filling of hollow spaces. The grinding direction has to be parallel to contact slot (fig. 18) so that movements within the surrounding insulation are more or less impossible. In order to meet the actual contact zone within the contact material thickness during grinding, it is necessary to look and grind alternately. The analysis of the cross section pictures has to be done with Tyco in case of doubt. The basic rule for stranded wire is: With 7-stranded wires, 4 single wires have to be seen in contact with the contact slot and in contact with themselves. With 12-stranded wires, a minimum of 9 wires have to be in the parallel slot area and have to be in a rigid compound. Fig. 16 Rev. F 8 of 9 114-18049-1 Wire Specification DGB I A A 1,30.1 1,30.1 1,30.1 0,1 A 0,1 A 0,1 A Stranded wire: AWG 24 7 x  0.2 = 0.22 mm² A A Bonded wire: 7 x  0.15 mm = 0.12 mm² 7 x  0.16 mm = 0.14 mm² Solid wire:  0.4 – 0.5 mm 1,30.1 0,1 A Stranded wire: AWG 22 12 x  0.20 mm= 0.35 mm² Wire Specification DGB II A 1,30.1 0,1 A Litze: AWG 22 7 x  0,25 mm = 0,35 mm² Wire Specification Ribbon Cable A 1,30,1 2,5 (Pos.-1)x 2.5 = X 0.1 0,1 A Same wire ranges as the single wires. CUT FREE +3 10 -2 Rev. F 9 of 9