0347630001

APPLICATION SPECIFICATION 154 WAY CMCHEADER REVISION: C ECR/ECN INFORMATION: EC No: UAU2012-1574 DATE: 06/15/2012 DOCUMENT NUMBER: AS-34763-001 TITLE: SHEET No. 154 WAY CMC HEADER 1 of 16 CREATED / REVISED BY: CHECKED BY: APPROVED BY: Brian Zelinski Dave Krawczyk Ron Bauman TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC APPLICATION SPECIFICATION 154 WAY CMC HEADER Table of Contents
154 way CMC Product Introduction
154 way CMCProduct Summary
154way CMCHeader Overview
154 way CMC CAD Model Reference
154 way CMC Header Product Identification
154 way CMC Header Packaging
154 way CMC Header-to-PCB Assembly Instructions
154 way CMC Header-to-PCB Assembly Tooling
154 way Header PCB Side Probing
154 way Harness Side Probing
53 wayand 48 way CMC Connector Mating &Unmating REVISION: C ECR/ECN INFORMATION: EC No: UAU2012-1574 DATE: 06/15/2012 DOCUMENT NUMBER: AS-34763-001 TITLE: SHEET No. 154 WAY CMC HEADER 2 of 16 CREATED / REVISED BY: CHECKED BY: APPROVED BY: Brian Zelinski Dave Krawczyk Ron Bauman TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC APPLICATION SPECIFICATION 154 WAY CMC HEADER PRODUCT INTRODUCTION 154 Way CMCHeader • Terminal Header Blades - The three-bay CMC Header assembly consisting of 154 blade contacts. - The blade contact interfaces are 0.6 mm, 1.50 mm and 2.80 mm. - This header assembly is intended to be attached to a printed circuit board by a press-fit compliant contact. Molex 53 / 48-wayCMC Connector System: • • • This is a sealed connection system. 53Way CMC Harness Connector – 64321xxxx / 98995xxxx 48Way CMC Harness Connector – 64320xxxx / 98993xxxx • Terminals used in the CMC connector system: - CP0.6 Sn Receptacle Terminal – 6432210x9 – 0.35mm2 - 0.75mm2 wire - CP0.6 Au Receptacle Terminal – 6432212x9 – 0.35mm2 - 0.75mm2 wire - CP1.5 Sn Receptacle Terminal – 6432310x9 – 0.5mm2 - 2.0mm2 wire - CP1.5 Au Receptacle Terminal – 643231x19 – 0.5mm2 - 2.0mm2 wire - CP2.8 Sn Receptacle Terminal – 6432410x9 – 2.5mm2 - 5.0mm2 wire Applicable Documents and Specifications • • • • • • • • • • REVISION: C 154way CMC Header Assembly – SD-34763-001 53way CMC Harness Connector – SD-64321-001 48way CMC Harness Connector – SD-64320-001 CP0.6 Sn Receptacle Terminal – SD-64322-001 CP1.5 Sn Receptacle Terminal – SD-64323-001 CP2.8 Sn Receptacle Terminal – SD-64324-001 EON 0.64 – SD-34481-012 EON 1.5 / 2.8 – SD-78007-012 32 and 48 CMC connector User Manual – AS-64319-001 53 way CMC connector User Manual –AS-64321-001 ECR/ECN INFORMATION: EC No: UAU2012-1574 DATE: 06/15/2012 DOCUMENT NUMBER: AS-34763-001 TITLE: SHEET No. 154 WAY CMC HEADER 3 of 16 CREATED / REVISED BY: CHECKED BY: APPROVED BY: Brian Zelinski Dave Krawczyk Ron Bauman TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC APPLICATION SPECIFICATION 154 WAY CMC HEADER 154 WAY CMC HEADER PRODUCT SUMMARY HIGHLIGHTS: • • • Connector is sealed. Connector provides temporary retention to the header before the Lever Arm is activated. Lever Arm remains in locked position until the harness connector is in pre-lock position on the header/controller. Compliant Interface • EON on 0.64 blades per SD-34481-012 • EON on 1.50 & 2.80 blades per SD-78007-012 • PCB specification - PCB in accordance with IEC 60352-5 - Material FR4 min. TG 130 - Single layer thickness larger than 0.8 mm - Total thickness of PCB from 1.5 to 2.4 mm in accordance with the IEC 60326-3. If other - PCB thickness required, Molex Engineering to approve. Temperature Operating: -40°C to +105°C Current • The maximum test current capability per USCAR-2 rev5: - 0.6 blade mated to a CP0.6 Sn or Au plated receptacle crimped to 0.75mm2 wire – 8.0 A - 1.50 blade mated to a CP1.5 Snor Au plated receptacle crimped to 2.0mm2 wire – 10.5 A - 2.80 blade (single strap) mated to a CP2.8 Sn plated receptacle crimped to 5.0mm2 wire – 13.5 A - 2.80 blade (dual strap) mated to a CP2.8 Sn plated receptacle crimped to 5.0mm2 wire – 17.0 A Voltage 250VAC per PS-64321-001 and PS-64319-001 For product ordering information, please contact your Molex Inside Sales Representative at (800)786-6539. For electronic copies and future updates of this document, and the Connector Reference Manual, refer to the Molex Website at http://www.molex.com/ REVISION: C ECR/ECN INFORMATION: EC No: UAU2012-1574 DATE: 06/15/2012 DOCUMENT NUMBER: AS-34763-001 TITLE: SHEET No. 154 WAY CMC HEADER 4 of 16 CREATED / REVISED BY: CHECKED BY: APPROVED BY: Brian Zelinski Dave Krawczyk Ron Bauman TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC APPLICATION SPECIFICATION 154 WAY CMC HEADER THIS PROCEDURE APPLIES TO ALL PART NUMBERS IN THE 34763-00xxSERIES REVISION: C ECR/ECN INFORMATION: EC No: UAU2012-1574 DATE: 06/15/2012 DOCUMENT NUMBER: AS-34763-001 TITLE: SHEET No. 154 WAY CMC HEADER 5 of 16 CREATED / REVISED BY: CHECKED BY: APPROVED BY: Brian Zelinski Dave Krawczyk Ron Bauman TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC APPLICATION SPECIFICATION 154 WAY CMC HEADER HEADER OVERVIEW PAP – “Pin Alignment Plate” 2.8 Blade 0.6 Blade 1.5 Blade 53 Way Pocket 53 Way Pocket 48 Way Pocket REVISION: C ECR/ECN INFORMATION: EC No: UAU2012-1574 DATE: 06/15/2012 DOCUMENT NUMBER: AS-34763-001 TITLE: SHEET No. 154 WAY CMC HEADER 6 of 16 CREATED / REVISED BY: CHECKED BY: APPROVED BY: Brian Zelinski Dave Krawczyk Ron Bauman TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC APPLICATION SPECIFICATION 154 WAY CMC HEADER 154 way CMC CAD MODEL REFERENCE CMC CADmodel reference for 154 way CMC header Top Plate, PCB and Casting. All CADmodels are to be used as REFERENCE ONLY. ALL FINAL DESIGNS FROM ALL CAD MODELS ARE THE RESPONSIBILITY OF THE CUSTOMER. Top Plate CM-34763-903 PCB CM-34763-901 154 way CMC Header Casting CM-34763-902 Holding Fixture CM-34763-904 REVISION: C ECR/ECN INFORMATION: EC No: UAU2012-1574 DATE: 06/15/2012 DOCUMENT NUMBER: AS-34763-001 TITLE: SHEET No. 154 WAY CMC HEADER 7 of 16 CREATED / REVISED BY: CHECKED BY: APPROVED BY: Brian Zelinski Dave Krawczyk Ron Bauman TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC APPLICATION SPECIFICATION 154 WAY CMC HEADER 154 WAY CMC HEADER PRODUCT IDENTIFICATION • All parts are laser marked with: Area (A) - Marking and Reading Standard: Data Matrix (ECC200) - Information Encoded: • CC – Configuration Number Per Configuration / BOM Table • YY – Year • DDD – Day of year • SSSS – Incremental Serial Number • MXN – Supplier Designation/Manufacturing Location Area (B) - Human readable code (HRC) - Information Encoded: • 9 Digit Molex Material Number • 4 Digit Julian Manufacturing Date Stamp DDDY • 4 Digit Incremental Serial Number • 1 Digit Molex Manufacturing Code Area (A) Area (B) XXXXXXXXX XXXX XXXXX X REVISION: C ECR/ECN INFORMATION: EC No: UAU2012-1574 DATE: 06/15/2012 DOCUMENT NUMBER: AS-34763-001 TITLE: SHEET No. 154 WAY CMC HEADER 8 of 16 CREATED / REVISED BY: CHECKED BY: APPROVED BY: Brian Zelinski Dave Krawczyk Ron Bauman TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC APPLICATION SPECIFICATION 154 WAY CMC HEADER 154 WAY CMC HEADER PACKAGING Molex recommends moving the cell pack box directly to the assembly line, this will insure against damage. Headers should remain in the Molex cell pack until assembled. Parts as received in cell pack PAP is not in pre-lock position scrap header PAP is shipped in pre-lock position All headers shipped in cell packed boxes REVISION: C ECR/ECN INFORMATION: EC No: UAU2012-1574 DATE: 06/15/2012 DOCUMENT NUMBER: AS-34763-001 TITLE: SHEET No. 154 WAY CMC HEADER 9 of 16 CREATED / REVISED BY: CHECKED BY: APPROVED BY: Brian Zelinski Dave Krawczyk Ron Bauman TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC APPLICATION SPECIFICATION 154 WAY CMC HEADER 154 WAY CMC HEADER-TO-PCB ASSEMBLY INSTRUCTIONS (Recommended header mounting strategies and mounting steps: areas where to apply force to seat header to the PCB) Header Fixture CM-34763-904 PCB Step 1 - Line up CMC to Fixture REVISION: C ECR/ECN INFORMATION: EC No: UAU2012-1574 DATE: 06/15/2012 DOCUMENT NUMBER: AS-34763-001 Step 2 – Slide CMC Header on Fixture Step 3 – Place PCB on CMC Header TITLE: SHEET No. 154 WAY CMC HEADER 10 of 16 CREATED / REVISED BY: CHECKED BY: APPROVED BY: Brian Zelinski Dave Krawczyk Ron Bauman TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC APPLICATION SPECIFICATION Step 4 – Press down on the PCB in these locations ONLY to mate the PCB to the CMC header DIM (A) DIM (A) – see EON Sales Drawings NOTE: DO NOT APPLYANY PRESSURE TO PINS. PRESSURE PLACED ON THE HEADER PINS MAY DAMAGE THE ASSEMBLY. REVISION: C ECR/ECN INFORMATION: EC No: UAU2012-1574 DATE: 06/15/2012 DOCUMENT NUMBER: AS-34763-001 TITLE: SHEET No. 154 WAY CMC HEADER 11 of 16 CREATED / REVISED BY: CHECKED BY: APPROVED BY: Brian Zelinski Dave Krawczyk Ron Bauman TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC APPLICATION SPECIFICATION 154 WAY CMC HEADER 154 WAY CMC HEADER-TO-PCB ASSEMBLY TOOLING Molex also offers a low volume PCB to header assembly tool for the 154way CMC Header. For product ordering information, please contact your Molex Inside Sales Representative at (800)786-6539. Reference- 154 Way PCB Insertion Tool Operation Manual Order No. 62203-0500 REVISION: C ECR/ECN INFORMATION: EC No: UAU2012-1574 DATE: 06/15/2012 DOCUMENT NUMBER: AS-34763-001 TITLE: SHEET No. 154 WAY CMC HEADER 12 of 16 CREATED / REVISED BY: CHECKED BY: APPROVED BY: Brian Zelinski Dave Krawczyk Ron Bauman TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC APPLICATION SPECIFICATION 154 WAY CMC HEADER 154 WAY HEADER PCB SIDE PROBING Electrical continuity check list Probe pin recommendations: 1. When testing the header for continuity it is imperative that you do not damage the pins. 2. Pogo pins should be checked for damage or sticking several times a shift. This should assure containment if an issue is found. 3. First a visual inspection of all the pins for damage should be performed. 4. Next a testing block should be used to depress all the pogo pins up into the barrel. If there is a bent or sticking pin, it should remain stuck in the barrel of the pogo pin. A damaged or stuck pin should be replaced before any additional testing is performed. Probing damage can occur: 1. If a sharp ended probe is used to contact the end terminal it may damage the pin tip and plating and increase contact resistance and mate force. 2. If a probe is inserted into the header on an angle or off center it may damage the pins, and or the connector. 154 way CMCPCB SIDELAYOUT (see SD-34763-001) REVISION: C ECR/ECN INFORMATION: EC No: UAU2012-1574 DATE: 06/15/2012 DOCUMENT NUMBER: AS-34763-001 TITLE: SHEET No. 154 WAY CMC HEADER 13 of 16 CREATED / REVISED BY: CHECKED BY: APPROVED BY: Brian Zelinski Dave Krawczyk Ron Bauman TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC APPLICATION SPECIFICATION 154 WAY CMC HEADER 154 WAY HEADER HARNESS SIDEPROBING Electrical continuity check list Probe pin recommendations: 5. When testing the header for continuity it is imperative that you do not damage the pins. 6. Pogo pins should be checked for damage or sticking several times a shift. This should assure containment if an issue is found. 7. First a visual inspection of all the pins for damage should be performed. 8. Next a testing block should be used to depress all the pogo pins up into the barrel. If there is a bent or sticking pin, it should remain stuck in the barrel of the pogo pin. A damaged or stuck pin should be replaced before any additional testing is performed. Probing damage can occur: 3. If a sharp ended probe is used to contact the end terminal it may damage the pin tip and plating and increase contact resistance and mate force. 4. If a probe is inserted into the header on an angle or off center it may damage the pins, and or the connector. 154 way CMC HARNESS SIDELAYOUT (see SD-34763-001) REVISION: C ECR/ECN INFORMATION: EC No: UAU2012-1574 DATE: 06/15/2012 DOCUMENT NUMBER: AS-34763-001 TITLE: SHEET No. 154 WAY CMC HEADER 14 of 16 CREATED / REVISED BY: CHECKED BY: APPROVED BY: Brian Zelinski Dave Krawczyk Ron Bauman TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC APPLICATION SPECIFICATION 154 WAY CMC HEADER 53 WAY AND 48WAY CMC CONNECTOR MATING& UNMATING The color marking on the cam Posts on the CMC header corresponds to the color of the front face of the connector that is to be mated to the correct bay. Mating the connector: 1. The lever must be in open (delivery) position before mating operation. 2. Insert the connector till it stops in the header pocket. 3. Rotate the lever and lock it on the wire cap. Color marking on header The lever must be in open (delivery) position before mating operation. - Insert the connector till it stops in the header pocket. - Rotate the lever till the stop and the locking on the cover REVISION: C ECR/ECN INFORMATION: EC No: UAU2012-1574 DATE: 06/15/2012 DOCUMENT NUMBER: AS-34763-001 TITLE: SHEET No. 154 WAY CMC HEADER 15 of 16 CREATED / REVISED BY: CHECKED BY: APPROVED BY: Brian Zelinski Dave Krawczyk Ron Bauman TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC APPLICATION SPECIFICATION Locking latch (on the wire cap / wire dress cover) Unmating the connector: 1. Press on the locking located on the wire cap and rotate the lever until its locking on the female housing 2. Remove the female connector from the header REVISION: C ECR/ECN INFORMATION: EC No: UAU2012-1574 DATE: 06/15/2012 DOCUMENT NUMBER: AS-34763-001 TITLE: SHEET No. 154 WAY CMC HEADER 16 of 16 CREATED / REVISED BY: CHECKED BY: APPROVED BY: Brian Zelinski Dave Krawczyk Ron Bauman TEMPLATE FILENAME: APPLICATION_SPEC[SIZE_A](V.1).DOC