0934457111

PRODUCT SPECIFICATION ML-XT COMMERCIAL VEHICLE CONNECTOR SERIES 1.0 SCOPE This Product Specification relates to the ML-XT Commercial Vehicle, (CV), Power and/or Signal wire-to-wire connector system. This system consists of 7 circuit sizes, 2, 3, 4, 6, 8, 12 and 18cct. The product terminals terminate with 20 to 12AWG wires using crimp technology (Please Contact Molex Sales representative for 12 & 20 AWG options). 2.0 PRODUCT DESCRIPTION 2.1 PRODUCT NAME AND SERIES NUMBER(S) ML-XT Receptacle Assembly: ML-XT Plug Assembly: ML-XT Receptacle Terminal (Male Pin): ML-XT Plug Terminal (Female Socket): ML-XT Receptacle Wedgelock: ML-XT Plug Wedgelock: ML-XT Receptacle W/Heat Shrink Assembly: ML-XT Plug W/Heat Shrink Assembly: 93444 93445 84524 84525 93447 93448 93444 Variation 93445 Variation 2.2 DIMENSIONS, MATERIALS, PLATINGS AND MARKINGS Housings: Nylon, 30% Glass filled, UL 94 HB Plug Seal: Liquid Silicone Rubber Back Seal: High Consistency Rubber Wedgelocks: Nylon, 30% Glass filled, UL 94 HB Female Receptacle Terminal: Copper Alloy, Nickel plating and Hard Gold over Nickel option Male Pin Terminal: Copper Alloy, Nickel plating and Hard Gold over Nickel option 2.3 SAFETY AGENCY APPROVALS UL File Number: Not Applicable CSA File Number: Not Applicable TÜV License Number: Not Applicable 3.0 APPLICABLE DOCUMENTS AND SPECIFICATIONS 934430010 PSD ML-XT 2cct Assembly Sales Drawing 934430020 PSD ML-XT 3cct Assembly Sales Drawing 934430030 PSD ML-XT 4cct Assembly Sales Drawing 934430040 PSD ML-XT 6cct Assembly Sales Drawing SD-93443-005 ML-XT 8cct Assembly Sales Drawing SD-93443-006 ML-XT 12cct Assembly Sales Drawing SD-93443-007 ML-XT 18cct Assembly Sales Drawing PK-93443-001 ML-XT Packaging Specification SD-84524-001 Male Pin Terminal 16-18AWG Sales Drawing SD-84524-002 Male Pin Terminal 14-18AWG Thin Wall Sales Drawing SD-84524-003 Male Pin Terminal 14-18AWG Sales Drawing SD-84525-001 Female Socket Terminal 16-18AWG Sales Drawing SD-84525-005 Female Socket Terminal 14-18AWG Thin Wall Sales Drawing SD-84525-007 Female Socket Terminal 14-18AWG Sales Drawing REVISION: ECR/ECN INFORMATION: TITLE: B EC No: 105261 DATE: 2016/05/30 DOCUMENT NUMBER: 934430010/PS/P/B SHEET No. ML-XT CV CONN SERIES PRODUCT SPECIFICATION 1 of 8 CREATED / REVISED BY: CHECKED BY: APPROVED BY: FDUGGAN NDOWDS JDWALLACE TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A4](V.1).DOC PRODUCT SPECIFICATION 4.0 RATINGS 4.1 CURRENT AND APPLICABLE WIRES AWG Amps 20 7.5 18 10 16 13 14 13 4.2 TEMPERATURE Operating: - 55°C to + 125°C Non-operating: - 55°C to + 125°C 5.0 PERFORMANCE 5.1 VISUAL REQUIREMENTS ITEM 1 DESCRIPTION Examination of Product SAE J2030, 6.1 2 TEST CONDITION REQUIREMENT Meets requirements of product drawing. All parts shall be free of hazardous substances. All parts to be free of dirt and grease. No Defects Parts checked for: Identification, Workmanship Finish, Markings, Cosmetic issues, Tool marks, Torn seals etc. Conduct a visual examination for identification of product such as torn seals, Visual Examination cracked plastic, evidence of fluid or dust ingress in sealed connector systems, SAE J2030, 6.27 arcing, charring, melting, or anything that could affect the performance and serviceability of the product. No Visual Defects as per Section 6.27 SAE J2030 5.2 ELECTRICAL REQUIREMENTS ITEM DESCRIPTION 3 Low voltage Resistance SAE J1614, 4.3.6 4 Insulation Resistance SAE J2030, 6.3 5 Connection Resistance @ Rated Current SAE J2030, 6.4 TEST CONDITION REQUIREMENT Test with applied voltage not exceeding 20mV open circuit and the test current shall be limited to 100mA. Maximum Resistance 10.0mOhms initial 20.0mOhms post endurance testing Apply a voltage of 1000 VDC between adjacent terminals and between terminals to ground. 20 MegaOhms Minimum Mate connectors: Measurements shall be taken after thermal equilibrium at rated current level. Voltage Drop not to Exceed levels in Table 1 (See Appendix 3) REVISION: ECR/ECN INFORMATION: TITLE: B EC No: 105261 DATE: 2016/05/30 DOCUMENT NUMBER: 934430010/PS/P/B SHEET No. ML-XT CV CONN SERIES PRODUCT SPECIFICATION 2 of 8 CREATED / REVISED BY: CHECKED BY: APPROVED BY: FDUGGAN NDOWDS JDWALLACE TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A4](V.1).DOC PRODUCT SPECIFICATION 6 7 Current Test @ Rated Current SAE J2030, 6.22 Voltage Drop not to Exceed levels in Table 3 of Section SAE J2030 6.4.1 (Use PS Rated Current: See Appendix 3) Apply maximum rated current to all o terminals. Ambient temperature: 125 C o +/-3 C for 24H a. 200 off/on cycles, at ambient of 125 °C ± 3 °C, each cycle to consist of 45 min on, 15 min off. b. 50 cycles of following: 20 min on at 125 Acceptance criteria per section Current Cycling Test °C ± 3 °C, 60 off at 21 °C ± 1 °C. 6.4 of SAE J2030. @Rated Current Transition rate is to be (Use PS Rated Current: See SAE J2030, 6.25 3 °C/ min +3/–0 °C/min without current Appendix 3) applied. c. Repeat a. and b. to complete 500 cycles 5.3 MECHANICAL REQUIREMENTS ITEM 8 DESCRIPTION Connector Mating Force TEST CONDITION REQUIREMENT Mate the male and female connectors. (Latches included) 135 N Maximum Unmate the male and female connector. (Latches disengaged) 135 N Maximum SAE J2030, 6.9 9 Connector Unmating Forces SAE J2030, 6.10 10 Terminal Retention in Connector Apply 110N load to the terminals in the connector housing for 1 minute. No Terminal Unmating Mate connectors and shock at 50 g with ½ sine wave (11 milliseconds) shocks in the X,Y,Z axes (10 shocks per axis total). 10 Ohms Maximum No discontinuity > 1 microsecond at 100 mA SAE J2030, 6.18 11 Shock (Mechanical) SAE J2030, 6.16 Vibration 12 SAE J2030, 6.15 Mate connectors; Sine sweep of 10 Hz to 2,000 Hz, back to 10 Hz in 20min, Test 10 Ohms Maximum duration 24hrs 1.78 mm displacement, 20 No discontinuity > 1 g acceleration. 12 cycles in each of the 3 microsecond at 100 mA for the mutually perpendicular axis. Apply the last hour of vibration in each rated current per table 3 of SAE J2030 for axis. the first 3 hours in each axis. REVISION: ECR/ECN INFORMATION: TITLE: B EC No: 105261 DATE: 2016/05/30 DOCUMENT NUMBER: 934430010/PS/P/B SHEET No. ML-XT CV CONN SERIES PRODUCT SPECIFICATION 3 of 8 CREATED / REVISED BY: CHECKED BY: APPROVED BY: FDUGGAN NDOWDS JDWALLACE TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A4](V.1).DOC PRODUCT SPECIFICATION Drop Test 13 SAE J2030, 6.17 14 Durability between Male and Female connectors 8 Drops from a height of 750 +/-25mm onto a concrete floor while attached to a cord 1500 +/- 25mm long. Rotate the connector through 45 degrees for each drop. See Section 6.17 of SAE J2030 Mate and unmate the connectors by hand at 10 cycles per minute for 50 cycles. See Section 6.11 of SAE J2030 SAE J2030, 6.11 222N applied to the 2cct 333N applied to the 3cct 15 Connector Retention Apply an axial pulling force to the mated connectors for 30s. SAE J2030, 6.20 350N applied to the 4cct and 6cct. Deviation from SAE J2030, 6.20 due to plug design constraints. 444N applied to the 8cct, 12cct and 18cct. 16 Connector Mismating Apply an axial force to same circuit size connectors with various keying options Polarization to resist 178N minimum mating force without change. The tensile strength of the crimped connection shall be tested within the range of 20 mm to 100 mm/ min. If the terminal has a cable insulation crimp it shall be rendered mechanically ineffective. See Table 6 of SAE J2030, 6.26. SAE J2030, 6.21 17 Terminal Crimp Strength SAE J2030, 6.26. 5.4 ENVIRONMENTAL REQUIREMENTS ITEM DESCRIPTION Thermal Shock 18 SAE J2030, 6.13 TEST CONDITION REQUIREMENT Cabled & mated connectors subjected to 10 cycles of thermal shock (soak @ -55˚C ambient then transition within 2 minutes to 125˚C ambient & soak before transition back to -55˚C. Soak time to ensure internal connector temp is within 5 C of ambient. No evidence of cracking or chipping or other damage / impaired operation allowed. No evidence of cracking, chipping or other detrimental damage to normal operation. REVISION: ECR/ECN INFORMATION: TITLE: B EC No: 105261 DATE: 2016/05/30 DOCUMENT NUMBER: 934430010/PS/P/B SHEET No. ML-XT CV CONN SERIES PRODUCT SPECIFICATION 4 of 8 CREATED / REVISED BY: CHECKED BY: APPROVED BY: FDUGGAN NDOWDS JDWALLACE TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A4](V.1).DOC PRODUCT SPECIFICATION Tested per SAE J2030 6.4 19 (Use PS Rated Current: See Appendix 3) for power circuit, Temperature/ Humidity (Cyclic) SAE J1614 4.3.6 for signal circuits (dependent upon power level requirements of contacts), and insulation resistance per SAE J2030 6.3. Visual: No Damage See Appendix 2 SAE J2030, 6.24 Mated connectors Duration: 96 hours exposure; Atmosphere: salt spray from a 5% by weight solution; Temperature: 35 +/-3°C; Allow to dry for 4 hours. Visual: No Detrimental evidence of corrosion on the connector or contacts. 21 Submerge mated connectors for 5 cycles of 5 minutes at the specified temperature in the following fluids: motor oil, brake fluid, diesel fuel, 50/50 anti-freeze mixture, Roundup original and aqueous urea. Visual: No Damage Post Test 22 Place wired connectors in oven at 125 C +/0 3 C for 1H and immediately place in 5% salt solution by weight content and 0.1g/L wetting agent to 1m for 4H. Water temp 0 0 23 C +/-3 C. Test for insulation resistance. Salt Spray 20 SAE J2030, 6.12 Fluid Resistance 0 Water Immersion SAE J2030, 6.19 Dust Test 23 SAE J2030, 6.23 24 25 Expose mated connectors to dust equivalent No impairment of function, to air cleaner fine dust defined by SAEJ726. performance and serviceability Minimum suspension concentration: per Severity Level 2 of ASABE 3 0.88g/m for 24H. EP455 Item 5.3.1 The test apparatus should be designed to provide 100% coverage of the exposed Pressure Washing surface of the mated and cabled connectors SAE J2030, 6.5 using flat fan spray nozzles located 20 cm to 30 cm away. The test should be run at 40 °C Maintenance Aging SAE J2030, 6.6 Insulation Resistance 20 MegaOhms Minimum. Visual: No moisture inside. An Insulation Resistance test (see SAE J2030 section 6.3) shall be conducted after this test. Subject 10% of the cavities to ten cycles of inserting and removing its respective contact. The ten cycles shall also include any See Section 6.6 of SAE J2030 disassembly required to remove the contacts. The connectors shall be mated and unmated during each cycle. 26 The cabled-mated connectors shall be Temperature Life subject to 1000 h at 125 °C ± 3 °C without SAE J2030, 6.7 current flowing. There shall be no evidence of cracking, distortion, or detrimental damage. 27 Expose the mated connectors for 1000 h per ASTM G 155 with extended U.V filter or Ultraviolet Effects ASTM G 154 using an unfiltered UVA 340 SAE J2030, 6.8 lamp with 20 h UV and 4 h of condensation for each cycle. See section 6.8 of SAE J2030 REVISION: ECR/ECN INFORMATION: TITLE: B EC No: 105261 DATE: 2016/05/30 DOCUMENT NUMBER: 934430010/PS/P/B SHEET No. ML-XT CV CONN SERIES PRODUCT SPECIFICATION 5 of 8 CREATED / REVISED BY: CHECKED BY: APPROVED BY: FDUGGAN NDOWDS JDWALLACE TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A4](V.1).DOC PRODUCT SPECIFICATION 6.0 QUALIFICATION TEST GROUPS AND SEQUENCES No 1 3 4 Item Examination of Product Low-Voltage Resistance Insulation Resistance 21 12 11 13 Connection Resistance Pressure Washing Maintenance Aging Temperature Life Ultraviolet Effects Mating Forces Unmating Forces Durability Salt Fog Thermal Shock Fluid Immersion Vibration Shock Drop Test 10 Terminal Retention in Connector 22 Water Immersion 15 16 6 Connector Retention Mismating Current Test 5 24 25 26 27 8 9 14 20 18 Test Group 1 2 3 4 5 1 1 1 1 1 2,14 2,11,16 3,6,8,17,19 3,14 2 2, 13 4 4 3 3, 15 5 2 5 4 4 3 6 4 5 7 8 5 6 6 7 7 9 9 10 12 13 15 10 12 5 8 9 10 6 7 16 7 8 9 11 REVISION: ECR/ECN INFORMATION: TITLE: B EC No: 105261 DATE: 2016/05/30 DOCUMENT NUMBER: 934430010/PS/P/B SHEET No. ML-XT CV CONN SERIES PRODUCT SPECIFICATION 6 of 8 CREATED / REVISED BY: CHECKED BY: APPROVED BY: FDUGGAN NDOWDS JDWALLACE TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A4](V.1).DOC PRODUCT SPECIFICATION 23 19 7 17 2 Dust Test Temperature /Humidity Current Cycling Terminal Crimp Strength Visual Examination 18 15 16 13 12 14 10 11, 20 17 8 11 17 Test Groups 1, 2, 3, and 4 are for sealed signal level connectors. Test Groups 3, 4 and 5 are for sealed power level connectors. Test Groups 2, 3, and 4 are for unsealed signal level connectors. Test Groups 3, 4, and 5 are for unsealed power level connectors 7.0 PACKAGING Parts shall be packaged to protect against damage during handling, transit and storage; reference the appropriate Packaging Specification. APPENDIX 1 CONTACT RESISTANCE MEASUREMENT Notes: 1. All dimensions are in millimetres 2. Measuring points are on the cable 3. Points of electrical connection are typically the joint of the cable to the terminal REVISION: ECR/ECN INFORMATION: TITLE: B EC No: 105261 DATE: 2016/05/30 DOCUMENT NUMBER: 934430010/PS/P/B SHEET No. ML-XT CV CONN SERIES PRODUCT SPECIFICATION 7 of 8 CREATED / REVISED BY: CHECKED BY: APPROVED BY: FDUGGAN NDOWDS JDWALLACE TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A4](V.1).DOC PRODUCT SPECIFICATION APPENDIX 2 Test samples to be placed in a temperature/humidity chamber and shall be subjected to 42 cycles described as follows: a. Chamber temperature raised to + 55ºC at 3ºC/min ± 1ºC/min. b. Chamber held for 16 hours at a relative humidity of 95 % ± 5% c. Chamber temperature lowered to - 55ºC at 3ºC/min ± 1ºC/min. d. Chamber held for 2 hours e. Chamber temperature raised to + 125ºC at 3ºC/min ± 1ºC/min. f. Chamber held for 2 hours g. Chamber temperature lowered to + 25ºC at 3ºC/min ± 1ºC/min. h. Chamber held for remainder of 24 hour cycle APPENDIX 3 Measurements at specified Current: Cable Size mm² (AWG) 14 16 18 20 Test Current Amps 13 13 10 7.5 Maximum Millivolt Drop (cable to device) (cable to cable) 100 100 100 100 Table 1: Measurements at Specified Current REVISION: ECR/ECN INFORMATION: TITLE: B EC No: 105261 DATE: 2016/05/30 DOCUMENT NUMBER: 934430010/PS/P/B SHEET No. ML-XT CV CONN SERIES PRODUCT SPECIFICATION 8 of 8 CREATED / REVISED BY: CHECKED BY: APPROVED BY: FDUGGAN NDOWDS JDWALLACE TEMPLATE FILENAME: PRODUCT_SPEC[SIZE_A4](V.1).DOC