SMTC 3 862 001_2010 接插件的技术条件

7/21/2019 SMTC 3 862 001_2010

http://slidepdf.com/reader/full/smtc-3-862-0012010- 1/40

!"#$%&' ()*+ ,-.) Copyright SAIC Group Confidential

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Enterprise Technical Standard of SAIC Motor Technical Center

SMT

SMTC 3 862 001

2010

V1"

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Connectors Technical Condition

2010-07-13 !/Issue 2010-07-14 "#/Implementation

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Technical Standardization Committee of SAIC Motor Technical Center

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Issue

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$ %/Contents

! Foreward .................................................................... III 1 "# Scope................................................................................................................................................. 1

2 $"%&'() Normative references ...................................................................................................... 1

3 *+ Definition ............................................................................................................................................... 1

3.1 ,-) Connector ...................................................................................................................................... 1

3.2 ./0, Conductor connection ............................................................................................................. 2

3.3 1, Crimp connection ............................................................................................................................. 2

3.4 23% Gas tight ........................................................................................................................................ 3

3.5 4*56 Current ratings.......................................................................................................................... 3

3.6 .7 Cable ................................................................................................................................................. 3

3.7 89:;<= Class maximum temperature ......................................................................................... 3

3.8 >?<= Class test temperature ............................................................................................................ 3

4 ,-)@<=ABCDClassification by temperatur e45 EFGH Drawing information .................................................................................................................... 4

6 >?IJ Test programme ............................................................................................................................ 4

6.1KL Overview ............................................................................................................................................ 4

6.2MNOPQ Supplier responsibility .......................................................................................................... 5

7 >?RST%UVW Test procedures and performance requirements ................................................ 5

7.1 >?$" General test general specifications ........................................................................................ 6

7.2 XY-XYZ-[\T]^\Connection and disconnection of terminal ........................................... 7

7.3 .7Z_à= Tensile strength of cable attachment ......................................................................... 8

7.4 b`>? Side pull test .............................................................................................................................. 8

7.5 XY-cdZ-[\ Terminal-Housing insertion force ........................................................................... 9

7.6 XYecdfZgh\Contact retention in housing............................................................................ 9

7.7 XY-cdZ]^\ Intentional contact removal from housing .......................................................... 107.8 ij,-)Z0,Connection of assembled connectors.................................................................. 10

7.9 klmnoij,-)Z0, Intentional disconnection of assembled connectors ................ .......11

7.10 plmnoij,-)0,Unintentional disconnection of assembled connectors ....................11

7.11 4*56 Nominal current ratings ........................................................................................................ 12

7.12 ,q5r-s51 Contact resistance-low voltage .............................................................................. 12

7.13 tu5r Insulation resistance ............................................................................................................. 14

7.14 tua= Dielectric strength ................................................................................................................. 16

7.15 vw>? Watertigtness test ................................................................................................................ 16

7.16 xy>? Salt corrosion test ................................................................................................................ 18

7.17 z1{w High pressure water jet ........................................................................................................ 18

7.18 <=/|=>? Temperature / humidity test ........................................................................................ 18

7.19 }~• Fretting corrosion .................................................................................................................. 207.20 !">? Vibration Test ......................................................................................................................... 20

7.21 #$>? Bump test ............................................................................................................................... 22

7.22 <=/!"/|=%&>? Combined temperature/vibration/humidity/endurance test ................ ... 23

7.23 '(%U Mechanical performance ..................................................................................................... 24

7.24 cd)*:I+ Housing ergonomics ................................................................................................. 24

7.25 ,->? Misalignment test .................................................................................................................. 25

7.26 ./>? Inhibition ................................................................................................................................. 25

7.27 0$a=>? Impact strength test ...................................................................................................... 26

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7.28 <=12 Temperature cycling ............................................................................................................. 26

7.29 s<>? Low temperature ................................................................................................................... 26

7.30 345 Thermal ageing ......................................................................................................................... 27

7.31 30$>?678<=95:Thermal shock test (rapid change of temperature) ................. ...... 27

7.32 v;>? Dust ingress test ................................................................................................................... 27

7.33 <5+=/>? Chemical fluids .......................................................................................................... 28

7.34 >?>? Mycological test ..................................................................................................................... 297.35 •%2/>? Flowing mixed gas corrosion test ........................................................................... 29

7.36 @A>? Ozone ..................................................................................................................................... 30

7.37 rB>? Flammability test ................................................................................................................... 30

8 ,-)>?VW Connector test requirements ........................................................................................ 30

8.1 %UVW Connectors performance requirements ............................................................................... 30

8.2 >?CDE Housed connectors test procedure matrix ...................................................................... 33

FG A6$"%FG:-,-)!"?HI Annex A6normative annex:-Connector vibration test...36

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Foreword

This standard is established for the

premise to specify the Connectors TechnicalCondition of SMTC technical standard.

Please note that some contents in thisdocument may relate to patent rights, whichSAIC Group shall not be held responsible foridentifying any or all such patent rights.

This standard is in Chinese and English. Ifin doubt, the Chinese version is the Master.

Annex A is normative.This standard was proposed by electronic

& electric sub-committee. This standard was approved by the SMTC

Technical Standardization Committee.

This standard is under the management ofStandardization working team. The drafting department of this standard

is: Electronic & Electric Dept.The main drafters of this standard are:

Chen wenjun$Zhang bin$Zhou wei)Zhang

yuexian.

This standard was first published on Jul.

13,2010 and implemented on Jul. 14, 2010.

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1 Scope

This standard specifies theperformance of inline connectors, PCB

connectors, connectors molded ontocomponents.

This standard applies to componentsas fitted to passenger cars, commercialderivatives, 4x4 off-road vehicles andcommercial vehicles, intended for allmarket zones, with nominal 12 V or 24 Velectrical systems.

For battery cable connectors seeSMTC 3 865 001 Battery Cable Assemblies.

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2 Normative references

The following normative documentscontain provision which, through referencein this text, constitute provisions of thisstandard. For dated reference,subsequent amendments to, or revisionsof, any of these publications do not apply(exclude the correction), but parties toagreements based on this standard areencouraged to investigate the possibility ofapplying the most recent editions of thestandards. For undated references, thelatest edition of the normative documentreferred to applies.

SMTC 3 800 001 Generic Electrical/Electronic Component Test

SMTC 3 861 003 Low-Voltage Wirefor Automobile Test Procedure

ES 62.21.632 CombinedTemperature, Vibration, andHumidity Test

BS EN 50 102 Impact Protection (IKcode)

BS EN 60068-2-29 EnvironmentalTest

DIN IEC 512-3 Current CarryingCapacity Tests

FMVSS302 Flammability 3 ./012

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3 Terms and Definition

For the purpose of this Standard thefollowing definitions apply.

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3.1 Connector

The assembly of one or moreterminals, a housing and any associatedparts to facilitate with the electrical

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connection of circuits.

3.1.1 Terminal

Electrical Terminals located in theconnector housing that include Male andFemale types.

a. Male terminal

Male terminal based on a flatrectangular shape, usually a blade or pin.

b. Female terminalFemale terminal based on a

cylindrical shape.

3.1.2 Housing

Plastic protective body that surroundsand retains the terminals.

a. Male Connector housingDesigned to accept the male terminals.

b. Female Connector housingDesigned to accept the female

terminals.

3.1.3 Accessorial part

a. CPA (Connector Position Assurance)

Mechanism assures correct connectorassembly with positive locking action.

b. TPA (Terminal Position Assurance)Mechanism keeps terminals correctly

located into connector and prevents anybacking out.

c. SealedSeals fixed on the leads and

terminals, avoiding water getting insideconnector and causing short circuits. Usedon water proof connectors in wet areas ofthe vehicle.

d. Dummy PlugComponent inserts into connector

cavity to avoid water getting into connectorand causing short circuit.

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3.2 Conductor Connection

The electrical and mechanicalconnection between a connector and aconductor.

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3.3 Crimp Connection

A conductor connection obtained bypressure forming or re-shaping the barreland the conductor within it so as toestablish a good electrical and mechanicalcontact.

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Crimp where there are no voids or airpockets within the crimp barrel.

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3.5 Current Ratings

The nominal current ratings aredefined as the current through one circuitof a mated connection which causes a30 rise on the surface of the contactoperating in an ambient temperature.

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3.6 Cable

3.6.1 Thin Wall Cable

Cable whose insulation is 0.25mm to0.40 mm depending on the cross-sectionalarea of the conductor.

3.6.2 Irradiated Cable

Cable insulated with irradiationcross-linked polymers.

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3.7 Class Maximum Temperature

The maximum operating temperatureof the connector system. The connectorcan carry 0 A at and above thistemperature. Limit is set through materialcharacteristics and the ability to passcurrent through the separable interface.

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3.8 Class Test Temperature

Temperature for testing the connectorsystem at. Limits are set through thematerials mechanical properties and ingeneral outside the connector systemsoperating limits.

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4 Classification by temperature

Applicable to the following classes: At class maximum temperature

(e.g.70 R for Class 1) the connector will

carry no current.Required life 12 years.

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Table -1 Connector Temperature Classes

AB/Class 2s<=R/ Environmental Temperature

1 -40 Rm+70 R

2 -40 Rm+85 R

3 -40 Rm+100 R

4 -40 Rm+125 R

5 -40 Rm+150 R

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5 Drawing information

The drawing should contain all therelevant information regarding themechanical, environmental and electricalspecification.

All dimensions quoted on drawings

shall be to S.I. units.The following information is to be

supplied on a SMTC Product Engineeringdrawing frame.

On acceptance of an existing or newconnector system the drawing mustcontain the following information.

a. supplier part number and drawingrevision

b. component family and number ofcavities

c. mating half part numbersd. overall component dimensionse. component control dimensions (i.e.

those which are critical to correctfunctioning)

f. molding dependenciesg. housing surface finishh. housing materiali. range of cable sizes for which the

connector is designed together withinsulation type e.g.

j. thin or thick wallk. seal materiall. terminal base material and plating ,

including dimensions (e.g. thickness,composition)

m. reference to supplier FMEA

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6.1 Overview

To obtain SMTC Product Engineeringapproval of new or existing designs, thesupplier shall supply the following:

a. A design FMEA.b. A detailed laboratory test report

showing conformity to allperformance, durability anddimensional requirements of this

specification. This report shall detailall measurements taken to showconformity to this specification.

c. A test summary sheet.d. Acceptance depends on thesatisfactory completion of all specifiedtests.

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6.2 Supplier responsibility

a. An SMTC Group Product Engineeringdetail drawing and 3D shall be preparedor updated by the supplier together.

b. All proposed subsequent changes ofmaterials, dimensions, etc. by the

Manufacturer/ Supplier must beconveyed to SMTC Group ProductEngineering, who may at their discretionrequest the re-validation of samples forapproval.

c. All drawings, connector database andassociated documentation must beupdated on approval of any change.

d. The manufacturer / supplier must informSMTC Group Product Engineering ofthe intended use of alternativematerials, component f itments, toolingetc. The intended change must conformto the requirements in Table-2 ChangeControl Process.

e. Routine audit checks on productionsupplies are the responsibility of thesupplier.

f. The level and frequency of the testingand the test programme content will beagreed with SMTC Group ProductEngineering before componentacceptance.

g. SMTC will confirm, where applicable,the suppliers concurrence to the agreeddrawing requirement.

h. It is the connector suppliers

responsibility to communicate anychanges with SMTC Group first tiersuppliers and manage change.

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Level of change requiring control tobe agreed between SMTC ProductEngineering and the supplier.

7 NOhi0)jkl 7 Test procedures and performancerequirements

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7.1 General test general specifications

a. Unless otherwise stated accuracy ofsetting is to be within the following

Temperature ^ 2 R (Performance

only)Temperature ^ 5 R (Temperature

cycling only)Voltage^1.5 %

Current^1.5 %

b. All instruments for checkingperformance shall be capable ofresolution equal to or better than 10%of the stated accuracy.

c. Instrumentation shall carry a validindication of calibration and thatcalibration shall be traceable tonational standards.

d. All dimensions shall be quoted in S.I.units unless otherwise stated.

e. Temperature shall be measured indegrees Celsius (R) unless otherwise

statedf. Room ambient temperature is defined

as623^5:R and a relative humidity

between 45 % and 75 % is used for alltests unless otherwise stated.

g. The samples shall comply with all therequirements of the componentdrawing.

h. Cables shall be fixed to the contacts inaccordance with the manufacturers specifications, evidence should be

provided to support this Crimp heightand width, crimp force and crimpcross-sectional area whereappropriate.

i. Cables used shall be in accordancewith 3 861 003 LOW-VOLTAGE WIREFOR AUTOMOBILE TESTPROCEDURE, and the cable(s) usedshall be noted in the test report.

j. Where the connector to be tested is onewhere the housing shell can cater fora range of ways e.g. 10 way shell size(referred to as parent) also used for 7,8 and 9 ways (referred to as children)

through cavity blanking, then it isreasonable to assume that themajority of the tests can be applied tothe parent. Where the child parts usedifferent terminal families to theparent then the assumption cannot beapplied and all tests must be appliedto the child parts.

k. All samples shall be labeled and storedby the supplier for 2 years.

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l. A master sample along with a copy ofthe test report will be kept by thesupplier. Each master sample shouldhave a master sample label which iscompleted and signed by SMTCGroup Product Engineering andcomponent supplier engineers and

will be kept by the supplier for aperiod of 10 years.

m. Test samples for all tests shall bepreconditioned for at least 16 hours atroom ambient temperature and nodirect solar.

n. Any mode of failure shall be recordedand supplied along with test samplesto SMTC Group Product Engineering.

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7.2.1 Test method

The rate for connection anddisconnection shall rise at a constantspeed between 50 mm/min and150 mm/min.

The applied speed shall be noted inthe test report.

The contact shall be subjected toconnection/disconnections cycles asdescribed in Table-3Connection/Disconnection Cycles.

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Table-3 Connection / Disconnection Cycles

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7.2.2 Performance requirements

The force shall be measured at: firstconnection, first disconnection, finalconnection, and final disconnection.

The maximum force to insert &remove the terminal shall comply with therequirements detailed on Table 4Engage/Disengage Forces.

If the dimensions of terminal are not inthe Table 4, the forces shall comply withthe requirements detailed on thecomponent drawing.

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Table 4 Engage/Disengage Forces

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0.64 &3.5

1.0 &5.5

1.5 &7

2.3 &10

4.8 &158 &20

9.5 &40

7.3 :CmwxyM 7.3 Tensile strength of cableattachment

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7.3.1Test method

The contact attached to the cable bythe normal production method.

If the cable breaks during the pull-offtest then the mode of failure must berecorded and supplied, along with

samples, to SMTC Group ProductEngineering for assessment.

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Table 5 Cable Pull Off Forces

.7mnQo/Nominal cross sectional area of conductor 6mm2: `*\/tensile strength 6N:

0.22 +40

0.35 +50

0.5 +70

0.75 +90

1 +115

1.5 +155

2 +195

2.5 +235

3 +260

4 +320

5 +360

6 +400

+10 +600

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Note: The minimum tensile strength of connections for cables with non-specified nominalcross-sectional area shall be determined by interpolation.

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Test results shall comply with therequirements of Table-5 Cable Pull Off

Force.

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7.4.1 Test method

The terminal shall be terminated withthe largest applicable cable size andassembled into housing.

An applied force to the connector inthe manner shown in Figure 1 Side Pull

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Test, of 80 % of the cable pull -off force(see Table-5 Cable Pull Off Force) shall beapplied.

The cavities chosen to test should bewithin the centre of the connector and atthe corners of the connector.

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Figure 1 Side pull tests

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The force shall not fracture or breakthe connector or terminal or short circuits.

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7.5.1 Test method

The insertion force of the contact intothe cavity shall be tested by using theminimum and maximum size of the cablewhich can be attached, and be applied inthe insertion direction via a test fixture, tobe positioned as close as possible to the

cable attachment to avoid pushing on thecable.Care should be taken that the contact

under test is inserted until locked asintended.

The rate for insertion shall rise to aconstant speed between 50 mm/min and150 mm/min until full insertion is achieved.

The applied speed and insertion forceshall be noted in the test report.

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The maximum force to insert theterminal in the cavity shall comply with therequirements detailed on the componentdrawing and no greater than 12 N.

7.6 56|78}m~•o 7.6 Contact retention in housing

7.6.1 NOrs

CpM=>fg64>?

7.6.1 Test method

The test method employed dependson the following:

a) Connectors with Fully IndependentSecondary Locking

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10


a) ek~<?@ADBZ,-)

1>XYCk$9DBkbTeD?`6XY

Z~/<X~4/9yhEZ\N|}XY

ecdj1"T

2>XYCk$ADBkbTV>vTpGB

*$ADB@+Z\TeD?`6XYZ

~/<X~4/9yhEZ\N|}XY

ecdj1"T

b) dek?@ADBZ,-)

XY@kZB*j-AVkbT

V>vTpGB*ADB@+Z\T

eD?`6XYZ~/<X~4/9yhEZ

\|}wXYecdj1"T

1. The contact shall have the primarylocking device only effective. A constantforce shall be applied to the front and/orback of the contact in an axial directionuntil the contact is displaced in thehousing.

2. The contact shall have the secondary

locking device only effective. The forcenecessary to apply the secondarylocking shall be measured andrecorded. A constant force shall beapplied to the front and/or back of thecontact in an axial direction until thecontact is displaced in the housing.

b) Connectors without IndependentSecondary Locking

The contacts shall have all lockingdevices effective.

The force necessary to apply lockingdevices other than the primary lockingshall be measured and recorded.

A constant force shall be applied tothe front and/or back of the contact in anaxial direction until the contact is displacedin the housing.

7.6.2 )jkl

>?:-N/&gh\9, 50 N TEFV

WT


The minimum force necessary todisplace the contact shall comply with therequirements detailed on the componentdrawing and not less than 50 N.

7.7 56-78mpqo 7.7 Intentional contact removal fromhousing

7.7.1 NOrs

XY@kB*j-F*JpbTeD?`

6XYZ~/<X~4/9yhEZ\|}

XYGcdj1^T

7.7.1 Test method

The contacts shall have all lockingdevices rendered ineffective. A constantforce shall be applied to the front and/orback of the contact in an axial directionuntil the contact is displaced in thehousing.

7.7.2 )jkl

>?:-N/&XY-cdZ]^\0,

20 NTHIEFVWT


The maximum force necessary todisplace the contact shall comply with therequirements detailed on the component

drawing and less than 20 N.

7.8 !34-m<3 7.8 Connection of assembledconnectors

7.8.1 NOrs

p 50 mm/min} 150 mm/minAZ*8=6

-N|},-)~<J&T

7.8.1 Test method

The rate for the applied force shallrise to a constant speed between50 mm/min and 150 mm/min until fullengagement is achieved.

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-[8=pGe>?12jT The applied speed shall be noted inthe test report.

7.8.2 )jkl

>?:-N/&-[\0, 80 N THIE

FVWT


The minimum force necessary toengage the connector for the tenth timefrom the same mating part shall comply

with the requirements of the componentdrawing and shall not be more than 80 N.

7.9 "#$tu!34-m<3 7.9 Intentional disconnection ofassembled connectors

7.9.1 NOrs

cdZ@kB*j-F*JpbT

,-)V@XIE 30,/no0pJjZV

W>vpMk\$900,N$90noN8

X900,N8X90noT

7.9.1 Test method

The housings shall have all lockingdevices rendered ineffective.

The connector shall be subjected toconnection/disconnections cycles asdescribed in Table-3 Connection/Disconnection Cycle.

The force shall be measured at: firstconnection, first disconnection, finalconnection, and final disconnection.

7.9.2 )jkl

>?:-N/&]^\0, 80 NTHIEF

VWT


The minimum force necessary todisengage the connector for the tenth timefrom the same mating part shall complywith the requirements of the componentdrawing and shall not be more than 80 N.

7.10 %#$tu!34-<3 7.10 Unintentional disconnection ofassembled connectors

7.10.1 NOrs

x1,/.7ZXYj$w,-)NT~<

J&T

;'&:Zj-6~<-/XYZ,-)6

4>?T

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?`?cdNR4/9yO9Z\|w,-)0

,noT

7.10.1 Test method

Where a latching feature is a part ofthe connector the following test shall becarried out.

The test for connection of fullyterminated and assembled connectorsshall be carried out using a suitable testapparatus.

The housings shall be fully terminatedwith the maximum cable size. With thelatch fully engaged an increasing tensileforce perpendicular to the mating faces

shall be gradually applied to the housinguntil the connectors disengage.

7.10.2 )jkl

>?:-N/&]^\9, 140 N THIE

FVW&


The minimum force necessary todisengage shall comply with therequirements of the component drawingand shall not be less than 140 N.

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7.11 @1AB 7.11 Nominal current ratings

7.11.1 NOrs

fg DIN IEC 512-356tuZv64>?

Pw<=QR7[U8SZ-,qRZ[C

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sV64TjT

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,U89mnQo.7ZXY3'89Z7

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"T

>?:-'E 2 @eX+4*56/YBZ7

E',/F^|T

7.11.1Test method

This test shall be carried out inaccordance with DIN IEC512-3 with thefollowing criteria applied:

After fitting temperature probes to thecontacts as close as possible to theseparable interface, the device shall beassembled and the component examinedto ensure adequate retention andinsulation. If secondary locking is afeature, it shall be fitted.

The cable sizes chosen for aparticular terminal shall be as follows:

Minimum cable size for terminalaccepting smallest cross sectional area ofcable.

Maximum cable size for terminalaccepting largest cross sectional area ofcable.

For additional terminals within thefamily the terminals shall be terminatedwith the average cross-sectional areacable for that terminal.

The results shall be presented in theform of a Nominal Current Rating /Deratedcurve graph as shown in Figure 2 Nominalcurrent Rating.

V 2'2@1AB/(R)CV

Figure 2 Nominal Current Rating/Derated Curve

7.11.2 )jkl

>?:-N/&EFVWT


Test results shall comply with therequirements of with the requirements ofthe component drawing.

7.12 3*A+-,A= 7.12 Contact resistance-low voltage

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7.12.1 NOrs

'd`P 50 mAZ|65N@E 351Y>

?@e>v,q5rT}~[* 15 minX64>

vT

J5d4\XY[UveZtu]UN>v

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V,q5r*+JK'`6mV/A:AZ5rab

Q"#f.75rTJh*.7Z5rNV>v 5 mc.

7Z5rT6>(Z5r64no).T

7.12.1 Test Method

A mated connection attached by theproposed production method to cablesshall with direct current source notexceeding 50 mA flowing, shall have thecontact resistance measured at the points

defined in Figure 3 Voltage DropMeasurements. The measurement shallbe carried out at the first engagement andafter stabilising for a minimum of 15minutes.

During the measurement the opencircuit EMF of the source shall not exceed20 mV DC, in order to prevent thebreakdown of possible insulating films onthe contacts.

For less than three way connectors,all circuits shall be tested, or else anythree circuits shall be tested.

Note: For the purpose of this test, the contact

resistance is defined as the resistance betweenthe reference points (mV/A) less the resistance ofthe included cable (ohms). To establish theresistance of the cable, the resistance of a 5 mlength shall be measured and the resistance ofthe test cables calculated accordingly.

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V 3 A=(NO Figure 3 Voltage Drop Measurements

U 6 3*A+

Table 6 Contact Resistance - After Testing

dj$/unassembled Qj$/assembled

&!/Tin surface 5.0 efg5rT/estarting value 3.5 efg5rT/estarting value

&"/Silver surface 5.0 efg5rT/estarting value 3.0 efg5rT/estarting value

&#/Gold surface 3.0 efg5rT/estarting value 2.0 efg5rT/estarting value

Vfg5re62~3:m!T6,lmSz3bNZz56XYTlmO91YZs56G"NA[*Jd+

V@zZ,q5rT

Note: Typical starting resistances would be considered to be between 62~3:m!. Higher contact resistances

are considered undesirable for high current terminals because of the increased heating effect and also for lowcurrent signals where there is an increased voltage drop.

7.12.2 )jkl

,q5rHIIE 6 ,q5rJZVWT


Unless the component drawing statesotherwise the contact resistance shall notexceed that stated in Table 6 ContactResistance-After Testing.

7.13 -.A+ 7.13 Insulation resistance

7.13.1 NOrs 7.13.1 Test method

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e@k0,e9|ZXYT9y2hcdZ

#•7iA4/9y 500 V Z|651N}~h

E 1 minT

T<|LNVw#•7i,ST

>vnjXYAZtu5rNe(w[*kpXpGT

The insulation resistance shall bemeasured by applying 500 V DC betweenall contacts connected together and ametal foil surrounding the housing for aminimum period of 1 minute.

The metal foil shall be connected toearth for safety reasons.

The measurements shall also bemade between each adjacent contact.

The insulation resistance shall berecorded when a stable reading isobtained.

V 4 a)-.A+NO-56 Figure 4 a) Insulation Resistance Test$Connector Terminals

V 4 b)-.A+NO-34-

Figure 4 b) Insulation Resistance Test - Connector

7.13.2 )jkl 7.13.2 Performance requirements

500VInsulationTester

/500Vtu>?

#•7i/

Metal FoilSurround

500 V tu>?`/500 V InsulationTester

,S/

Earth Lead

,-)/

Connector

, S /Earth

Lead

,-)

/Connector

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>?:-N/&tu5r9, 100 M!T Insulation resistance shall be 100 M! minimum.

7.14 -.yM 7.14 Dielectric strength

7.14.1 NOrs

6@k0,e9|ZXYT2hcdZ#•7iN4/9ClZ 1 000 V(50 Hz)ZY651

< 1 600 VZ|651T

T<|LNw#•7i,ST

>vnjXYAZtu5rNekp[*X

pGT

7.14.1 Test method

An AC voltage of 1 000 V (50 Hz) or a

DC voltage of 1 600 V shall be applied for1 minute across all contacts connectedtogether and a metal foil surrounding thehousing.

The metal foil shall be connected toearth for safety reasons.

The measurements shall also bemade between each adjacent contact.

The insulation resistance shall berecorded when a stable reading isobtained.

7.14.2 )jkl

>?UA,-)d[^FQD5\T


No dielectric breakdown or flash-overshall occur during the test.

7.15 /0NO

WM>?mn_:',vwC<TjeBo

Z B1NC1ND1NEIJZ,-)NLIE 7Tj

IJCDprJT

7.15 Water tightness test

Applicable if the component isintended for exposed environments andvehicle zones B1, C1, D1, E, see table 7Installation Area Classification Codes.

U 7 1!23ST45

% 7 Installation Area Classification Codes

A Aqr

/Vehicle InteriorPassenger Compartment

A1 pOgVW/Without particular requirement

A2 |,X/Direct solar radiation

A3 ste3=WuM/With exposure to heat radiation(e.g. from heater)

A4 Aqrr•/Passenger compartment door

A4a AqrbQ/Attached to passenger compartment side

A4b •bQ/Attached to door cavity side

B1"*r

/Engine Compartment

B1 FeBv/ Attached to body

B2 Owy/ Attached to intake manifold

B3 1"*/ On/in the engine

B4 98x/ On/in the transmission

B5 y3r/ On/in the radiator

C Bvf~

/Vehicle Exterior Body

C1 Bv/ On the body

C2 eBvz{/ Under body/wheel housing

C3 dTj|}ZBz/BzDUnsprung masses wheel/axle

C4 V\IJ/Other area

C5 1"*r~•/Engine compartment bonnet

C6 4r!/Boot lid

C7 "•/Tail gate

C8 A#T C#jA/Between A and C pillars

D o5IJ/Cavity D1 $?fZo5/Cavities open to exterior D2 $?'Zo5/Cavities open to interior

E 4r/Boot E 4r/Boot/luggage compartment space

7.15.1 NOrs

@E 5 vw>?@e64vwO%Z>?N

7.15.1 Test method

Test apparatus as in Figure 5 Watertightness Test shall be used to test the

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17


w%=gheM<NT&'k8w/o( 5 %Z

xT 0.1 %Z)|*6+,x:T

wk}-[wj|wk}ÈQ-wQ

200 mm6LE 5vw>?:T

ww-Tk}Z[>?xjNx>?xjZ

1\Y} 60 kPaTghQ1\ 30 minT

i>?xj1\MYoNtoV(.k}T

ok2//^NTpGe>?12jT

cXp 2.5 kPa/min Z8=Sz1\|}w

h921680 90 kPa:T

Vjk+VNeQo[wk}G>?xj3^T

k}gh6200^10:mm Z0=1ewj

24 hNUA656640EL|T

@'=ik}64?HNCg';<rì

ik}Zdt5qT

water tightness of sealed connectors. Thewater solution shall be at room ambienttemperature, and shall consist of 5 % saltand 0.1 % wetting agent (dishwater soap)to water by volume.

The sample shall be inserted into thewater bath until the top surface of the

sample is 200 mm below the water surface(see Figure 5 Water tightness Test)

The water bath and sample shall beinserted into a vacuum chamber and thevacuum chamber pressure reduced to60 kPa and held at that pressure for 30minutes.

Whilst the chamber pressure is beingreduced the sample shall be visuallymonitored for escaping air, any beingnoted within the test report.

The pressure shall then be increasedby 2.5 kPa/min until atmospheric pressureis reached (a minimum of 90 kPa).

Note: At this point the sample can beremoved from the vacuum chamber if required.

The sample shall remain in the waterbath for a further 24 hours at a depth of

6 200^10:mm. Continuous electrical

monitoring shall be carried out whilst thesample is under test.

Where cavity blanking plugs can befitted to the housings the test shall berepeated on 2 samples each with 50 % ofthe cavities blanked, cavities blanked offshall not be repeated between samples.

V 5/0NO

Figure 5 Water tightness Test

7.15.2 )jkl

>?UApGOPiy&256Z90N3

56d`P 100 4 AT


The current into each pin shall becontinuously recorded. During the test theleakage current flow into any pin shall not

rise above 100 4 A.

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18


7.16 67NO

WM>?mn_:',vwC<TjeBo

ZB1NC1ND1NEIJZ,-)NLIE7TjI

JCDprJT

7.16 Salt corrosion test


7.16.1 NOrs

@X SMTC 3 800 001jIxy>?JZVW

64>?T

ed3^<dU56S>?24 hXN6k}

64I,q5r-s51JPMT

7.16.1 Test method

The assembled connector shall betested to the requirements of the !Salt

Spray Test in SMTC 3 800 001.

After 24 hours the sample, withoutbeing disengaged or otherwise disturbed,shall also be checked in accordance with!7.12 Contact resistance-low voltage.

7.16.2 )jkl

>?UApGOPiy&2Z5690N3

56d`P 100 4 ATO 500 V|65oN#•7AZ5r9, 1 M!Np7wF8^FT


The current into the pin shall becontinuously recorded. During the test theleakage current flow into the pin shall not

rise above 100 4 A. Resistance betweenthe circuit and the metal plate not be lessthan 1 M! when tested with 500 V DCapplied. Connectors shall be parted andany evidence of water or salt ingressrecorded.

7.17 8=90

WM>?mn_:',vwC<TjeBo

Z B1NC1ND1NEIJZ,-)NLIE 7Tj

IJCDprJT

7.17 High pressure water jet


7.17.1 NOrs

fg IP X5ZVW64>?T

9:kVW'NQ>?epMM)64

M<

21 86 kPaw 106 kPa

e(w SMTC bcl}:I~•*[Zfg

MN;<>?@X IP X6ZVW64T

7.17.1 Test method

This test is to be carried out to therequirements of IP X5.

The following environmentalconditions apply for this test unlessotherwise specified:

Room ambient temperature Air pressure 86 kPa to 106 kPa.On agreement of SMTC Group

Engineering testing to the requirements ofIP X6 is permissible.

7.17.2 )jkl

,q5r>?:-N/&IE 6 ,q5rJ

Z$*T


The contact resistance of theconnection shall not exceed valuesspecified in Table 6 ContactResistance-After Testing.

7.18 LM/:MNO 7.18 Temperature/humidity test

7.18.1 NOrs

>?nZTg.,-)e=P<=T|=Z

7.18.1 Test method

The purpose of the test is to ensurethe connectors correct function after being

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SMTC 3 862 001#2010 V1"

19


./M)XNUgh•U>#T

+;'$?ij/Z,-)64<=/|=

12>?T

>?oVCg;'XY;<Z89T80m

nQoZ57T

>?k}6$?0,:V@XME>?@J

64 10y12Niy12 24 hZ>?TAB<

=_-LE 8 |=>?Z<=VWT

subjected to extremes of temperature andhumidity.

The temperature / humidity cyclingtest shall be carried out using connectionswith the housings being fully populated.

The connector shall be tested withcables assembled of the minimum and

maximum cross-sectional areas that thecontact system allows.

The test samples (mated

connections) shall be subjected to 10cycles of 24 h of the following testsequence. The class of temperature istaken from Table 8 Humidity TestTemperatures.

V 6 LM/:M)C

Figure 6 Temperature/Humidity Profile

a)gh>?xZ<=e623^5:RNn6|=6RH:45 %m75 % 4 h

b)e RH 95 %m99 %N0.5 hfw>?x<=6CT:Szw655;2:R

c)gh CTe655;2:RNRH 95 %m99 % 10 h

d)e 2.5 hfw CTYsw6-40;2:R

e)gh CTe(-40;2)R 2 h

f)e 1.5 hfw CTG6-40;2:RS}AB>?<=;2R

g)gh CTe(AB>?<=;2R) 2 h

h)e 1.5 hfAxw623;5:R

Ve d),e),f),g)T h:UAd+|P|=Tj-

>?x+V`P 1.5 hBUhwAB>?<=Ns f:P

I[UCcoAThkZD[nNE8PI a:ZoAT

eiy12:FoN>?vjnTjnUA

a) Hold chamber at 623^5:R and

45 % to 75 % relative humidity (RH) for 4 hb) Raise chamber temperature (CT) to

655^2:R at 95 % to 99 % RH within

0.5 hc) Hold CT to 655^2:R at 95 % to

99 % RH for 10 h

d) Lower CT to 6-40^2:R within

2.5 h

e) Hold CT to 6-40^2:R for 2 hf) Raise CT to class test temperature

^2R within 1.5 h from6-40^2:R

g) Hold CT to class test temperature^2R for 2 h

h) Recover to 23^5R within 1.5 hNotes: During periods d), e), f), g) and h), the

humidity is uncontrolled. If the chambertemperature needs more than 1.5 h to reach classtest temperature, the duration of period f) may beextended. In this case period a) is to be reduced

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20


Vwk}gheRS a:*+Z2sM)MTj

noA+pGe>?12jT

accordingly.

At the end of a cycle, the test may beinterrupted. During the interruption the testsamples shall remain at the ambientconditions as defined in a). Interruptiontime shall be noted in the test report.

U 8 :MNOmLMkl

Table 8 Humidity Test Temperatures

AB/Level 2s<=/Environment Temperature6R: >?<=/Testing Temperature6R:

1 -40m+70 100

2 -40m+85 115

3 -40m+100 130

4 -40m+125 155

5 -40m+155 185

7.18.2 )jkl

,q5r>?:-N/&IE 6 ,q5rJ

jZ$*N&cdpQD'9T4'T


The contact resistance of theconnection shall not exceed valuesspecified in Table 6 Contact

Resistance-After Testing. There shall beno visible warping, creep or cracking of thehousing material.

7.19 <=>? 7.19 Fretting corrosion

7.19.1 NOrs

hgXYe!"2sMU>#:;Zfg

MNG64Q>?T

XY,*e:iZ>?_c`T@XIE 9

}~•>?J_->?KpT

e>?PIj6,q5r640EL>T

7.19.1 Test method

Terminals for board to boardapplications shall be tested via thismethod.

The terminals shall be mounted onsuitable test apparatus. The test shall becarried out as in Table 9 Fretting Corrosion

Test ParametersThe contact resistance shall bemonitored continuously.

U 9 <=>?NO@v

Table 6-6 Fretting Corrosion Test Parameters

>?Kp/Test Parameters

}~q1/Friction Path 50 "m

!"HI/Frequency 1 Hz

120p/Number of cycles 100 000

tu/Electrical load maximum 20 mV, 10 mA

7.19.2 )jkl

,q5r>?:-N/&IE 6 ,q5rJ

jZ$*T


The contact resistance of theconnection shall not exceed valuesspecified in Table 6 ContactResistance-After Testing.

7.20 ABNO 7.20 Vibration test


1. The vibration test shall be carried outwith mated connectors mounted on a

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21


1.@XFG A@ew,-)Tjw!"IT

2.,-)Op 100 mA|65NL>yy>?

jZ,q5r95T

3.!"KpZ_-jMT

vibration table shown in Appendix A-Connector Vibration Test.

2. All connectors shall be wired in series,and connected to a DC source allowinga current flow of 100 mA to monitorcontact resistance variation during theentire test.

3. While being monitored, the connectionshall be subjected to a simple harmonicmotion. The parameters shall be asfollows.

U 10 ABNO@v

Table 10 Vibration Test Requirements

q1//8=

Displacement/ Acceleration

HI/Frequency range (Hz)

6.2 mm 15.0 28.6

20.0 gn 28.6 500.0

U 11CyABNOklm@v

Table11 Enhanced Vibration Test Requirements

q1 //8= Displacement/

Acceleration

HI/Frequency (Hz)

5.00 gn 10 25

2.00 mm 25 50

20.00 gn 50 141

0.25 mm 141 200

40.00 gn 200 500

1. OP 1JH6pKH|Z9HIT

2. e_yLnM|Zl?64!"Ni9yl

?k 24 h6: 72 h:

3. :'Nk}V/&nt'UZ>vBo!"_

-T

4. fg SMTCbcl}:I~•ZVWNk/a

!"VWZ,-)V/&E11Oa!">?VW

ZKpT

5. >v`V`PMNq-T,q5rZ>vVO

P;'XAHe!"_cq-Z>?k}|6

4T

1. The frequency variation shall becarried out by logarithmic sweepings of1 octave/min

2. The motion shall be applied for aperiod of 24 h on each of the threemutually perpendicular directions (total

test time 72 h)3. In addition the sample can be

subjected to a measured vehiclevibration profile for the same duration.

4. At the request of SMTC Group ProductEngineering connectors with enhancedrequirements for vibration shall besubjected to parameters in Table 11Enhanced Vibration TestRequirements.

5. The measuring points shall be beyondthe support positions. Measurements ofcontact resistance shall be made with

the test samples in position on vibrationequipment before and after use.

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V 7 ABNO

Figure 7 Vibration test discontinuity profile

7.20.2 )jkl

,q5r>?:-N/&E 6 jZ$*T

k}p45Nn'NO"^FNQDod^F

,q5rJ 10 k!<^F,q5r9, 7 ! o

A9, 1 4 sNb*Jd&=T


The contact resistance of the connectionshall not exceed values specified in Table 6Contact Resistance-After Testing. Thesamples shall show no cracking, breaking orloosening parts, no loss of electrical

continuity greater than 7 ! for 14 s throughany of the vibration tests and not greater than

10 k! at any point.

7.21 DENO 7.21 Bump test


w$?,-)Tjw>?_c`6LFG

A-,-)!">?:T

x>?k)0,wL>`NL>>?UA

`P 1PQZn5T

fg BS EN 60068-2-29R#$>?T

Cge_yLnM|ZD`Np 6 msZS

0'UN40 gnZ/8=N61m2:#$/QN#

$64 000^10:6: 12 000#$:T

The bump test shall be carried out withmated connectors on a bump test fixture(see).

All connectors shall be wired in series,and connected to a monitor during the entiretest phase for electrical discontinuity greater

than 1 microsecond.The sample shall be bump tested to therequirements of BS EN 60068-2-29.

The test shall consist of 64 000^10 :

bumps at an acceleration of 40 gn with apulse duration of 6 ms in one sense in eachof three mutually perpendicular axes at a rate

of 61m2:bumps/second (a total of 12 000

bumps).

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23


7.21.2 )jkl

>?k)p45Nn'NO"Nn5oA

d(`P 1 4 sN,q5r/&IE 6,q5rJ

ZVWT


The sample shall survive the testconditions and show no sign of cracking,breaking or loosening of parts, no loss of

electrical continuity greater than 1 4 s and

shall be re-checked to the requirements of

Table 6 Contact Resistance-Low Voltage.

7.22 LM/AB/:MFGNO 7.22 Combined temperature/vibration/humidity/endurance test

7.22.1 NOrs

fg ES 62.21.632I<=/!"/|=%&

>?JZVW64>?T

+R 12y12Niy12 24 hT

k}d64•U>?Nu+V3oL>5

6ZOnT

7.22.1 Test method

The test shall be performed inaccordance with the requirements of ES62.21.632 !Combined Temperature,Vibration, and Humidity Test, With thefollowing additional criteria:

The above test cycle of 24 hours shallbe repeated continuously for 12 cycles.

There are no functional tests to performon the component but current through thecomponent shall be continuously monitored.

V 8 LM/:M)C

Figure 8 Temperature And Humidity Profile

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24


V 9 ABHI

Figure 9 Vibration frequency Profile

9y'UR 48y!"12N@XEFVW64TVibration will operate in parallel with the above i.e. 48 vibrationcycles in 24 hours. Unit to be operated to most arduous conditions as stated on drawing.

7.22.2 )jkl

,q5r/&IE 6,q5rJZVWT

7.22.2 Performance Requirements

Test results shall comply with therequirements of Table 6 !7.12 Contactresistance-low voltage.

7.23 JK)j 7.23 Mechanical performance

7.23.1 NOrs

;'X10ZZ9T6k}Z64'(PMT

TdRPV\>?Zk}646(NPMcd

ToveUV,-)•UZWXNY'NEQ

U4'AT

7.23.1 Test method

The use of x10 magnification aid isrecommended for detailed examination ofthe samples. Comparison shall be made toan untested sample.

Housings shall be examined for signs ofdiscoloration, crazing, surface desalinationsand cracking etc. that can be consideredharmful to connector function.

7.23.2 )jkl

dveUV,-)*B$52%UZ45N

V\OgVWLEFT


Connector mechanical, electricalspecifications should be in good condition.See component drawing for any special test.

7.24 78LMJZN 7.24 Housing ergonomics

7.24.1 NOrs

'(PMT

7.24.1 Test method

Visual inspection.

7.24.2 )jkl

cdNKkUVTrZj$Z[\T


Housings will be free of sharp/roughedges that will affect either operator

7/21/2019 SMTC 3 862 001_2010


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25


assembly or snagging in manufacture.

7.25 OPNO 7.25 Misalignment test

7.25.1 NOrs

1>>?k}VTV6$X,- 10]N4/

60m35:NZ\N;VT6$)^&Ti0Ys 2]NDx>?N|}~<^&T

2>gh,-)f~3_3Zq-p1"N

dUV3_O%T

3>et9WQ`Dx 30>?Ni0wk

}TV6$)`" 90]T

7.25.1 Test method

1. The sample connector shall be misaligned10 degrees from its mating part and a

force, rising from 0 to 35 N, applied toattempt to mate it. This shall be repeatedat decreasing angles, in increments of 2degrees, until mating is achieved.

2. The seals in connector should remain inplace with no rolling or damage that willaffect its sealing properties.

3. The test method shall be repeated afurther 3 times in the same plane but withsample and mating part rotated by 90degrees each time.

V 10 OPNO

Figure 10 Misalignment tests

7.25.2 )jkl

dU5\cd$XY$3_iN>>?:

FXNN@Xab 7.12 ,q5r-s51ZV

WGP>,q5rT


The sample shall suffer no damage to

housing, pins and where applicable seals,and shall be re-checked to the requirementsof Clause 7.12 Contact Resistance-LowVoltage.

7.26 QRNO 7.26 Inhibition

7.26.1 NOrs

'5J-[\90Z\64,-)Z^&T

7.26.1 Test method

Using up to five times the normal

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26


maximum mating force to mate connector.

7.26.2 )jkl

i'Q\64c;oNTd[Ugh,-

):d<N9Z~yT


It should not be possible to matemulti-way connectors, or to maintaincomplete circuits during or after an attemptedmating.

7.27 SEyMNO 7.27 Impact strength test

7.27.1 NOrs

;'le>?Efg BS EN 50 102 0$g

q6IKr:64T

C,-)^&Td^&=>*WNeM<

2sM64>?T

7.27.1 Test method

This test is to be carried out inaccordance with BS EN 50 102 ImpactProtection (IK Code) using the Pendulum testmethod. Test is to be conducted at roomambient temperature.

Connectors are to be tested in matedand unmated conditions.

7.27.2 )jkl

>?:-N/&EFRSZ IKrVW&


Test results shall comply with therequirements of IK code stated thecomponent drawing.

7.28 LMTU 7.28 Temperature cycling

7.28.1 NOrs

6^&*WZ>?k}@XRSSMTC 3 800

001jZI<=95>?J64>?T>?PI

+/u4*56T

VTHNT8zAB<=ab 30 RT

7.28.1 Test method

The assembled component shall betested in accordance with the !Change ofTemperature Test in SMTC 3 800 001. The

connectors shall carry their rated current.Note: T H shall be maximum class temperature

less 30R.

7.28.2 )jkl

>>?:FXNN@Xab 7.12,q5r

-s51ZVWGP>,q5rT

7.28.2 Performance requirements At the completion of the test, test

samples shall be re-checked to therequirements of Clause 7.12 ContactResistance-Low Voltage.

7.29 ,LNO 7.29 Low temperature

7.29.1 NOrs

Px^&*WZ>?k}e6-40^2:R

2sjvZ 16 hN,feM<M)MvZ 16 hN

yyPI+n5vZTjXN>?k}+64

1000,noc;NG@X,q5r-s51j

ZVW>v,q5rTs<>?6|=pVWT

7.29.1 Test method

The mated connection(s) shall besubjected to a 16 hour soak at 6-40^2:R,

followed by 16 hours at room ambienttemperature with no current flow throughout

test. The contact resistance shall bemeasured as defined in 7.12 Contactresistance-low voltage. The sample shall besubjected to 10 furtherdisengagement/engagement cycles, afterwhich the contact resistance shall bemeasured as defined in 7.12 Contactresistance-low voltage. The tests shall becarried out with humidity uncontrolled.

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7.29.2 )jkl


-s51ZVWGP>,q5rT


At the completion of the test, testsamples shall be re-checked to therequirements of Clause 7.12 ContactResistance-Low Voltage.

7.30 VWX

7.30 Thermal ageing

7.30.1 NOrs

wj$/Z>?k}Z[>?xjN@E 1

,-)<=ABZVWNe6NABZ8z<

=MZ- 100 hT

7.30.1 Test method

The fully equipped test sample shall beplaced in a test chamber at the classtemperature as in Table1 ConnectorTemperature Classes for 100 h.

7.30.2 )jkl


-s51ZVWGP>,q5rTcddNk9

'N4'AT


At the completion of the test the sampleshall comply with the contact resistance testas defined in Clause 7.12 ContactResistance-Low Voltage. There shall be novisible warping, creep or cracking of the

housing material.

7.31 VSENOYZ[LMcX\

fgE 1 ,-)<=ABjZ8s<= TL

T8z<= THN64>?T

7.31 Thermal shock test (rapid changeof temperature)

The thermal shock test is to beperformed at the lowest and highesttemperatures according to the environmentaltemperature class of the connector, T L andT H set accordingly, see Table1ConnectorTemperature Classes.

7.31.1 NOrs

>?k}+64 1000,noc;XNG64Qm>?T

6^&*WZk}N@XRS SMTC 3 800

001jZI30$>?J64>?T

7.31.1 Test method

The samples shall be connected and

disconnected 10 times, in order to conditionthe interface sufficiently to reveal any surfacedegradation during test.

The assembled component shall betested in accordance with the !ThermalShock Test In Air in SMTC 3 800 001.

7.31.2 )jkl


-s51ZVWGP>,q5rT


At the completion of the test, thesamples contact resistance shall be tested toClause 7.12 Contact Resistance-LowVoltage.

7.32 /]NO

7.32 Dust ingress test

7.32.1 NOrs

6^&*WZ,-)@XRS SMTC 3 800

001jZIv;>?JN64>?T

7.32.1 Test method

The assembled component shall betested in accordance with the !Protection Against Foreign Bodies (Dust Test) in SMTC 3

800 001.

7.32.2 )jkl



On completion of the test the sampleshall be removed from the cabinet and

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28


-s51ZVWGP>,q5rT re-checked to the requirements of Clause7.12 Contact Resistance-Low Voltage.

7.33 ^XN_;NO 7.33 Chemical fluids

7.33.1 NOrs

>?k}6gh\Zi_\T

c;)uVVlT<vqT

i>>?=Cg;'dtk}T

x>?k}1jeE 12jZ?*R>?T

7.33.1 Test method

The samples shall be tested for

resistance to contaminants.Safety precautions shall be taken to

ensure protection to all personnel. A separate sample shall be used for

each of the test fluids.The samples shall be tested by

immersion in the fluids in Table-12Contaminants.

U 12 XNO`

Table 12 Contaminants

?*Dg/Test Fluid $=/Specification <=/Liquid Temperature6: oA/Durationof immersion

6min:

Acid perspiration RES.30.CR.129 70 24 hours Alkaline perspiration RES.30.CR.129 70 24 hours

LubricantsEngine Oil ASTM D-471 Oil 1 100 24 hours

Manual Gearbox / Hypoid Oil ASTM D-471 Oil 3 100 24 hours

Grease Castrol LM Grease(Mineral Oil based , Lithiumsoap , general purposegrease NLGI 2)

room ambient temperature 60

Power Steering Oil Dexron IID 85 60Engine Bay Contaminants

Sulphuric Acid BS3031 (25 % solution-laboratory grade)


Brake / Clutch fluid RES.22.BF.01 Class BF2/1(DOT 4)

85 60

Antifreeze (50 % ) 50 % Mono Ethylene Glycol ,50 % Water

118 60

Fuels

Unleaded Petrol / Methanol(85% leaded petrol to 15%Methanol by volume)

42.5 % Toluene42.5 % Tri-MethylPentane15 % Methyl Alcohol


Unleaded Petrol 50 % Toluene50 % Tri-MethylPentane


Diesel Fuel BS EN 590 1993 room ambient temperature 60Bio - Diesel 90 % Diesel (BS EN 590

1993)10 % RME (Rape seedmethyl ester


Kerosene BS2869 Class C1 room ambient temperature 60Cleaning solutions

Window washer fluid Ethyl alcohol 27 ml

Isopropanol 10 mlEthyleneglycol 3 mlWater 60 ml, 0.1 % Teepol

50 60

Engine Cleaning Solvent Gunk room ambient temperature 60

White Spirit ASTM D-484 (Stoddardsolvent)


Anti - corrosion substances

Engine bay laquer room ambient temperature 60

Underbody waxes room ambient temperature 60

~R1jXwk}e 50 RM)Mk-

48 hNcXl!k}TRP>T

On completion of the immersion the

samples shall be allowed to drain at 50 R

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29


for 48 hours. They shall then be cleaned,dried and examined.

7.33.2 )jkl

,#•~)p'9NWXT

PM3_iZz{NTRV^mnToE

>pT


-s51ZVWGP>,q5rT


There shall be no deterioration of thenon-metallic parts. The color of the housingshall not show any appreciable deterioration

when compared with untested samples.Seals shall be checked to overalldrawing dimensions and any swelling,shrinkage or degradation noted.

The samples shall comply with thecontact resistance test as defined in Clause7.12 Contact Resistance-Low Voltage.

7.34 abNO 7.34 Mycological test

7.34.1 NOrs

@XRS SMTC 3 800 001jZI>?>?J

Mn64>?T

7.34.1 Test method

The test shall be carried out inaccordance with the !Mycological Test inSMTC 3 800 001

. 7.34.2 )jkl

>?:-N/&p>?pqZ$*<MN

OUtMcdZ]^.8T


No observable growth shall beaccepted; alternatively the supplier of thehousing material shall submit certification ofconformance.

7.35 >?)>;NO 7.35 Flowing mixed gas corrosion test

7.35.1 NOrs

@XRS BS EN 60068-2-60jlE 464

>?6LE 13•2/r=:T

>?_cZH/VWL BS EN 60068-2-60T

>?'UJ 21sT

9tZk}H,^&*WN9tZk}H

,d^&*WT

7.35.1 Test method

Test method is based on BS EN60068-2-60, severity method 4. (See Table13 Flowing Mixed Gases Concentration).

For detail of the test apparatus andmeasurement of copper coupons refer to BSEN 60068-2-60.

Duration for the test shall be 21 days.50 of the samples shall be mated and 50

of the samples unmated.

U 13>?)>;cM

Table 13 Flowing Mixed Gases Concentrations

Kp/Parameters VW/Method H2S (nL/L 10^5

NO2 (nL/L 2) 200^20 Cl2 (nL/L 10^5

SO2 (nL/L 200^20

<=/Temperature R 25^1|=/RH% 75^3

i0o/o95/Volume changes per hour 3m10

1) H2S1 ug/m3 = 0.71 mm3/m3

2) NO2 1 ug/m3 = 0.53 mm3/m3

3) Cl2 1 ug/m3 = 0.34 mm3/m3

4) SO2 1 ug/m3 = 0.38 mm3/m3

7.35.2 )jkl



On completion of the test contact

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30


-s51ZVWGP>,q5rT resistance shall be tested to Clause 7 .12Contact Resistance-Low Voltage.

7.36 deNO 7.36 Ozone

7.36.1 NOrs

^&*WZ>?k}e650^5:4 L/LZ@AMjvZ 24 hT

7.36.1 Test method

The samples shall be tested in theirmated condition. The connector shall besubjected to ozone which has a

concentration of 650^5:4 L/L for 24 hours.

7.36.2 )jkl


-s51ZVWGP>,q5rT


On completion of the test contactresistance shall be tested to Clause 7.12Contact Resistance-Low Voltage.

7.37 +fNO 7.37 Flammability test

7.37.1 NOrs

@XRS FMVSS 30264>?T

7.37.1 Test method

The test method shall comply withFMVSS 302.

7.37.2 )jkl

cd]^vw/& RES.30.MS.302 ju^

ZBuI< FMVSS 302 jZf~]^[B%V

WT


The housing material must conform tothe burn rate laid down in RES.30.MS.302. Alternatively certification shall be obtained toensure that the housing material complieswith FMVSS 302, !Flammability of InteriorMaterials.

8 34-NOkl 8 Connector test requirements

8.1 )jkl 8.1 Connectors performancerequirements

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U 14 34-)jkl

Table 14 Connector performance requirements

>?mnv

"/Test No. >?mn/Description %UVW/ Performance Requirements

7.2

XY-XYZ-[\T]

^\/Connection anddisconnection of

terminal

>?:-/&IE 4-[\&]^\JTEFZVWT/The maximum force

to insert the terminal in the cavity shall comply with the requirements of!Table 4 Engage/Disengage Forces and detailed on the component

drawing.

7.3 .7Z_à=/Tensile

Strength of Cable Attachment

>?:-N/&IE 5.7`*\JZVWT/The cable shall not pull off

from the contact at less force than shown in Table 5 cable Pull OffForces.

7.4 b`>?/Side Pull Test b`\d[7R,-)<XYZ45<n'Ntog.520,[6T

/No deformation of the housing should occur or short circuits.

7.5XY-cdZ-[\

/Terminal-HousingInsertion Force

>?:-N/&XY-cdZ-[\0, 12 N TEFVWT/The

maximum force to insert the terminal in the cavity shall comply with therequirements detailed on the component drawing and no greater than

12 N. />?:-N/&XY-cdZ-[\0, 12 NTEFVWT

7.6XYecdfZgh\/Contact Retention in

Housing

>?:-N/&gh\9, 50 N TEFVWT/The minimum force

necessary to displace the contact shall comply with the requirementsdetailed on the component drawing and not less than 50 N.

7.7XY-cdZ]^\/Intentional Contact

Removal from Housing

>?:-N/&XY-cdZ]^\0, 20 N THIEFVWT/The

maximum force necessary to displace the contact shall comply with therequirements detailed on the component drawing and less than 20 N.

7.8ij,-)Z0,

/Connection of Assembled Connectors

>?:-N/&-[\0, 80 NTHIEFVWT/The minimum force

necessary to engage the connector for the tenth time from the samemating part shall comply with the requirements of the componentdrawing and shall not be more than 80 N.

7.9

klmnoij,-)

Z0,/Intentional

Disconnection of Assembled Connectors

>?:-N/&]^\0, 80 NTHIEFVWT/The minimum force

necessary to disengage the connector for the tenth time from the samemating part shall comply with the requirements of the componentdrawing and shall not be more than 80 N.

7.10

plmnoij,-)

0,/Unintentional


>?:-N/&]^\9, 140 NTHIEFVWT/The minimum force

necessary to disengage shall comply with the requirements detailed onthe component drawing and not less than 140 N.

7.11

4*56/Nominal

Current Rating

>?:-w/&EFVWT/The tests must meet the values in the

component drawing. For a new connector system these methods canbe used to determine the drawing information.

7.12,q5r-s51

/Contact Resistance "Low Voltage

,q5rHIIE 6 ,q5rJZVWT/Unless the component drawing

states otherwise the contact resistance shall not exceed that stated inTable 6 Contact Resistance-After Testing.

7.13tu5r/Insulation

Resistance

>?:-N/&tu5r9, 100 M!T/Insulation resistance shall be

100 M! minimum.

7.14tua=/Dielectric

Strength

>?UA,-)d[^FQD5\T/No dielectric breakdown and

flash-over shall occur during the test.

7.15vw>?/Water

tightness Test

>?UApGOPiy&2Z5690N356d`P 100 4 AT,-)

f~p7wF8^FT>>?_)6vwC,-)T/The current into

each pin shall be continuously recorded. During the test the leakage

current flow into any pin shall not rise above 100 4 A. Excess watershall be removed from the connector and upon parting there should beno visible ingress of water.

7.16xy>?/Salt Corrosion

Test

>?UApGOPiy&2Z5690N356d`P 100 4 ATO 500 V|65oN#•7AZ5r9, 1 M!Np7wF8^FT>>?_)6

vwC,-)T/ The current into the pin shall be continuouslyrecorded. During the test the leakage current flow into the pin shall not

rise above 100 # A. (shall not apply to unsealed connectors)Resistance between the circuit and the metal plate not be less than1M! when tested with 500 V D.C. applied.

7.17 z1{w/High Pressure

Water

,q5r>?:-N/&IE 6,q5rJZ$*T/Contact resistance

shall be tested to able 6 Contact Resistance-Low Voltage.

7.18<=/|=>?

/Temperature/Humidity,q5r>?:-N/&IE 6,q5rJjZ$*N&cdpQD'

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U 14 34-)jklYg\

Table 14 Connector performance requirements continued"

>?mnv

"/Test No. >?mn/Description %UVW/ Performance Requirements

9T4'T/Shall be checked to the requirements of Table 6 ContactResistance-Low Voltage. There shall be no visible warping, creep orcracking of the housing material.

7.19 }~•/FrettingCorrosion

,q5r>?:-N/&IE 6,q5rJjZ$*TContact resistanceshall be tested to Table 6 Contact Resistance-Low Voltage.

7.20 !">?/Vibration Test

,q5r>?:-N/&E 6jZ$*Tk}p45Nn'NO"^FN

QDod^F,q5rJ 10 k! <^F,q5r9, 7 ! ZoA9,

14 sNb*Jd&=T/The contact resistance of the connection shall notexceed values specified in Table 6 Contact Resistance-Low Voltage.The samples shall show no cracking, breaking or loosening of parts, no

loss of electrical continuity greater than 7 ! for 1 4 s through any of the

vibration tests and not greater than 10 k! at any point.

7.21 #$>?/Bump Test

>?k)p45Nn'NO"Nn5oAd(`P 14 sN,q5r/&

IE 6,q5rJZVWT/The sample shall survive the test conditions

and show no sign of cracking, breaking or loosening of parts, no loss of

electrical continuity greater than 14 s and shall be re-checked to the

requirements of Table 6 Contact Resistance-Low Voltage.

7.22

<=/!"/|=%&>?/Combined

Temperature/Vibration/Humidity/Endurance

Test

+R 12y12Nk}d64•U>?Nu+V3oL>56ZOnT,q5r/&IE 6,q5rJZVWT/The component shall be subjected

to 12 cycles. There are no functional tests to perform on thecomponent but current through the component shall be continuouslymonitored. Contact resistance shall be re-checked to the requirementsof Table 6 Contact Resistance-Low Voltage.

7.23'(%U/Mechanical

Performance

dveUV,-)*B$52%UZ45NV\OgVWLEFT/Connector mechanical, electrical specifications should be in goodcondition. See component drawing for any special test. Seecomponent drawing for any special test.

7.24cd)*:I+

/Housing Ergonomics

cdNKkUVTrZj$Z[\T/Housings will be free of sharp /

rough edges that will affect either operator assembly or snagging inmanufacture.

7.25,->?/Misalignment

Test

dU5\cd$XY$3_iN~R>>?XNN@Xab 7.12,q5

r-s51ZVWGRP>T/The sample shall suffer no damage to

housing, pins and where applicable seals, and shall be re-checked tothe requirements of Clause 7.12 Contact Resistance-Low Voltage.

7.26 ./>?/Inhibitioni'Q\64c;oNTd[Ugh,-):d<N9Z~yT/It should

not be possible to mate multi-way connectors, or to maintain completecircuits during or after an attempted mating.

7.270$a=>?/Impact

Strength Test

>?:-N/&EF IK rVWT/The component shall meet the

performance required for the IK code stated on the componentdrawing.

7.28<=>?/Temperature

Cycling

>>?:FXNN@Xab 7.12,q5r-s51ZVWGP>,q5

rT/ At the completion of the test the connection shall comply with the

contact resistance test as defined in Clause 7.12 ContactResistance-Low Voltage.

7.29s<>?/Low

Temperature

N@Xab 7.12 ,q5r-s51ZVWGP>,q5rT/Contact

resistance shall be measured in accordance with Clause 7.12 ContactResistance-Low Voltage.

7.30 345/Thermal Ageing

>>?:FXNN@Xab 7.12,q5r-s51ZVWGP>,q5rTcddNk9'N4'AT/ At the completion of the test the sample

shall comply with the contact resistance test as defined in Clause 7.12Contact Resistance-Low Voltage. There shall be no visible warping,creep or cracking of the housing material.

7.31

30$>?678<=9

5:/Thermal shock Test

(Rapid Change ofTemperature)


rT/Contact resistance shall be tested to Clause 7.12 Contact

Resistance-Low Voltage.

7.32v;>?/Dust Ingress

Test


rTOn completion of the test the sample shall be removed from the

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33


cabinet and re-checked to the requirements of Clause 7.12 Contact

U 14 34-)jklYg\

Table 14 Connector performance requirements continued"

>?mnv

"/Test No.

>?mn/Description %UVW/Performance Requirements

Resistance-Low Voltage.

7.33<5+=/>?/Chemical Fluids

,#•~)p'9NWXTPM3_iZz{NTRV^mnToE>

pT>>?:FXNN@Xab 7.12 ,q5r-s51ZVWGP>,q5rT/There shall be no deterioration of the non-metallic parts. Thecolor of the housing shall not show any appreciable deterioration whencompared with untested samples. Seals shall be checked to overalldrawing dimensions and any swelling, shrinkage or degradation noted.The samples shall comply with the contact resistance test as defined inClause 7.12 Contact Resistance-Low Voltage.

7.34>?>?/Mycological

Test

>?:-N/&p>?pqZ$*<MNOUtMcdZ]^.8T

/No observable growth shall be accepted; alternatively the supplier ofthe housing material shall submit certification of conformance.

7.35•%2/>?/Flowing

Mixed Gas CorrosionTest

On completion of the test contact resistance shall be tested to Clause

7.12 Contact Resistance-Low Voltage. />>?:FXNN@Xab 7.12

,q5r-s51ZVWGP>,q5rT

7.36 @A>?/Ozone

>>?:FXNN@Xab 7.12 ,q5r-s51ZVWGP>,q5

rT/Contact resistance shall be tested to Clause 7.12 ContactResistance-Low Voltage.

7.37rB>?/Flammability

Test

cd]^vw/& RES.30.MS.302ju^ZBuI< FMVSS 302 jZf

~]^[B%VWT/The housing material must conform to the burn

rate laid down in RES.30.MS.302. Alternatively certification shall beobtained to ensure that the housing material complies with FMVSS302 !Flammability of Interior Materials.

8.2 NOhiU 8.2 Housed connectors test procedurematrix

U 15 NOhiU

Table 15 Housed connectors test procedure matrix

Og>?/

SpecialTests

J"/No >?mn/Test

Description

k}iv"/ Sample Group Number

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

7.2

XY-XYZ-[\T]

^\/Connection and

Disconnection ofTerminal

2

7.3.7Z_à=/Tensile

Strength of Cable Attachment

4

7.4 b`>?/Side Pull Test 6

7.5XY-cdZ-[\/Terminal-HousingInsertion Force

1

7.6XYecdfZgh\/Contact Retention inHousing

2 9

7.7XY-cdZ]^\/Intentional ContactRemoval from Housing

1

7.8

ij,-)Z0,

/Connection of AssembledConnectors/

2 3

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34


U 15 NOhiUYg\

Table 15 Housed connectors test procedure matrix continued"

Og>

? /

Special

Tests

J

"/No

>?mn/Test

Description


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

7.9

klmnoij,-)

Z0,/IntentionalDisconnection of

Assembled Connectors

3 4

7.10

plmnoij,-)

0,Unintentional


4 8

7.114*56/Nominal

Current Rating 1

7.12,q5r-s51

/Contact Resistance-Low Voltage

1,32,

9

3,

5,71,3 1,3 1,3 1,4,6 1,4

1,3,

6,8

1,3 1,3,5 1,7 1,4 1,3 3,7 1,4

7.13tu5r/Insulation

Resistance 1,5 3

7.14tua=/Dielectric

Strength 2,6

S 7.15vw>?/Watertightness Test

3 6 4 2

S 7.16Salt Corrosion Test/x

y>? 2

S 7.17z1{w/High

Pressure Water Jet 5

7.18<=/|=>?/Temperature/Humidity

2 2

7.19}~•/Fretting

Corrosion 2

7.20!">?/Vibration Test 7

7.21#$>?/Bump Test 4

7.22

<=/!"/|=%&>

?/CombinedTemperature/Vibration/Humidity/Endurance Teat

2

7.23'(%U/MechanicalPerformance

8 1 3 5 3,5 3

7.24cd)*:I+/Housing Ergonomics

2

7.25,->?/MisalignmentTest/

2

7.26./>?/Inhibition 5

7.270$a=>?/Impact

Strength Test 7

7.28<=12/Temperature

Cycling

4

7.29s<>? Low

Temperature 6

7.30 Thermal/345 2 2

7.31

Thermal Shock Test(Rapid Change of

Temperature)30$>

?678<=95:

2

7.32v;>?/Dust Ingress

Test 2

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35


7.33<5+=/>?/Chemical Fluids

4

U 15 NOhiUYg\

Table 15 Housed connectors test procedure matrix continued"

Og>

? /

Special

Tests

J"/No >?mn/Test

Description


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

7.34>?>?/Mycological

Test

MNOtM]^.8/Certification to be supplied by manufacturer

7.35•%2/>?/Flowing Mixed GasCorrosion Test

2

7.36@A>?/Ozone 4

7.37rB>?/ Flammability

Test MNOtM]^.8/Certification to be supplied by manufacturer

VS Ee_)6;'eBoIJ B1NC1ND1NEZvwC,-)

Note: S denotes tests only for sealed connectors as used in areas B1,C1,D1,E

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jk A

Y(&)jk\

34-ABOlm

Annex A

)normative annex*

Connector Vibration Test

V A.1 34-ABOlm

Figure A.1 Connector Vibration Test

Documents

SMTC 3 862 001_2010 接插件的技术条件