A P Products GREAT JUMPERS User Manual

Great Jumper

CABLE ASSEMBLIES ­A P PRODUCTS GREAT JUMPERS

A P Products

A P Products

About A P Products ...

Since A P Products has first joined the market in 1967 with the IC-Testclip it has developed into preferred manufacturer
of proprietary, high performance Electronic Interconnect Products. Those provide cost-effective solutions to the electronic
and mechanical challenges posed by ever-increasing signal frequencies and decreasing package sizes.

A P Products has earned a reputation for its responsiveness and creativity in solving unusual interconnect problems
concerning e.g. packaging specifications.

Initially known as A P Incorporated, and steadily growing for nearly 20 years, Associated Enterprises took products to
market through ist subsidiary companies known as A P Products Inc., APTronics, Chabin, Symbex, 4C and A P
Products GmbH. The task of A P Products GmbH as an international sales organisation was to handle the assembly and
sales functions, while research and development was centralized and provided by Associated Enterprises. Component
level manufacturing was performed by a Division of Associated Enterprises, known as Omnitec.

In 1986 A P Products GmbH became a seperate company, but the relationship to Associated Enterprises is still close.
Cooperation on projects and resource-sharing is most common; nevertheless manufacturing now is also part of A P
Products GmbH functions.

A P Products GmbH policy is to sell mostly indirect through local distibutors. Additional offices in Saffron Walden, Great
Britain and in Milano, Italy help to organize the market.

An over 650 m² stock and a team of about 20 co-workers - dedicated to excellence, flexibility and responsiveness ­ensure a short delivery time and products made to customer specification. A P Products GmbH is always trying to
provide the customers with on-time delivery of competitive standard products as well as innovative, high-quality and cost­effective solutions to unique interconnection problems.

Also made by A P Products:

IC Test Clips

A P Products Test Clips the industry
standard for faster, easier DIP IC
testing, quality control inspection and
field service. The Test Clips provide easy
attachment, „hands-free“ testing and
positive clamping. Reliable contacts and
rugged construction allow a save way
for testing.

• Over 150 models to fit every size DIP
up to 64 pins.

• Nailhead and connector compatible
„headless“ available.

Male Header

A P Products offers a wide range of
either custom made or standard male
headers. The wide assortment of
standard male headers include sin­gle, double and triple row, straight and
right angle, gold and solder plating
and in various pinlength up to 36 pins
per row.

• 2,36mm / 5,97mm / 8,07mm
interface area

• Mate with industry standard

connectors or headers with
contacts spaced on 2,54mm

Female Header

The wide standard assortment of
female headers include single, double
and triple row female headers with up
to 36 pins per row which can easily be
cut down to any desired length.

• A variety of gold and tin platings
available

• Mate with industry standard
connectors or headers with contacts
spaced on 2,54mm

A P Products GmbH

Postfach 1158
D-71089 Weil im Schönbuch
Deutschland
Tel.: [phone]
Fax: [phone]
Web: www.ap-products.de
E-mail: [e-mail]

A P Products Ltd.

80 Cromwell Road
Saffron Walden, CB11 4BE
Great Britain
Tel.: [phone]
Fax: [phone]
Web: www.ap-products.co.uk
E-mail: [e-mail]

A P Products S.r.l.

Viale Abruzzi, 87
I-20131 Milano
Italia
Tel.: [phone]
Fax: [phone]
Web: www.ap-products.com
E-mail: [e-mail]

AP1100

Great Jumper

A P Products

Technical Information: Molded-On Concept

Molded-On is the term we at A P
Products use to describe the
integration of cable and contact
into one-piece, inseparable cable
assemblies by means of injection
molding. The process, itself, is
unique in the industry, and so are
the resulting functional and
economic advantages in
interconnection systems.

The most obvious advantage of
"molded-on" cable assemblies is
that they are one piece and
therefore inseparable. There are
no individual components to come
apart, lose, stock, assemble, test
or scrap. They are factory tested
and ready to install when shipped.

Integral Molding

Flat ribbon cable conductors are
IDC mass terminated to
preformed contacts and the entire
terminated cable end is enclosed
in a mold configured as a
connector. Hot, molten polyester
thermoplastic is then injected into
the connector mold under intense
pressure. The pressurized molten
plastic penetrates and fills all mold
cavity space while simultaneously
engulfing the shouldered portion
of the contacts, the cable cut off
end, and the insulated lead-in
portion of the cable itself. The PVC
insulation is thermally fused to the
polyester plastic of the connector
body.

The finished part, now an integral,
single-end assembly, cools and is
ejected from the mold. For double­ended assemblies, the opposite
cable end also is IDC mass
terminated to contacts and
molded into a connector body.

One-piece daisy chain assemblies
are produced by using through­cable molds that permit any
connector body style to be molded
around IDC mass terminated
contacts anywhere on the cable.

Special configuration, one-piece
assemblies incorporating any
number of connectors, with the
same or different body styles and

A P Products

sizes, are easily produced to
customer specifications with our
unique „molded-on“ process.

Structural and Electrical

A polyester thermoplastic was
selected for the connector body
material because of inherent
mechanical strength, dielectric
strength, flame retardants and
moldability properties.

The advantages for one-piece
cable assemblies (listed in the
picture) are numerous and
distinctive. These benefits derive
exclusively from the „molded-on“
concept, and are unachievable
with other manufacturers’ cable
assemblies consisting of many
separate plastic and metal parts
that rely on mechanical means of
attachment to the cable.

Unlike multi-piece mechanical
assemblies, A P Products’ one­piece cable assemblies have no
air space between adjacent IDC
contacts. The contacts and cable
are embedded in a solid block of
plastic, providing significantly
improved insulation resistance
and higher breakdown voltage.

Because the body plastic encases
the shouldered portion of the
contact shank as well as the cable,
it functions as a unifying medium
that anchors both against relative
motion. This important advantage
is markedly absent in assembled
connectors where the contacts are
only loosely retained by
mechanical means.

Another unique advantage of
„molded-on“ cable assemblies is
that they need no added-on strain
relief as do mechanically joined
assemblies. Thermal fusing of the
cable to the connector plastic
creates the ultimate strain relief
that is unachievable by simply
clamping. The „molded-on“ strain
relief also permits a low profile
since bulky wrap-around covers
are unnecessary.

The constant overriding
consideration in the design of
each style of A P Products'
"molded-on" connector is that the
engineering design adheres to
accepted industry-standard
interconnection techniques for
plug/unplug and solder-in
applications. The resulting
engineered one-piece assemblies
interface with all industry-standard
interconnections with ease and
precision and may be used as
direct replacements for
mechanically joined connector/
cable assemblies.

The physical configuration of each
connector style is dimensioned to
mate precisely at every critical
OEM interconnection system
interface; electrical contacts; PC
board contact and mounting hole
patterns; polarity keys, slots and
tabs; lock/eject latches and where
necessary, external envelope
clearance dimensions. However,
in noncritical areas, such as those
portions of the connector bodies
that do not interface with OEM
system devices, space-saving low

profiles and generally more
compact housing are
characteristic of A P Products'
connector designs.

These features are made possible
primarily because the molding
process permits elimination of
unreliable mechanical covers and
separate bulky strain reliefs.

All connectors are recognized
under the Component Program of
U.L., Inc. (File number and yellow
card available.)

A P Products GmbH

Postfach 1158
D-71089 Weil im Schönbuch
Deutschland
Tel.: [phone]
Fax: [phone]
Web: www.ap-products.de
E-mail: [e-mail]

A P Products Ltd.

80 Cromwell Road
Saffron Walden, CB11 4BE
Great Britain
Tel.: [phone]
Fax: [phone]
Web: www.ap-products.co.uk
E-mail: [e-mail]

A P Products S.r.l.

Viale Abruzzi, 87
I-20131 Milano
Italia
Tel.: [phone]
Fax: [phone]
Web: www.ap-products.com
E-mail: [e-mail]

AP1100

Great Jumper

A P Products

Technical Information: Cable Materials

Flat ribbon cables employed in
cable assemblies are of industry­standard geometry - AWG 26 or
AWG 28 conductor size, 0,050
inch (1,27 mm) center-to-center
conductor spacing, and PVC
insulation material. This geometry
is specifically designed to meet
the stringent, high-speed, digital
signal transmission requirements
of the computer and peripheral
equipment industries.

The close-tolerance spacing of the
parallel-conductor geometry
produces the consistently uniform
and predictable controlled
impedance and capacitance
characteristics shown in the table
below. The use of PVC insulation
uniformly convoluted as measured
in a ground-signal-ground
configuration.

Cable assemblies also are
compatible with industry-standard
IDC-mass-termination techniques
and maintain excellent impedance
continuity at the cable/contact
juncture. Their symmetrical
convolutions permit reliable
termination from either side to
accomodate both „stripe-up“ and
„stripe-down“ cable configurations.

Solid conductors in the 0,050-inch­flat-ribbon cable geometry also are
available on special order. Send
specifications for samples and
quotation.

Cable Style No.:

39304 39306 39322

Physical

Insulation

Material:

Color:

First Conductor:

Conductor

Size:

Stranding:

Material:

Resistance:

(Ohms/1000ft.)

Gray Gray Multi

Red Red Brown

28 AWG 28 AWG26 AWG

7 x 36 7 x 367 x 34

Copper Copper Copper

65 41 65

Electrical

Voltage Rating:

Insulation

Resistance:

(Ohms/1000ft.)

Impedance

Unbalanced:

Capacitance
Unbalanced:

Inductance

Unbalanced:

Propagation Delay

Unbalanced:

108,00 Ohms 89,00 Ohms

12,80 pF/ft. 16,20 pF/ft. 14,10 pF/ft.

0,15 µH/ft. 0,13 µH/ft. 0,15 µH/ft.

1,40 ns/ft. 1,44 ns/ft. 1,47 ns/ft.

>1x10

10

PVCPVC PVC

300V300V 300V

10

>1x10

>1x10

105,00 Ohms

9

„Tear-down“ separation between
conductors is readily
accomplished for circuit routing of
separate conductors.

Cables also have excellent flexing
characteristics and are easily
folded to any required
configurations.

Environmental

Temperature

Rating:

Flammability

Rating:

-4°C to 105°C

UL: VW-1

AWM

-4°C to 105°C -4°C to 105°C

UL: VW-1

AWM

UL: VW-1

AWM

A P Products

Technical Information: Contact Materials

All contacts in cable assemblies
(Great Jumper) or headers are
tempered nickel-silver alloys. This
metal was selected for its
excellent overall combination of
characteristics which provide
reliable electrical performance with
or without gold plating or cladding.

High Strength

The high content of alloying
elements in nickel silvers provide
superior strength, hardness, and
ductility at lower cost than other
high-strength metals. The
hardening and the large volume of
solute nickel and zinc atoms in the
basic crystalline structure of
copper. This process eliminates
the need for costly heat treating
and provides a high work­hardening rate.

Surface Finish Materials

Surface (Minimum Thickness 1,27 µm)

No.

Base metal (no additional surface)

00

Tinned 2,54 µm (Tin/Lead, non RoHS)

01

Gold 0,25 µm

02

03

Gold 0,51 µm (available on request)

04

Gold 0,76 µm (available on request)

05

Tinned 2,54 µm (RoHS compliant)

99 Other contact finishes can be produced.

Send specifications for quotation.

Fatigue Strength

Nickel silver posseses a
maximum fatigue strength in
excess of 25.000 psi for

100.000.000 cycles. This
characteristic permits consistent

Cladding and Plating

Nickel silver readily accepts any
thickness of gold plating and inlay
cladding. Both are offered as
options on Great Jumpers
contacts (see table as above).

retention of normal forces over a
long service life.

Spring Properties

The properties of stiffness and
resilience, which combine to
create a contact’s spring
characteristics, are inherent in
nickel-silver alloys. The modulus
of elasticity (18.000.000 psi)
provides excellent stiffness while
being sufficiently low when
combined with the high yield
strength (92.000 to 120.000 psi) to
produce superior resilience ­resulting in high normal force
capabilities for producing gas-tight
contact seals.

A P Products GmbH

Postfach 1158
D-71089 Weil im Schönbuch
Deutschland
Tel.: [phone]
Fax: [phone]
Web: www.ap-products.de
E-mail: [e-mail]

Corrosion Resistance

Another invaluable characteristic
of nickel silver is its superior
resistance to oxidation, fretting,
thermal shock, tarnish and
corrosive attack by moistures
containing dissolved salts.

Solderability

Nickel silver needs only
conventional cleaning or fluxing to
remove any thin surface film before
soldering or brazing by traditional
production methods, including
wave soldering.

A P Products Ltd.

80 Cromwell Road
Saffron Walden, CB11 4BE
Great Britain
Tel.: [phone]
Fax: [phone]
Web: www.ap-products.co.uk
E-mail: [e-mail]

A P Products S.r.l.

Viale Abruzzi, 87
I-20131 Milano
Italia
Tel.: [phone]
Fax: [phone]
Web: www.ap-products.com
E-mail: [e-mail]

AP1100