din 41612/iec 60603-2 press-fit connectorsc1170156.r56.cf3.rackcdn.com/uk_ern_593414_ds.pdf ·...
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catalog E 074484 05/02 Edition 4
ERNIPRESSDIN 41612/IEC 60603-2 Press-fit connectors
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catalog E 074484 05/02 Edition 4
Benefits of ERNIPRESS
No soldering errors
Gas-tight, corrosionproof andmechanically strong connection
No terminal stress
Easy handling No flux problems
No additional manual solderingof interface connectors
No additional fastening of the connectors
Contact is made in the copper-layer, not in the
tin-layer of the pcb
Assembly possible on both sides
No additonal washing, thereforeno environmental pollution due
to cleaning agents
Low tooling investment Interchangeable contacts
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General
In a electronics and electrical engineering the solderlesspress-fit technique has become more and more widespread in the light of increasing miniaturization and higher packingdensities.
ERNI’s compliant press-fit zone is reliable connection betweenthe PC Board and the connector.
ERNI offers a comprehensive press-fit range for all connectortypes. Also included in the ERNI press-fit range are the rightangle press-fit connectors for mounting on the plug-in modulePCB’s (see ERNI’s „Plug-in conntectors with right angledpress-in terminations“ catalog). The press-fit zone is designedso that the gas-tight corrosion-free contact takes place in thecopper layer of the plated-through drillhole. The tin layer of thePCB drillhole is penetrated.
Solderless press-fit connectors are an integral part of today’smodern electronic packaging bus systems. The main functionof a bus system is to connect assemblies with one anotherand their power supply. Since plug-in modules are becomingmore and more powerful, the demands placed on the bussystems are continually increasing. Higher system speeds andthe overall shrinking of the connection structure are makingthe bus system a more crucial part of the control system.
With newer assembly processes for PC Boards, like press-fittermination, the mechanism is now available to utilize morepowerful electromechanical components. ERNIPRESS solderless press-fit connectors are a perfect fit for such applications. Furthermore, there are many applications wherethe delicate structure of the PC Board cannot withstand theharshness of automated soldering processes.
Requirements expect of the PCB
In manufacturing the PC Board for the press-fit technique it isessential that the recommended DIN PC Board specificationsbe met. The dimensions of the plated through drillholes andtheir hole design are described in IEC 60352-5.
The quality and long-term performance of a press-fit connec-tor are influenced by the following factors:
a) Base material of the PCB.To meet UL requirements, epoxy glass fabric type Hgw 2372.1 to DIN 7735, FR 4, should be used.
b.) Adherence to drillhole tolerances.For optimum and uniform plating of the metallization of the PCB, a selective rack technique, flexible anode
arrangement and continuous plating bath monitoring aresuggested.
c.) Drillhole diameter and positioning.Maintaining the correct roughness of the drillhole wall andrestricting drill bit travel are critical production processes.
d.) PCB hole and layout requirements.A minimal residual ring width of 0.1 mm, finished hole tolerances, layer thicknesses, and a high quality consistentconductive pattern are all critical.
e.) Insertion and retention forces.Measurement of these forces should be checked.
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Insertion and retention forces
The design of the press-fit zone of the ERNIPRESS connectors performs a dual function. On the one hand thisdesign has high elasticity and therefore can accomodate largehole tolerances. On the other hand, the press-fit zone’s designensures high edge loading at the copper layer of the PCB holeresulting in a gas-tight, corrosion-proof and mechanicallysecure connection.
Due to the special shape of the press-fit zone, insertion forcesare not detrimental to the hole plating.
Retention forces of the contacts in the PCB hole are sufficient to withstand the torques which occur during wirewrap termination. Typical average values for retention forceare between 50 – 110 N per contact depending upon PCBthicknesses.
For more details please refer to the data sheet entitled „ERNI-PRESS – Long-term test programms to DIN 41611, Part 5 forCompliant Press-fit zones“.
Hole design
Female connectors size B, B/2, B/3,C, C/2, C/3,M, E 160,H 11, H 15
Male connectors size Q, Q/2, Q/3,R, R/2, R/3,RD 128, TE 160
1)
Restring width
Diameter of finishedplated-through hole
Diameter of drilled hole
max. 15 µmSn/SnPb
min. 25 µm Cu
ø1+0.09-0.06
ø1.15 ±0.025
min. 0.1
1)
Restring width
Diameter of finishedplated-through hole
Diameter of drilled hole
max. 15 µmSn / SnPb
min. 25 µm Cu
ø1.75 ±0.025
ø1.6 ±0.09
min. 0.15
Female connectors size D, E, F
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PSB drillhole pattern
Insertion sideFemale connectors B1) and CMale connectors Q1) and R
Female connectors B/21) and C/2Male connectors Q/21) and R/2
Female connectors B/31) and C/3Male connectors Q/31) and R/3
for other dimensions see fig. 1
for other dimensions see fig. 1
1) For sizes B, B/2, B/3, Q, Q/2 and Q/3 only rows a and b apply
Female connectors D Female connectors E Female connectors F
for other dimensions see fig. 1 for other dimensions see fig. 1 for other dimensions see fig. 1
Fig. 1
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PSB drillhole pattern
Insertion side
for other dimensions see fig. 1 for other dimensions see fig. 1 for other dimensions see fig. 1
Female connectors E 160Male connectors TE 16 Female connectors M
for other dimensions see fig. 1 for other dimensions see fig. 1
Female connectors H 11 Female connectors H 15 Female connectors CD 128Male connectors RD 128
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Codings
Various coding systems are available for the connectorscontained in this data sheet.• Integrated coding with coding wedges. In this case coding
wedges are fitted into the female connectors and the maleconnectors are provided with corresponding recesses.
• Integrated coding with coding pins. In this case coding pinsare inserted into the female connectors and holes are drilledin the male connectors in the coding positions.
• Coding with coding strips.These coding strips are mountedtogether with the connector. For ERNI coding strips noextra modular space is required in the 19" rack system.
Wiring accessories
The ERNI connector housing range together with the ERNIinterface connector system offers optimum protection for allplug-in interfaces for DIN 41612/IEC 60603-2 connectors.The range is dimensioned for the 19" rack system. Suitablevariants are available for virtually every type of connector.Whether you intend to use a short type B/2 connector or a64-pin insulation displacement connector, the ERNI rangeoffers you the ideal housing.• KSG 173 Sizes: B, C, D, E, M, H11, H15, Q,
R, E160, TE160, RD128• KSG 193 Sizes: B/2, C/2, Q/2, R/2• KSG 203 Sizes: F, Fi• KSG 253 Sizes: C (IDC)• KSG 204 Sizes: F, Fi
The connector housings are prepared for a maximum of 3 cable outlets and are fitted with strain-relief clamps. A metal-plated version for screening purposes is also available. For plug-in interfaces on the front or back panel of the rackERNI has developed guide elements and guide frames in collaboration with well-known users. These elements permitexact guidance for correct mating and provide robust screwlocking. In addition you can fit a coding device.
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Pre-centering
For applications of connectors with early make/last break contacts the male connector moulding with pre-centeringensures even more reliable mating.The mouldings of the female connectors have a recess at anappropriate point. The dimensions of these versions do not conform to the specifications of DIN 41612/IEC 60603-2. The ordering detailsare not listed in this data sheet but they can be supplied onrequest.Male connectors with pre-centering do not fit femaleconnectors without a pre-centering recess.
Types of termination on ERNI connectors
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Electrical and Mechanical CharacteristicsSize B C D E F H M CD128 E160
B/2 C/2B/3 C/3
Reversed Size Q R RD128 TE160Q/2 R/2Q/3 R/3
Max. number of pins 64 96 32 48 48 11 15 78 128 16032 4820 30
Contract row designation of male and female connectors ab abc ac ace zbd ac zd abc abcd abcde
Temperature range -65° . . . + 125°C
Permissible humidity Annual average ≤ 80%, max. 100%
Cr 1.8 1.8 6.0 8.0 4.5 3.0 1.8
Cl 1.6 1.6 3.5 4.5 4.5 2.5 1.6
Cr 1.2 3.0 3.0 8.0 4.5 1.2 1.2
Cl 1.2 3.0 1.6 4.5 4.5 1.2
Cr 1.2 3.0 3.0 3.0 8.0 4.5 1.2 1.2
Cl 1.2 3.0 3.0 1.6 4.5 4.5 1.2 1.2
Current Arating at + 20°C 4.0 5.5 20.0 4.0 3.0ambient + 70°C 2.0 4.0 15.0 2.0 2.0temperature + 100°C 1.0 2.5 10.0 1.0 1.0
Test voltage, 50Hz, 1minContact/contact Veff 1000 1000 1550 3100 1000Contact/ground Veff 1550 1550 2500 3100 1550
Contact resistance mΩ ≤ 20 ≤ 15 ≤ 8 ≤ 20
Insulation resistance Ω ≥ 1012 at 100 VDC
Shock and vibration no contact breakdownproofness at 20g and 10...2000Hz
Housing material of male PC 30% GVand female connectors PBT 30% GV PBT 30% GV PBT 30% GV
Comparativecreepage figure PBT CTI 275/CTI 175 M CTI 275/CTI 175 M CTI 275/CTI 175 Mto DIN IEC 112 PC CTI 150-175/CTI 100M
Service life to Performance level 1 ≥ 500 Mating-cyclesDIN 41 612, Part 5 Performance level 2 ≥ 400 Mating-cycles
Performance level 3 ≥ 50 Mating-cycles
Mating and withdrawal ≤ 60 ≤ 90 ≤ 40 ≤ 60 ≤ 75 ≤ 80 ≤ 90 ≤ 90 ≤ 120 ≤ 150force for the assembled ≤ 30 ≤ 45connector N ≤ 18 ≤ 28
Withdrawal force per contact ≥ 0.15 ≥ 0.2 ≥ 0.15(test blade) N
Inflammability PBT UL 94 V-0 UL 94 V-0 UL 94 V-0of the plastic PC UL 94 V-1
betweena row
Contact tocontactwithin a row
Contact to ground
Creepage (Cr) and clearance (Cl) in mm
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Certificates of approval Early make/last break
Performance levels
107 Conforms to the requirements as per DIN 41612/IEC 60603-2performance level 1 500 mating cyles Contact zone gold-platedTerminal zone tin-plated
101 Same as for version 107 buttransfer zone (5.0 mm) in theterminal area gold-plated
207 Conforms to the requirements as per DIN 41612/IEC 60603-2performance level 2 400 mating cyles Contact zone gold-platedTerminal zone tin-plated
201 Same as for version 107 buttransfer zone (5.0 mm) in theterminal area gold-plated
307 Conforms to the requirements as per DIN 41612/IEC 60603-2performance level 3 50 mating cyles Contact zone gold-platedTerminal zone tin-plated
301 Same as for version 107 buttransfer zone (5.0 mm) in theterminal area gold-plated
UL Connectors size B, C, B/2, C/2, B/3, C/3, E 160, H 11,H 15, D, E, F and the reversed size Q, R, Q/2, R/2, Q/3and R/3 have been approved by the American approvalauthority „Underwriters Laboratories Inc.“. File no. E 84703.
CSA Size B, C, B/2, B/3, C/3, E 160, H 11, H 15, D, E, F, Q,R, Q/2, R/2, Q/3 and R/3 are listed by the Canadianapproval authority „Canadian Standards Assocation“under file no. LR 62504.
0.8 mm early make/last break male contacts are possible atall positions in rows a, b, c, d and e.
Other lengths on request.
Example how to order
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Size BSize B/2Size B/3
acc. to DIN 41 612/IEC 60603-2
acc. to VG 95324, short version of size B
third-length of size B
Dimensional drawingsFemale connector
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Ordering informationsFemale connector
Female connectors with transfer-zone
1) Terminals nickel-plated over full length.Transfer-zone (5.0 mm) hard gold-plated. Other versions on request.
414 388 414 389 414 390
023 364 023 365
414 310
414 313
023 366
023 368414 397 414 398 414 399
023 367 023 108
023 371 023 372
023 378 023 379
023 369 423 213 023 370
023 375 023 376 023 377 023 380 023 381
023 374023 373
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Size CSize C/2Size C/3
acc. to DIN 41 612/IEC 60603-2
acc. to VG 95324, short version of size C
third-length of size C
Dimensional drawingsFemale connector
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Ordering informations
Female connector
414 430 414 431 414 432
004 707 913 111
023 620 414 361 023 382
414 427 414 428 414 429
023 383 913 132
414 358 023 384
414 436 414 437 414 438
013 159 913 110
023 761 023 385
414 272 414 273 414 274
013 990 913 133
414 367 023 386
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Ordering informations
Female connector
593 274 593 275 593 276
023 387 913 135
023 388 023 389
593 271 593 272 593 273
023 390 913 134
023 391 023 392
003 533 003 534 023 393
013 808 013 964
023 394 023 395
003 531 003 532 023 396
013 991 013 397
023 398 023 399
1) Terminals nickel-plated over full length.Transfer-zone (5.0 mm) hard gold-plated. Other versions on request.
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Size CD 128Connector with 4 rows of contacts, each with up to 32 contacts
Dimensional drawings
Female connector Female connectors with transfer-zone
1) Terminals nickel-plated over full length.Transfer-zone (5.0 mm) hard gold-plated.
033 355 913 655
913 658 033 035
033 104
033 223
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Size Macc. to DIN 41612/IEC 60603-2
Dimensional drawingsFemale connector
The size M connectors come with a range of 5 different housings with a specific number of pre-loaded signal pins ineach. The balance of the connector housing would be customer loaded with the individual M series contacts(referred to here as SK’s); either high current contacts (up to 40 A), coaxial contacts, and/or fiber optic contacts.For more information refer to „Connectors Type M DIN 41 612/IEC 60603-2“ data sheet.
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Ordering informations
Female connectors Contact supporting press-in tool
593 784 593 785 593 787 593 788 593 790 593 791
593 793 593 794 023 433 023 434
594 132 594 133
594 141 594 142
594 135 594 136
023 501 023 502
593 796 593 797
593 805 593 806
593 799 593 800
023 445 023 446
594 138 594 139
593 802 593 803
Other versions on request.
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Ordering informations
Female connectors Contact supporting press-in tool
Female connectors with transfer-zone
1) Terminals nickel-plated over full length.Transfer-zone (5.0 mm) hard gold-plated.
Other versions on request.
594 144 594 145 594 147 594 148 594 150 594 151
594 153 594 154 023 408 023 409
433 884 433 883 023 400
023 401 023 410
023 402 004 837 004 128
023 403 023 411
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Ordering informations
Female connectors with transfer-zone Contact supporting press-in tool
023 435 023 437 023 439
1) Terminals nickel-plated over full length.Transfer-zone (5.0 mm) hard gold-plated.
Other versions on request.
023 441 023 443
023 436 023 438
023 442 023 444
023 440
Special applicationTo provide protection of the pins on the back panel and toallow for additional connection to the front and back panel,ERNI offers the modular connector housing system. This system is made up of guide frames and cable housingsfor the panel connectors and individual wire connectors formating.This individual wire connectors utilize a discrete wire insulationdisplacement (IDC) termination method for efficiently connecting to multiple round wires. These wire connectors are available in a series of pin counts in both 2 and 3 rowsversions.For more details, please refer to „Mateable transfer wiring-system“ and „Modular connector housing system“ catalogs.
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Size H 11Mating and mounting conditions acc. to DIN 41612/IEC 60603-2
Dimensional drawingsFemale connector
Ordering informations
Female connectors
424 655
Flat press-in tool
Mating side electroplated with silver.Wiring side tin-plated.
Other versions on request.
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Size H 15acc. to DIN 41612/IEC 60603-2
Dimensional drawingsFemale connector
Ordering informations
Female connectors
594 752
Flat press-in tool
Mating side electroplated with silver.Wiring side tin-plated.
Other versions on request.
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Ordering informationsFemale connector
023 404 004 886
Flat press-in tool
Female connectors with transfer-zone
1) Terminals nickel-plated over full length.Transfer-zone (5.0 mm) hard gold-plated.
Size E 160Same design as size E acc. to DIN 41612/IEC 60603-2
Dimensional drawingsFemale connector
023 406 004 885
023 405 004 887
023 407 013 315
Other versions on request.
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Guide framefor mounting on PC Boardswith connectors size C, R, CD 128, RD 128, E 160, TE 160
Interface on the wiring side of a control system with the aid ofinterface connectors play an important role in signal transfer.One of the many advantages of the press-fit technique ist thatthe interface connection to the wiring side can be made easily.This connection to the wiring side of a PC Board loaded withpress-fit connectors can be accomplished by simply mountingguide frames to the rear (wiring) side. ERNI has developedguide frames with varying heights for the C, R, CD 128, RD 128, E 160 and TE 160 sizes.For information on the ERNI guide frames, please contact thelocal ERNI sales office.
064 729 064 728 433 215 034 798
064 586 064 584 434 286 034 797
064 708 064 713 013 275 034 702
064 585 064 583 414 715 034 799
064 709 064 714 014 145 034 796
064 710 064 715 333 139 034 800
064 711 064 716 414 219 034 801
064 712 064 717 413 971 034 802
Please abserve sufficient overlapping length.
Ordering informations(All dimensions in mm)
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Size QSize Q/2Size Q/3
Reversed style, acc. to DIN 41 612/IEC 60603-2
Reversed style, short version of size Q
Reversed style, third-length of size Q
Dimensional drawingsMale connector
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Ordering details
Male connectors Contact supporting press-in tool
Male connectors with transfer-zone
1) Terminals nickel-plated over full length.Transfer-zone (5.0 mm) hard gold-plated.
Other versions on request.
593 963 593 964
023 418 593 952
023 416 593 949 013 887 023 417
004 740 433 777
023 420 023 421
0,8 mm early make/last break contacts are possible at all positions.
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Size RSize R/2Size R/3
Reversed style, acc. to DIN 41 612/IEC 60603-2
Reversed style, short version of size R
Reversed style, third-length of size R
Dimensional drawingsMale connector
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Ordering informations
Male connectors Contact supporting press-in tool
Other versions on request.
414 690 414 691 004 993 023 419
414 687 414 688 023 422 023 423
593 413 593 414 004 480 433 780
593 410 593 411 004 502 023 424
0,8 mm early make/last break contacts are possible at all positions.
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Ordering informations
Male connectors with transfer-zone Contact supporting press-in tool
414 702 414 703 023 425 023 426
414 699 414 700 023 427 023 428
1) Terminals nickel-plated over full length.Transfer-zone (5.0 mm) hard gold-plated.
Other versions on request. 0,8 mm early make/last break contacts are possible at all positions.
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Application example
In order to avoid any incorrect connections being made whichcould lead to the damage of sensitive electronic equipmentdue to overload, provisions are available for coding the connector halves.Connector sizes B/2, B/3, C/2, C/3, M and the inverse versions are provided with this integral coding.
The integral coding is accomplished by breaking off (with pliers) the coding tab positions on the male connector.Coding slots are made on the corresponding locations as wellon the female connector.For information on coding systems, please contact the localERNI sales office.
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013 181
013 178
013 154
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Size RD 128Reversed style with 4 rows of contacts, each with up to 32 contacts
Dimensional drawingsMale connector
Ordering informationsContact supporting press-in tool
Male connectors Male connectors with transfer-zone
Other versions on request.
1) Terminals nickel-plated over full length.Transfer-zone (5.0 mm) hard gold-plated.
0,8 mm early make/last break contacts are possible at all positions.
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013 164
013 161
013 155
Size TE 160Reversed style of size E 160
Dimensional drawingsMale connector
Ordering informationsContact supporting press-in tool
Male connectors Male connectors with transfer-zone
Other versions on request.
1) Terminals nickel-plated over full length.Transfer-zone (5.0 mm) hard gold-plated.
0,8 mm early make/last break contacts are possible at all positions.
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Ordering informations
424 797 424 798 424 799
424 803 424 804 424 805
1) Terminals nickel-plated over full length.Transfer-zone (5.0 mm) hard gold-plated.
Size Dacc. to DIN 41 612/IEC 60603-2
Dimensional drawingsFemale connector
424 801
Other versions on request.
Contact supporting press-in toolFemale connectors Female connectors with transfer-zone
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Ordering informations
424 806 424 807 424 808
424 812 424 813 424 814
1) Terminals nickel-plated over full length.Transfer-zone (5.0 mm) hard gold-plated.
Size Eacc. to DIN 41 612/IEC 60603-2
Dimensional drawingsFemale connector
424 810
Other versions on request.
Contact supporting press-in toolFemale connectors Female connectors with transfer-zone
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Ordering informations
593 990 593 991
593 993 593 994
013 970 594 491
023 429 433 010
Size Facc. to DIN 41 612/IEC 60603-2
Dimensional drawingsFemale connector
Other versions on request.
Contact supporting press-in toolFemale connectors Female connectors with transfer-zone
1) Terminals nickel-plated over full length.Transfer-zone (5.0 mm) hard gold-plated.
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Application example
Apart from the connectors which the user press-fits himself,ERNI also offers complete bus systems. These systems arematched to solderless wiring at the layout stage in collaboration with the user.
Our comprehensive service includes:
• Collaboration on layout preparation• Procurement of PC Board• Testing of PC Board• Assembly of the components• Electrical testing of the system for short circuit and continuity
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Press-in tools
Pneumatically assisted bench press with pressure measuringunit.
GeneralThe male and female connectors are press-fitted into the PCBoard in a one-step operation. No additional securing such asscrew hardware is necessary.Press-fitting of female connector sizes B, B/2, B/3, C, C/2,C/3, M, D, E and F is performed with the aid of a contact-supporting press-in tool which transmits the insertion force tothe individual contacts direct.For female connector sizes B and C, an additional version isoffered which can be press-fitted with just a flat press-in tool.Insertion force is absorbed by the connector housing.Female connector sizes E 160, H 11 and H 15 are similarypress-fitted with a flat press-in tool.When press-fitting the inverted male connectors the insertionforce is transferred to the male contacts direct.The forces occuring can be indicated on a pressure measuring unit during the press-fit process and printed out viaan analysis system.
Flat press-in tool
Pressure measurement analysis system
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Ordering informations
Press-in tools for female connectors
Press-in tools for reversed male connectos
On request ERNI offers you various versions of bench presses.
473 277 473 382
473 278
473 468
473 275 473 383 473 161
473 279
473 469
473 436
473 435 473 362
473 347
473 346 473 161
473 345
473 344
473 363 473 362
473 260
473 257 473 222
473 262
473 323
473 464 473 161
473 466
473 233
473 465 473 161
473 467
471 605 473 362
471 607