din 41612/iec 60603-2 press-fit connectorsc1170156.r56.cf3.rackcdn.com/uk_ern_593414_ds.pdf ·...

132 www.ERNI.com/contact/

catalog E 074484 05/02 Edition 4

ERNIPRESSDIN 41612/IEC 60603-2 Press-fit connectors



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

135www.ERNI.com/contact/


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.



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



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



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



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.



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



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



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





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



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



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



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




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




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.



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



Size Macc. to DIN 41612/IEC 60603-2


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.




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.




Female connectors Contact supporting press-in tool




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




Female connectors with transfer-zone Contact supporting press-in tool

023 435 023 437 023 439



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.



Size H 11Mating and mounting conditions acc. to DIN 41612/IEC 60603-2



Female connectors

424 655

Flat press-in tool

Mating side electroplated with silver.Wiring side tin-plated.




Size H 15acc. to DIN 41612/IEC 60603-2



Female connectors

594 752

Flat press-in tool

Mating side electroplated with silver.Wiring side tin-plated.




Ordering informationsFemale connector

023 404 004 886

Flat press-in tool



Size E 160Same design as size E acc. to DIN 41612/IEC 60603-2


023 406 004 885

023 405 004 887

023 407 013 315




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)



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



Ordering details

Male connectors Contact supporting press-in tool

Male connectors with transfer-zone



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.



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





Male connectors Contact supporting press-in tool


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





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


Other versions on request. 0,8 mm early make/last break contacts are possible at all positions.



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.

013 181

013 178

013 154



Size RD 128Reversed style with 4 rows of contacts, each with up to 32 contacts


Ordering informationsContact supporting press-in tool

Male connectors Male connectors with transfer-zone






013 164

013 161

013 155

Size TE 160Reversed style of size E 160


Ordering informationsContact supporting press-in tool

Male connectors Male connectors with transfer-zone







424 797 424 798 424 799

424 803 424 804 424 805


Size Dacc. to DIN 41 612/IEC 60603-2


424 801


Contact supporting press-in toolFemale connectors Female connectors with transfer-zone




424 806 424 807 424 808

424 812 424 813 424 814


Size Eacc. to DIN 41 612/IEC 60603-2


424 810






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







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



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




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

din 41612/iec 60603-2 press-fit connectorsc1170156.r56.cf3.rackcdn.com/uk_ern_593414_ds.pdf ·...

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