Elcon CROWN EDGE Card Edge-style High Current Connectors

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Damon Walsh
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Elcon CROWN EDGE Card Edge-style High Current Connectors CROWN EDGE is a board-to-board power interconnect solution that uses Elcon high performance Crown contact technology configured to mate

Power, signal and mixed contact modules can be combined and mounted endto-end to meet the requirements of the application.

The desired current rating for any given application can be achieved by bussing multiple or even modules.

1 Elcon CROWN EDGE Card Edge-style High Current Connectors CROWN EDGE is a board-to-board power interconnect solution that uses Elcon high performance Crown contact technology configured to mate directly with a printed circuit board edge or for higher currents with a solid bus bar. Power, signal and mixed contact modules can be combined and mounted endto-end to meet the requirements of the application. High-current Card Edge Interface CROWN EDGE uses Elcon s proven Crown that provide multiple points of contact for high current, and low voltage drop and minimal heat generation. The desired current rating for any given application can be achieved by bussing multiple or even modules. For even higher currents, CROWN EDGE can be mounted onto a bus bar, and mate directly with a bus bar tab. Optimum interface to the mounting PC board is achieved through five termination tails. Flexible Modular Design To make easy work of power distribution design, CROWN EDGE is available in modules of 2 and 3 contact segments, each of which may have power or signal or a combination of both in a single module. Modules can be placed end-to-end for assemblies up to 8" ( mm) long. Custom molded configurations are possible on highvolume projects. Consult Elcon for details. PRODUCT SERVICE Bauart geprüft Versatile Power Arrangements Opposing are isolated, so power connections at different voltage levels can be on one side of the board, with ground or power return on the other side. True Hot Plug Support CROWN EDGE power modules that support current interruption under load as defined by safety regulatory agencies are also available. These true hot plug modules allow current interruption under load by incorporating a contact Elcon True Hot Plug Contact design that restricts the effects of arcing to areas that do not compromise the integrity of the connection when mating with a metal blade or bus bar tab. See HOT PLUG REQUIREMENTS on last page for details. Leaders in Current Thinking KEY FEATURES Low cost power solution Power, signal and mixed modules 30A per power contact Mates with.062" (1.6 mm) thick card edge or bus bar tab Press-fit or solder tail terminations True hot plug power modules Meets regulatory safety requirements TARGET APPLICATIONS Board-to-board power connections DC-DC converters UPS Power supplies ORDERING INFORMATION Part numbers for standard CROWN EDGE modules are shown on inside pages under DIMENSIONS AND PART NUMBERS. For more information about this or any other Elcon connector product, visit the Elcon website at: Elcon is a Tyco Electronics brand. To find out more about other Tyco Electronics brands, products and services, visit the Tyco Electronics website at:

2 DIMENSIONS AND PART NUMBERS Power Press-fit tail, non-hot plug Short solder tail, non-hot plug Long solder tail, non-hot plug Press-fit tail, hot plug Short solder tail, hot plug Long solder tail, hot plug Non-hot plug version of the module shown. Dimensions for hot plug and non-hot plug versions of the modules are the same..932 (23.67) Units: Inches (mm).072 (1.83) (26.8).032 (0.8).077 (1.95).902 (22.90).077 (1.95).131 (3.33) Signal Press-fit tail Short solder tail Long solder tail (2.50).932 (23.67).114 (2.90) 20 ø.040 (1.02) (26.8).032 (0.8).803 (20.40) 2 power + 8 signal Press-fit tail Short solder tail Long solder tail.213 (5.40) (2.50) 16 ø.040 (1.02).032 (0.8) (26.8).932 (23.67) Power Contacts Side Signal Contacts Side (2.50).077 (1.95).803 (20.40).049 (1.25) (2.5).163 (4.15).100 (2.54).066 (1.67) 18 ø.040 (1.02) External appearance, dimensions and specifications are subject to change without notice.

3 Power Press-fit tail, non-hot plug Short solder tail, non-hot plug Long solder tail, non-hot plug Press-fit tail, hot plug Short solder tail, hot plug Long solder tail, hot plug Units: Inches (mm) Non-hot plug version of the module shown. Dimensions for hot plug and non-hot plug versions of the modules are the same (36.57) (39.7).032 (0.8).077 (1.95) (35.80).077 (1.95).131 (3.33).114 (2.90) (2.50).114 (2.90) 30 ø.040 (1.02) Signal Press-fit tail Short solder tail Long solder tail (36.57) (39.7).032 (0.8) 4 power + 8 signal Press-fit tail Long solder tail Short solder tail (36.57) (39.7).032 (0.8) Power end Signal end External appearance, dimensions and specifications are subject to change without notice.

CONNECTOR MOUNTING Solder Tails Solder termination is available in two lengths. See table below for board thicknesses and recommended tail lengths.

) Dimension A (see table below) PC Board Surface (ref.) Tail length vs. board thickness Board Thickness.062" (1.6mm).092"/.125" (2.3/3.0mm) Solder Tail Detail Dimension A.100".140" (2.55 3.57mm) [.

5mm) nominal] Press-fit tail detail Tooling for compliant press-fit assemblies Pressing fixtures are recommended for compliant press-fit assemblies.

013) Copper Plate:.0010 (.025) min. (per surface) Tin Plate:.0003 (.008) min.

4 CONNECTOR MOUNTING Solder Tails Solder termination is available in two lengths. See table below for board thicknesses and recommended tail lengths. Press-fit Tails CROWN EDGE uses truly compliant eye of the needle press-fit tails designed for boards 0.093" thick and above. PC Board Surface (Ref.) Dimension A (see table below) PC Board Surface (ref.) Tail length vs. board thickness Board Thickness.062" (1.6mm).092"/.125" (2.3/3.0mm) Solder Tail Detail Dimension A.100".140" ( mm) [.115" (2.92mm) nominal].160".200" ( mm) [1.77" (4.5mm) nominal] Press-fit tail detail Tooling for compliant press-fit assemblies Pressing fixtures are recommended for compliant press-fit assemblies. Contact Elcon for fixtures or a detailed tool drawing. Suggested printed circuit hole for power contact Finished Hole: Ø.040 ±.003 (Ø1.02 ±.08) Drilled Hole: Ø.0453 ±.0005 (Ø1.151 ±.013) Copper Plate:.0010 (.025) min. (per surface) Tin Plate:.0003 (.008) min. (per surface) Spacing between modules in end-to-end mounting The spacing between plated thru holes for end-to-end mounting varies depending on the chosen module combination. Spacing for the three possible combinations is shown below. Power-to-power Signal-to-signal Power-to-signal.157 (4.00).256 (6.50).207 (5.25) Power Power Signal Signal Power Signal CUSTOM SOLUTIONS Non-standard Modules In case the standard CROWN EDGE modules do not meet your design requirements, Elcon has the capability to mold any combination of power and signal contact layouts in 2 and 3 segment modules. Application-specific Custom Designs Elcon has a long history of designing and building application specific custom connectors, and CROWN EDGE is no exception. A one-piece CROWN EDGE insulator, instead of a combination of several modules, provides a more robust interconnect design, as well as cost savings in high volume projects. Consult Elcon for details. Photogaphs may show simulated images.

5 PRODUCT SPECIFICATIONS MATERIALS & FINISHES Insulators Contacts ELECTRICAL Current ratings Non-hot contact Hot plug power contact plug power Signal Power contact Insulation resistance Contact holder Crown element Note: Product specifications are subject to change without notice. CURRENT RATINGS The chart below demonstrates the performance of the CROWN EDGE power contact by showing the temperature rise at different current levels applied to two power connected in series. PPA, UL 94-V-0 flammability rated, color black Copper alloy, selectively plated with gold per MIL-G and bright tin/lead per MIL-T-10727, all over nickel per QQ-N-290 Phosphor bronze alloy per ASTM-B103, selectively plated with bright tin/lead per MIL-T on terminations, all over nickel per QQ-N-290 Copper alloy per ASTM-B194, selectively plated with gold per MIL-G-45204, all over nickel per QQ-N-290 Phosphor bronze alloy per ASTM-B-103, selectively plated with gold per MIL-G-45204, and bright tin/lead per MIL-T on terminations, all over nickel per QQ-N A (see graph below) S ignal contact 3A max. 5,000MΩ minimum at 500VDC for 2 minutes, per MIL-STD 1344, Method 3003 Dielectric strength 1,500VDC for 1 minute, per MIL-STD 1344, Method 3001 MECHANICAL Mating PCB thickness Insertion Forces Extraction Forces Tooling " (1.6 mm) ±.006" (0.15 mm) 2 segment power module 5.0 lbf typical using.062" (1.6 mm) thick mating board with 5 oz. of copper 3 segment power module 6.0 lbf typical using.062" (1.6 mm) thick mating board with 5 oz. of copper 2 segment power module 3.0 lbf typical using.062" (1.6 mm) thick mating board with 5 oz. of copper 3 segment power module 5.0 lbf typical using.062" (1.6 mm) thick mating board with 5 oz. of copper Press fixture is recommended for compliant press fit assemblies. Consult Elcon for details. SAFETY REGULATORY COMPLIANCE CROWN EDGE has been evaluated by Underwriters Laboratories and has been found to comply with the requirements of U.S. standard UL1997 and Canadian standard C22.2 No M1987. CROWN EDGE also has TÜV certification. Temperature Rise (C ) A 10A 15A 20A 25A 30A 35A 40A 45A 50A 60A Current (A) Current rating for any given application will depend, among other things, on the module combination, PCB copper trace volume, and internal equipment temperature/air flow. Mounting and mating to a bus bar will increase current ratings. Elcon True Hot Plug Contact File No. E PRODUCT SERVICE Bauart geprüft Certificate No. B Compliance with Current Interruption Requirements Hot plug CROWN EDGE modules are available for applications that require current interruption as defined by safety regulatory agencies. These power-only modules have been evaluated and recognized by Underwriters Laboratories for current interruption up to 50 cycles as per the UL1977 standard. For more details, see HOT PLUG REQUIREMENTS on last page.

6 DESIGN NOTES Mating PCB requirements Mating PCB edge fingers should be gold plated, have.050" (1.3 mm) side margins, and be of suitable copper weight for power applications. Sequenced mating Sequenced mating can be achieved by designing one or more setback traces on the mating card edge, or by notching the edge of the card. End-to-end mounting CROWN EDGE modules can be placed end-to-end for connector assemblies up to 8" ( mm) long. MATING PC CARD EDGE SAMPLES The drawings below show two PC card edge samples with signal and power lines designed to mate with 2 and 3-segment CROWN EDGE modules. Mating board thickness:.062" (1.6 mm) (26.90) (39.80) Double-sided mating PCB card.148 (3.75) Mounting PC board.394 (10.0).472 (12.00).472 (12.00) (7.87).818 (20.77) MIN (23.37) ±.003 (.08) (33.67) MIN (32.27) ±.003 (.08) (1.32) (2.50).139 (3.53) 2 2 segment modules provide two sequenced power traces and 8 signal traces 2 3 segment modules provide ground plane and 12 signal lines. HOT PLUG REQUIREMENTS Hot plug application of this product requires the use of the CROWN EDGE true hot plug modules (see part numbers on inside pages under DIMENSIONS AND PART NUMBERS) mated with a customer-supplied metal blade or bus bar. Dimensions of a sample mating blade for use with CROWN EDGE hot plug modules is shown below. Consult Elcon for detailed requirements. Bus bar blade Suggested bus bar blade.394 ±.003 (10.00 ±.08).413 (10.50) max. insertion.062 (1.6) thick blade chamfer To find out more about this or any other Elcon product, visit the Elcon website at or simply contact the Elcon office nearest you: Mounting PC board Worldwide Headquarters elcon.sales@tycoelectronics.com Lawrence Place, Fremont, CA Tel: Fax: European Head Office elcon.sales-uk@tycoelectronics.com Tel: Fax: Spain Office elcon.sales-sp@tycoelectronics.com Tel: Fax: Nihon Elcon KK (Japan) elcon.sales-jp@tycoelectronics.com Tel: +81(0) Fax: +81(0) Your Authorized Representative/Distributor: Copyright Elcon Products International Company 2000, 2001, 2002 CE A/5000 Elcon, CROWN EDGE and Crown Band are trademarks of Elcon Products International Company.

The con ectors serve low durability cycle applications

The con ectors serve low durability cycle applications Power Connectors & Interconnection Systems Introduction to High Current Card Edge Connectors Product Facts Contacts on.100 [2.54] Centerlines Selective gold plating of contacts for high performance at