ODU-MAC. Modular Connector System with High Power, Signal, Coaxial and fiber optic contacts, pneumatic modules

Transcription

1 Catalogue No. 100-c ODU-MAC Modular Connector System with High Power, Signal, Coaxial and fiber optic contacts, pneumatic modules ODU-Steckverbindungssysteme GmbH & Co. KG, Pregelstraße 11, D-85 Mühldorf/Inn Telephone: +9/ 86 1/ , Telefax: +9/ 86 1/ ,

2 ODU-MAC Product description: The ODU-MAC connector system consists of a variety of customizable rugged frames, plastic insulation bodies (modules) with many of insert patterns, and crimpable, removable contacts for high currents (power), low currents (signal), and RF-signals. Modules can be arranged in different patterns in the frame according to application. Unit spacing is.5 mm (.100") or a multiple thereof. Guide pins and guide bushings prevent misconnections and provide easy alignment for accurate mating. Aluminum-Frame This frame has two end pieces and two rails with guiding and mounting hardware. The socket part (receptacle) is generally fixed while the pin part (plug) is typically mounted floating. This frame can accept between to 60 units with a width of.5 mm each. For example, if 10 position modules are used, a connector with max. 600 AWG contacts can be assembled. ODU-MAC in DIN Housing ODU-MAC in DIN housing with locking latch is available in four sizes. Size I accepts 10 modules (.5 mm ea.) while Size IV accommodates up to models (.5 mm ea.). Size IV can have max. 0 contacts AWG. DIN-Housing with Locking Spindle To make the standard DIN housing with locking latch more user-friendly, a quick connect-disconnect locking spindle was developed. As an option, the DIN housings are offered with a precision locking spindle. The locking spindle provides very smooth locking and unlocking of the connector with a single twist. The locking spindle system is especially designed for high number of connects and disconnects. The precision of the spindle allows more than 5,000 mating cycles. All dimensions in mm. All figures are illustrations or Photos. Changes reserved. Page ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ ,

3 ODU-MAC Contents Page ODU-MAC Product Description ODU-Springwire Contact Principle ODU-MAC Modules: Insulation Bodies, Contacts, Technical Data 7 ODU-MAC Aluminum Frame 5 ODU-MAC DIN Frame 9 ODU-MAC DIN Housing 1 ODU-MAC Crimp Tools 6 Technical Information ODU-MAC Application Examples 8 Technical Article 51 ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ , Page

4 ODU-MAC The Concept of Springtac Springwire Contacts. The springwire contact is the invention of Otto Dunkel. The Figure shows a Springtac socket and solid pin. The socket has a multitude of preformed springwires. The springwires are parallel to the plugging direction. They form a flexible cage, with one end fixed at the bottom of the socket, the other end free to move. The springwires are independent from each other and make contact with the surface of the pin. This arrangement creates in the mated condition an almost constant normal pressure over the entire contact surface of the pin. A springwire socket for a 1.0 mm dia. (AWG 0) pin has about 19 springwires. The number of springwires increases with the size of the contact. This results in many contact points between pin and socket, creating a large contact area for excellent current transmission. Springtac contacts are available from 0.6 mm dia. to more than 50 mm dia. They can be supplied with solder, crimp, or threaded stud termination. Contact retention in a connector insulation body is via military-style contact clips. The outstanding advantages of ODU Springtac contacts are: Very high contact reliability Low contact resistance High current carrying capability High resistance to vibration Low mating and demating force High number of mating cycles Long service life Springwire Surface Finish Socket Wall Contact Surface Contact Pin Page ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ ,

5 ODU-MAC The Modules The insulation bodies (modules) are presently available in 11 different versions (sizes as well as number of contacts per module). Figure beside shows a few examples. Insulation bodies are made of glass-filled thermoplastic polyester, UL-9 0 rated. Unit width of a module is.5 mm. Modules come in multiples of unit width. Insulation bodies consists of two parts which are ultrasonically welded together. The crimped contacts snap into the cavities from the rear and can be removed in seconds with standard contact removal tools. The modules are locked into the connector frame with locking ridges in grooves. Contact Retention Figure beside shows a contact inside a module. Contacts are inserted from the rear. Retention clips snap over the shoulder of the contact and hold the contact in place. Removal of the contacts is very simple with the use of standard contact removal tools. Although this type of retention clips and insulation bodies require expensive precision production methods, the military-style contact retention system is a very desirable approach to contact retention. It offers significant advantages over fixed contacts. Higher operating voltages for each module can be achieved by leaving adjacent contact cavities empty. ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ , Page 5

6 For your notes Page 6 ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ ,

7 Modules Module, 10 Positions Spacer (Blank) (Dummy Module) For Springtac Contact 0.76 mm (.00") Dia. Rated Voltage: V Rated Surge Voltage: 0.8 kv Degree of Pollution: Test Voltage acc. VDE 0100: 875 V~ Total Mating Force (Average): 7.7 N (7 oz.) Total Demating Force (Average): 7.1 N (5 oz.) Contact Diameter: 0.76 mm (.00") Contact Finish: 0 µ" Au over 50 µ" Ni Materials: Insulation Body: Contact Body: Contact Spring: Glass-filled thermoplastic (Polyester), UL-9 V0 rated Cu-Alloy Cu Be Module Width: 1 Unit (.5 mm,.100") Operating Temperature: -0 C up to 15 C Module, 10 Positions Spacer (Blank) Dummy Contact Plugging Direction 19 10,1,5,5 8 (by solder- in version),5 =,86 = 0 0 Removal Tool Current load only for single contacts. For multiple contacts derate acc. to VDE 098. Module Spacer Removal Tool Pin Contact Grd. Pin Contact Socket Contact Pin Contact Grd. Pin Contact Socket Contact Pin Contact Grd. Pin Contact Socket Contact Dummy Contact Termination AWG/mm AWG AWG AWG AWG /8 AWG /8 AWG /8 PCB Solder Pin Ø 0,76 max. Current (A) Contact Resistance (mω) average Crimp Instructions see Page 6/7 ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ , Page 7

8 Modules Module, for Print, Wire Wrap Termination and IDC-connectors 10 Positions For Springtac Contact 0.76 mm (.00") Dia. Rated Voltage: V Rated Surge Voltage: 0.8 kv Degree of Pollution: Test Voltage acc. VDE 0100: 875 V~ Total Mating Force (Average): 7.7 N (7 oz.) Total Demating Force (Average): 7.1 N (5 oz.) Contact Diameter: 0.76 mm (.00") Contact Finish: 0 µ" Au over 50 µ" Ni Materials: Insulation Body: Contact Body: Contact Spring: Glass-filled thermoplastic (Polyester), UL-9 V0 rated Cu-Alloy Cu Be 6 Positions Module Width: 1 Unit (.5 mm,.100") Operating Temperature: -0 C up to 105 C Pin Insert,86,5 Ø 0,6 Ø 0,6 15 9,5,5 Socket Insert =,86 = ,6 0,6 Pin Insert Socket Insert 10 Positions Positions Print Termination for IDC connectors Wire Wrap Page 8 ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ ,

9 Modules Special ODU-MAC connector, mixed contact configuration, with a max. 10-way module for wire-wrap resp. IDC connectors Socket Connectors - Series 517 with Single-U IDC Contact, double action wiping spring contact Pos Without Strain Relief XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX Without Strain Relief XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ , Page 9

10 Modules Module, 6 Positions Spacer (Blank) (Dummy Module) For Springtac Contact 1.0 mm (.00") Dia. Rated Voltage: 6 V 50 V Rated Surge Voltage:.5 kv.5 kv Degree of Pollution: Test Voltage acc. to VDE 0100: 1,50 V~ Total Mating Force (Average): 6.5 N ( oz.) Total Demating Force (Average): 6.0 N ( oz.) Contact Diameter: 1.0 mm (.00") Contact Finish: 0 µ" Au over 50 µ" Ni Materials: Insulation Body: Contact Body: Contact Springs: Glass-filled thermoplastic (Polyester), UL-9 V0 rated Cu-Alloy Cu Be Module Width: Units (5.08 mm,.00 ") Operating Temperature: -0 C up to 15 C Module, 6 Positions Spacer (Blank) Dummy Contact Plugging Direction 19 10,1,81 5,08 8 (by solder in version) 5,08 = 19,05 = 0 0 Removal Tool Current load only for single contacts. For multiple contacts derate acc. to VDE 098. Module Spacer Removal Tool Pin Contact Grd. Pin Contact Socket Contact Pin Contact Grd. Pin Contact Socket Contact Pin Contact Grd. Pin Contact Socket Contact Dummy Contact Termination AWG/mm AWG 0/ AWG 0/ AWG 0/ AWG /8 AWG /8 AWG /8 PCB Solder Pin Ø 1.0 max. Current (A) Contact Resistance (mω) average Crimp Instructions see Page 6/7 Page 10 ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ ,

11 Modules Module, 1 Positions Spacer (Blank) (Dummy Module) For Springtac Contact 1.0 mm (.00") Dia. Rated Voltage: 0 V 15 V Rated Surge Voltage: 1.5 kv 1.5 kv Degree of Pollution: Test Voltage acc. VDE 0100: 1,000 V~ Total Mating Force (Average): 1. N (51 oz.) Total Demating Force (Average): 1.5 N (9 oz.) Contact Diameter: 1.0 mm (.00") Contact Finish: 0 µ" Au over 50 µ" Ni Materials: Insulation Body: Contact Body: Contact Spring: Glass-filled thermoplastic (Polyester), UL-9 V0 rated Cu-Alloy Cu Be Module Width: Units (7.6 mm,.00 ") Operating Temperature: -0 C up to 15 C Module, 1 Positions Spacer (Blank) Dummy Contact Plugging Direction 19,5 10,1,65 7,6 8 (by solder in version) 7,6 = 1,9 = 0 0 Removal Tool Current load only for single contacts. For multiple contacts derate acc. to VDE 098. Module Spacer Removal Tool Pin Contact Grd. Pin Contact Socket Contact Pin Contact Grd. Pin Contact Socket Contact Pin Contact Grd. Pin Contact Socket Contact Dummy Contact Termination AWG/mm AWG 0/ AWG 0/ AWG 0/ AWG /8 AWG /8 AWG /8 PCB Solder Pin Ø 1,0 max. Current (A) Contact Resistance (mω) average Crimp Instructions see Page 6/7 ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ , Page 11

12 Modules Module, 5 Positions Spacer (Blank) (Dummy Module) For Springtac Contact 1.5 mm (.059") Dia. Rated Voltage: 0 V 50 V Rated Surge Voltage:.5 kv.5 kv Degree of Pollution: Test Voltage acc. VDE 0100: 1,000 V~ Total Mating Force (Average): 10. N (7 oz.) Total Demating Force (Average): 8.5 N (1 oz.) Contact Diameter: 1.5 mm (.059") Contact Finish: Contact Body: 0µ" Au over 50 µ" Ni Contact Springs: 0 µ" Ag Materials: Insulation Body: Contact Body: Contact Spring: Glass-filled thermoplastic (Polyester), UL-9 V0 rated Cu-Alloy Cu Sn Module Width: Units (5.08 mm,.00") Operating Temperature: -0 C up to 15 C Module, 5 Positions Spacer (Blank) Dummy Contact Plugging direction 19 1,1 5,08 5,08 8 (by solder in version) 5,08 = 0, = 0 0 Removal Tool Current load only for single contacts. For multiple contacts derate acc. to VDE 098. Module Spacer Removal Tool Pin contact Grd. pin contact Socket contact Pin contact Grd. pin contact Socket contact Pin contact Grd. pin contact Socket contact Pin contact Grd. pin contact Socket contact Pin contact Grd. pin contact Socket contact Pin contact Grd. pin contact Socket contact Dummy Contact Termination AWG/mm 1.5 mm 1.5 mm 1.5 mm AWG 16 AWG 16 AWG 16 1 mm 1 mm 1 mm AWG 0/ AWG 0 AWG 0/ AWG /8 AWG /8 AWG /8 PCB Solder Pin Ø 1.5 max. Current (A) Contact Resistance (mω) average Crimp Instructions see Page 6/7 Page 1 ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ ,

13 Modules Module, Positions Spacer (Blank) (Dummy Module) For Springtac Contact.1 mm (.095") Dia. Rated Voltage: 15 V 50 V Rated Surge Voltage:.5 kv.5 kv Degree of Pollution: Test Voltage acc. VDE 0100: 1,500 V~ Total Mating Force (Average): 19.5 N (70 oz.) Total Demating Force (Average): 17.0 N (61 oz.) Contact Diameter:.1 mm (.095") Contact Finish: 0 µ" Ag Materials: Insulation Body: Contact Body: Contact Spring: Glass-filled thermoplastic (Polyester), UL-9-V0 rated Cu-Alloy Cu Sn Module Width: Units (7.6 mm,.00") Operating Temperature: -0 C up to 15 C Module, Positions Spacer (Blank) Dummy Contact Plugging Direction 19 1,1 6,5 7,6 8 (by solder in version) 7,6 = 19,05 = 0 0 Removal Tool Current load only for single contacts. For multiple contacts derate acc. to VDE 098. other contact Ø on request Module, Positions Spacer Removal Tool Pin Contact Grd.Pin Contact Socket Contact Pin Contact Grd.Pin Contact Socket Contact Pin Contact Grd.Pin Contact Socket Contact Pin Contact Grd.Pin Contact Socket Contact Pin Contact Grd.Pin Contact Socket Contact Pin Contact Grd.Pin Contact Socket Contact Dummy Contact Termination AWG/mm AWG 1 AWG 1 AWG 1.5 mm.5 mm.5 mm 1.5 mm 1.5 mm 1.5 mm 1.0 mm 1.0 mm 1.0 mm AWG 0/ AWG 0/ AWG 0/ PCB Solder Pin Ø, max. Current (A) , Contact Resistance (mω) average Crimp Instructions see Page 6/7 ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ , Page 1

14 Modules Module, Positions Spacer (Blank) (Dummy Module) For Springtac Contact.0 mm (.118") Dia. Rated Voltage: 100 V 50 V Rated Surge Voltage:.5 kv.5 kv Degree of Pollution: Test Voltage acc. to VDE 0100: 1,500 V~ Total Mating Force (Average): 18.5 N (67 oz.) Total Demating Force (Average): 16.0 N (58 oz.) Contact Diameter:.0 mm (.118 ") Contact Finish: 0 µ" Ag Materials: Insulation Body: Contact Body: Contact Spring: Glass-filled thermoplastic (Polyester), UL-9-V0 rated Cu-Alloy Cu Sn Module Width: Units (7.6 mm,.00 ") Operating Temperature: -0 C up to 15 C Module, Positions Spacer (Blank) Dummy Contact Plugging Direction 19 1,1 7,6 7,6 7,6 = 15, = 0 0 Removal Tool Current load only for single contacts. For multiple contacts derate acc. to VDE 098. other contact Ø on request Module, Positions Spacer Removal Tool Pin Contact Grd. Pin Contact Socket Contact Pin Contact Grd. Pin Contact Socket Contact Pin Contact Grd. Pin Contact Socket Contact Pin Contact Grd. Pin Contact Socket Contact Pin Contact Grd. Pin Contact Socket Contact Dummy Contact Termination mm.0 mm.0 mm.0 mm.5 mm.5 mm.5 mm 1.5 mm 1.5 mm 1.5 mm 1.0 mm 1.0 mm 1.0 mm AWG 0/ AWG 0/ AWG 0/ max. Current (A) Contact Resistance (mω) average Crimp Instructions see Page 6/7 Page 1 ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ ,

15 Modules Module, Position Spacer (Blank) (Dummy Module) For Springtac Contact.0 mm (.157") Dia. Rated Voltage: 15 V 50 V Rated Surge Voltage:.5 kv.5 kv Degree of Pollution: Test Voltage acc. to VDE 0100: 1,500 V~ Total Mating Force (Average): 18.5 N (67 oz.) Total Demating Force (Average): 16.0 N (58 oz.) Contact Diameter:.0 mm (.157 ") Contact Finish: 0 µ" Ag Materials: Insulation Body: Contact Body: Contact Spring: Glass-filled thermoplastic (Polyester), UL-9-V0 rated Cu-Alloy Cu Sn Module Width: 5 Units (1.7 mm,.500 ") Operating Temperature: -0 C up to 15 C Module, Positions Spacer (Blank) Dummy Contact Plugging Direction 1 8,89 1,7 1,7 17 = 17,78 = 0 0 Removal Tool Current load only for single contacts. For multiple contacts derate acc. to VDE 098. Module, Positions Spacer Removal Tool Pin Contact Grd. Pin Contact Socket Contact Dummy Contact Termination mm 6.0 mm 6.0 mm 6.0 mm max. Current (A) Contact Resistance (mω) average Crimp Instructions see Page 6/7 ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ , Page 15

16 Modules Module, Position Spacer (Blank) (Dummy Module) For Springtac Contact 5.0 mm (.197") Dia. Rated Voltage: 15 V 50 V Rated Surge Voltage:.5 kv.5 kv Degree of Pollution: Test Voltage acc. to VDE 0100:,50 V~ Total Mating Force (Average):.0 N (79 oz.) Total Demating Force (Average): 18.0 N (65 oz.) Contact Diameter: 5.0 mm (.197 ") Contact Finish: 0 µ" Ag Materials: Insulation Body: Contact Body: Contact Spring: Glass-filled thermoplastic (Polyester), UL-9-V0 rated Cu-Alloy Cu Sn Module Width: 5 Units (1.7 mm,.500 ") Operating Temperature: -0 C up to 15 C Module, Positions Spacer (Blank) Dummy Contact Plugging Direction 1,7 1, ,7 0 0 Removal Tool Current load only for single contacts. For multiple contacts derate acc. to VDE 098. Module, Positions Spacer Removal Tool Pin Contact Grd. Pin Contact Socket Contact Pin Contact Grd. Pin Contact Socket Contact Dummy Contact Termination mm 10.0 mm 10.0 mm 10.0 mm.0 mm.0 mm.0 mm max. Current (A) Contact Resistance (mω) average Crimp Instructions see Page 6/7 Page 16 ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ ,

17 For your notes ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ , Page 17

18 Modules Module for 50 Ω RF-Coaxial Contacts (Old version)* Module, Pin & Socket, Positions Plugging Direction Frequency range: GHz Test voltage (DIN 775): 1100 V~ Insulation resistance: >100 G Ω Total Mating Force (Average): 9 N ( oz.) Total Demating Force (Average): 7.5 N (7 oz.) Materials: Insulation Body: Glass-filled thermoplastic (Polyester) UL-9 V0 Insulation Body for Center Contact: PTFE or similar Contact Body: Cu-Alloy Contact Springs: Cu Sn Contact Finish: Pin, center contact: 0 µ Au over 50 µ Ni Pin, outer contact: 0 µ Ni Socket, center contact: Socket, outer contact: Springs 0 µ Au over 50 µ Ni Springs 0 µ Au over 50 µ Ni Module Width: 5 Units (1.7 mm,.500 ) Operating Temperature: -0 C up to 15 C High frequency characteristics of the 50Ω Coaxial Contacts Insertion Loss 1,7 1 11,8 ± 0,0 0 Strip off length.5 VSWR S1 in db Frequency in GHz VSWR 7 Frequency in GHz inner conductor soldered outer conductor soldered or crimped *only for replacement Module, Positions Pin Contact, Straight Pin Contact, Straight Pin Contact, Straight Pin Contact, Straight Socket Contact, Straight Socket Contact, Straight Socket Contact, Straight Socket Contact, Straight Crimp Tool for EMI Sleeve Cable Impedance (Ω) Cable (Examples) RG178 / RG196 RG17 / RG188 / RG16 YCY 0, /,5 / RG1 RG58 RG178 / RG196 RG17 / RG188 / RG16 YCY 0, /,5 / RG1 RG58 Crimp Dies Page 18 ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ ,

19 Modules Module for 50 Ω RF-Coaxial Contacts with the clip principle (New version)* Module, Pin & Socket, Positions Frequency range: GHz Test voltage (DIN 775): 1100 V~ Insulation resistance: >100 G Ω Total Mating Force (Average): 9 N ( oz.) Total Demating Force (Average): 7.5 N (7 oz.) Materials: Insulation Body: Glass-filled thermoplastic (Polyester) UL-9 V0 Insulation Body for Center Contact: PTFE or similar Contact Body: Cu-Alloy Contact Springs: Cu Sn Contact Finish: Pin, center contact: 0 µ Au over 50 µ Ni Pin, outer contact: 0 µ Ni Socket, center contact: Socket, outer contact: Springs 0 µ Au over 50 µ Ni Springs 0 µ Au over 50 µ Ni Module Width: 5 Units (1.7 mm,.500 ) Operating Temperature: -0 C up to 15 C High frequency characteristics of the 50 Ω Coaxial Contacts Insertion Loss Strip off length 7 1,7 11,8 ± 0,0 0 VSWR S1 in db Frequency in GHz VSWR.5 Frequency in GHz inner conductor soldered outer conductor soldered or crimped Removal Tool *Cable assembly possible independantly from insulating body Module Spacer Dummy Contact Removal Tool Pin Contact, Straight Pin Contact, Straight Pin Contact, Straight Pin Contact, Straight Pin Contact, Straight Socket Contact, Straight Socket Contact, Straight Socket Contact, Straight Socket Contact, Straight Socket Contact, Straight Crimp tool for EMI Sleeve Cable Impedance (Ω) Cable (Examples) RG178 / RG196 RG17 / RG188 RG1 / YCY 0. /.5 RG58 RG RG178 / RG196 RG17 / RG188 RG1 / YCY 0. /.5 RG58 RG Crimp Dies ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ , Page 19

20 Modules Module for 75 Ω RF-Coaxial Contacts Frequency range: MHz Test voltage (DIN 775): 1100 V~ Insulation resistance: >100 G Ω Total Mating Force (Average): 6 N (10 oz.) [ positions] 18 N (65 oz.) [1 position] Total Demating Force (Average): 0 N (108 oz.) [ positions] 15 N (5 oz.) [1 position] Materials: Insulation Body: Glass-filled thermoplastic (Polyester) UL-9 V0 Insulation Body for Center Contact: PTFE or similar Contact Body: Cu-Alloy Contact Springs: Cu Sn Contact Finish: Pin, center contact: 0 µ Ag Pin, outer contact: 0 µ Ni Socket, center contact: Body 0 µ Ag, Springs blank Socket, outer contact: Body 0 µ Ni, Springs blank Operating Temperature: -0 C up to 15 C Socket Module, Pos. Pin Module, Pos. Module, 1 Pos. (Pin & Socket) High frequency characteristics of the 75 Ω Coaxial Contacts Plugging Direction Plugging Direction Plugging Direction Insertion Loss ,6 0,6 18,6 0,6 10,5 0, S1 in db ,5 0 (16 Units wide) 0 10,5 0 (8 Units wide) Frequency in GHz 1.8 VSWR 1.6 VSWR Termination Style: Frequency in GHz Socket Module, Positions Pin Module, Positions Module (Socket & Pin) 1 Position Pin contact Pin contact Pin contact Pin contact Socket contact Socket contact Socket contact Socket contact Assembly Tool Termination Style 1 1 Cable Impedance (Ω) Cable RG 59 RG 59 RG 179 RG 59 RG 59 RG 59 RG 179 RG 59 Page 0 ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ ,

21 Modules Module for 75 Ω RF-Coaxial Contacts with the clip principle (New version)* Module, Pin & Socket, Positions Frequency range: 0 - GHz Test voltage (DIN 775): 1100 V~ Insulation resistance: >100 G Ω Total Mating Force (Average): 9 N ( oz.) Total Demating Force (Average): 7.5 N (7 oz.) Materials: Insulation Body: Glass-filled thermoplastic (Polyester) UL-9 V0 Insulation Body for Center Contact: PTFE or similar Contact Body: Cu-Alloy Contact Springs: Cu Sn Contact Finish: Pin, center contact: 0 µ Au over 50 µ Ni Pin, outer contact: 0 µ Ni Socket, center contact: Springs 0 µ Au Socket, outer contact: over 50 µ Ni Springs 0 µ Au over 50 µ Ni Module Width: 5 Units (1.7 mm,.500 ) Operating Temperature: -0 C up to 15 C High frequency characteristics of the 75 Ω Coaxial Contacts 0.00 Insertion Loss Strip off length 1,7 11,8 ± 0, VSWR S1 in db Frequency in GHz VSWR Frequency in GHz inner conductor soldered outer conductor soldered or crimped Removal Tool *Cable assembly possible independantly from insulating body Module Spacer Dummy Contact Removal Tool Pin Contact, Straight Pin Contact, Straight Pin Contact, Straight Socket Contact, Straight Socket Contact, Straight Socket Contact, Straight Crimp tool for EMI Sleeve Cable Impedance (Ω) RG179 / RG187 G 0 (H+S) RG59 RG179 / RG187 G 0 (H+S) RG59 Cable (Examples) Crimp Dies ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ , Page 1

22 Modules Module for compressed air valve Tube Ø max. mm Materials: Insulation Body: Glass-filled thermoplastic (Polyester) UL-9 V0 rated Compressed Air Valve: Cu-Alloy Contact Finish: blank Air Pressure: shut off max. bar not shut off max. 6 bar Operating Temperature: -0 C up to 15 C Flowrate (l/min) Drop of pressure (bar) Module, Pin & Socket, Positions plug sleeve coupling plug Plugging Direction ,7 for different kind of termination: 11,8 ± 0,0 0 A A X both side shut off version on request Socket Module, Positions Plug Sleeve (not shut off) Plug Sleeve (not shut off) Plug Sleeve (not shut off) Coupling Plug (not shut off) Coupling Plug (not shut off) Coupling Plug (not shut off) Coupling Plug (shut off) Coupling Plug (shut off) Size A Ø M5 M5 Size X Page ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ ,

23 1 Modules Module for compressed air valve Tube Ø max. 6 mm Materials: Insulation Body: Glass-filled thermoplastic (Polyester) UL-9 V0 rated Compressed Air Valve: Cu-Alloy Contact Finish: blank Air Pressure: shut off max. bar not shut off max. 6 bar Operating Temperature: -0 C up to 15 C Socket Module, Pos. Pin Module, Pos. Module, 1 Pos. (Pin & Socket) Plugging Direction Plugging Direction Plugging Direction 0, 18, ,6 18,6 0,6 10,5 10,5 10,5 0 (8 Units wide) 0 0 (16 Units wide) Couppling Plug Plug sleeve X 1 1 X both side shut off version on request Ø A Flowrate (l/min) Drop of pressure (bar) Socket Module, Positions Pin Module, Positions Module (Socket & Pin) 1 Position Plug Sleeve (not shut off) Plug Sleeve (not shut off) Coupling Plug (not shut off) Coupling Plug (not shut off) Coupling Plug (shut off) Coupling Plug (shut off) Size A Ø Size X ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ , Page

24 Modules Module for Fiber Optic Contacts for 1 mm POF (Polymer-Optical-Fiber) with. /. mm outer diameter Insertion loss: typical: during livetime: 1.5dB at 670nm < db at 670nm Mating cycles: > Total Mating Force (Average): 1N ( oz.) Materials: Insulation Body: Glass-filled thermoplastic (Polyester) UL-9 V0 Fiber Optical Contact: Cu-Ni-Zn Alloy Type of Optical Fiber: Polymer-Optical-Fiber (POF) 980/1000 or 980/1550 Fiber fastening: Clamping Temperature range: standard Fiber: -0 C/+85 C high Temperature fiber: -0 C/+115 C Module Width: 5 Units (1.7mm,.500 ) Module, Pin & Socket, Positions Jack Plugging Direction 1 1,7 Plug 11,8 ± 0,0 0 Assembly: Cable assembly possible independantly from insulating body. Please ask for the assembly instruction. Module, Positions Jack 980/1000 µm Plug 980/1000 µm Jack 980/1550 µm (Most standard) Plug 980/1550 µm (Most standard) Tool for cable-stripping Spare blades Wrench/Spanner.5 mm Wrench/box spanner 8 mm Polish-device for jack Polish-device for plug Sandpaper Polishfleece Polish for acrylic glass Fiber optical contact for glass fiber on request Page ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ ,

25 Aluminium Frame ODU-MAC-S Aluminum Frame Standard version Pin Ø Ø 5 Ø Ø Ø,1 Ø Ø 1,5 Ø 1,0 Ø 0,76 L *) 8 L1 6 L *) = First-Make Ground Pin 1 max L *) L1 Frame for Sockets, without Guide Pins Socket Contact Ø Ø 76 Ø 1,0 Ø 1,5 Ø Ø,1 Ø Ø Ø 5 Frame for Pin Contacts, with Guide Pins End Piece Left Center Piece with Locking Module (On Request) End Piece Right End Piece Left Center Piece with Locking Module (On Request) End Piece Right 7 7 Ø, Ø 8,5 5,5 8,5 z 15 l L 5,5 8,5 z 15 l L s for Frame Parts Please assemble the part numbers as follows: X Guide Pins (only for selfcentering) Ø,,5 Centering Socket axial free space: 0, radial free space: 0,6 (parts are delivered loose) x = Number of Modules Maß l = x y + z (l max. = 15,5 mm for 60 Units) y = Width of Modules; Maß L = l + 0 z = Center Module = 1.7 mm (.500") (optional) Order Example: Frame with guide pins with l = 17.1 mm has 50 units at.5 mm each. ( X = Length of guide pins) ; X = ; X = 1, ; X = 10 with labeling ; X = 1 locking spindle Frame without guide pins with l = 17,1 mm has 50 units at.5 mm each ( with labeling) Individual frame parts are available on request. ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ , Page 5

26 Aluminum Frame Alignment Requirements between Surface B and Surface S for Standard version The values are for connectors in mated condition and are determined by the float in the guide bushings. B ODU-MAC Socket Part (Fixed) Mounted on surface B without float. Guide Pin for S into B S Guide Bushing: Axial Float: 0, mm Radial Float: 0,6 mm Pins only for self-guiding of ODU-MAC ODU-MAC Pin Part (Plug) mounted with Guide Bushing (floating) onto surface S Page 6 ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ ,

27 Aluminum Frame ODU-MAC-L Aluminum Frame Special Design with longer guide pins and -bushes for higher mating cycles and bigger radial offset. Panel Cut-Out 6 (Number of Units at,5 +) +0, -0 max. R Mounting area + 1 M Guide Plane Steel Socket Contact Plane A B C D E F G H I K 0 8 For example see page 58 Axial tolerances 0. mm, Radial tolerances ± 1. mm Application Example L+ 6 Pin Frame (Plug) Frame for Sockets (Receptacle) XX XX Keying Positions possible - please request Additional Ordering Information Dim. L = Numbers of units x.5. XX = Denotes number of units ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ , Page 7

28 Aluminum Frame ODU-MAC-M Frame for Pins (Plug) for reduced layout Ø, ,1 L L + 1 Pin Frame (Plug) XX Dim. L = Number of units x.5, XX = Denotes number of units Additional Ordering Information ODU-MAC-M Frame for Sockets (Receptacle) for reduced layout 7 Ø, 10 L L + 1 Frame for Sockets (Receptacle) XX Dim. L = Number of units x.5 mm XX = Denotes number of units Additional Ordering Information Page 8 ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ ,

29 DIN Frame ODU-MAC Frame for Housing without grounding termination 10 7,5 7 Version 1: 7,5 10 M C B A Version : Version 1: Sockets (Receptacle) in Panel-Mounted or Box-Mounted Base Pins (Plug) in Cable Hood Size Socket Frame for Panel or Box Mounted Base Pin Frame for Cable Hood max. Units á,5 mm ODU-MAC Dim. A Dim. B Dim. C Assembly tool for frame P/N: Version : Sockets (Plug) in Cable Hood Pins (Receptacle) in Panel-Mounted or Box-Mounted Base Size Socket Frame for Cable Hood Pin Frame for Panel or Box Mounted Base max. Units á,5 mm ODU-MAC Dim. A Dim. B Dim. C Assembly tool for frame P/N: Housings see on page 1-5 ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ , Page 9

30 DIN Frame ODU-MAC Frame for Housing with grounding termination 10 7,5 7 M Version 1: C B A Version : 7,5 10 Version 1: Sockets (Receptacle) in Panel-Mounted or Box-Mounted Base Pins (Plug) in Cable Hood Size Socket Frame for Panel or Box Mounted Base Pin Frame for Cable Hood max. Units á,5 mm ODU-MAC Dim. A Dim. B Dim. C ,5 0, Assembly tool for frame P/N: Version : Sockets (Plug) in Cable Hood Pins (Receptacle) in Panel-Mounted or Box-Mounted Base Size 0 Socket Frame for Cable Hood Pin Frame for Panel or Box Mounted Base max. Units á,5 mm ODU-MAC Dim. A Dim. B Dim. C Assembly tool for frame P/N: Housings see on page 1-5 Page 0 ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ ,

31 R R DIN Housing ODU-MAC DIN Housing Panel-Mounted Base including lever locking (with and without cover) lever locking 5 8,5 (B) D +1 0 C B A R Mounting area () Panel Cut-Out M 7 Ø, Size Panel-Mounted Base Panel-Mounted Base with cover Dim. A Dim. B Dim. C Dim. D ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ , Page 1

32 C C R R R R DIN Housing ODU-MAC DIN Housing Cable Hood - with straight exit or right angled exit for lever locking Right angled exit Pg B A Sraight exit Pg 7 M Size Cable Hood Right angled exit Cable Hood Straight exit Dim. A Dim. B Dim. C Exit PG 16 PG 16 PG 1 PG 9 PG 9 PG 9 Page ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ ,

33 R R R DIN Housing ODU-MAC DIN Housing Box-Mounted Base including lever-locking (with and without cover) lever locking High Type C B A Ø 5,5 G D M G D 7 E F Low Type Size 1 Box-Mounted Base Box-Mounted Base with Cover Dim. A Dim. B Dim. C Dim. D Dim. E Dim. F Dim. G 5 Exit PG 16 PG 16 PG 9 PG 1 ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ , Page

34 R R R DIN Housing ODU-MAC DIN Housing for Spindle Locking Panel-Cut-out B A +1 R mounting area Size Dim. A Dim. B R A A R Cable Hood Cable Hood R B R Panel-Mounted Base B Box-Mounted Base D D C C Ø,5 Ø,5 Size Cable Hood Panel-Mounted Base Dim. A Dim. B Dim. C Dim. D Exit PG 1 PG 9 PG 9 PG 9 Size Cable Hood Box-Mounted Base Dim. A Dim. B Dim. C Dim. D Exit PG 1 PG 9 PG 9 PG 9 Page ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ ,

35 DIN-Housing ODU-MAC Spindle Locking System, Version 1 For Sockets (Receptacle) in Panel- or Box-Mounted Base and Pins (Plug) in Cable Hood. Center Module Locking Spindle Space requirement: 5 units (5 x,5 mm) ODU-MAC Spindle Locking System, Version For Sockets (Plug) in Cable Hood and Pins (Receptacle) in Panel- or Box-Mounted Base. Center Module Locking Spindle Version 1 Version Size Locking Spindle in Cable Hood Center Module for Panel or Box Mounted Base Size Locking Spindle in Cable Hood Center Module for Panel or Box Mounted Base ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ , Page 5

36 Crimp Tools Crimp Instructions 8 crimp tool 8 crimp tool 8 crimp tool Termination cross section AWG mm Contact Ø strip-off length Gauge Ø Contact Holder Identification groove Gauge Ø Contact Holder Identification groove Position no. Contact Holder >0.65 <0.70 >0.65 <0.70 /8 0.08/ >0.65 < >0.65 < >0.90 <0.95 >0.90 < / 0.8/ >1.1 <1.15 >1.1 < >1.0 < >1.0 < >1.0 <1.5 >1.0 < >1.60 <1.65 >1.60 < Page 6 ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ ,

37 Crimp Tools 8 crimp tool 6 crimp tool 6 crimp tool Position no. Crimp dies Contact Holder Termination cross section AWG mm Contact Ø /8 0.08/ / 0.8/ ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ , Page 7

38 Crimp Tools Crimp Tools and Contact Preparation Crimping creates an easy, reliable, corrosion-free, and long-term connection between conductor and contact. It requires little skill and can be performed by non-experts. Crimping causes cold-flow of the conductor and contact material creating a gas-tight connection between contact and conductor. A stiffening of the conductor at the connection, as it is possible with soldering, can not occur. Crimping can be performed on very small or very large conductor cross sections. For smaller cross sections ( mm ) an industry-standard 8-point crimp tool is used. Larger cross sections require a hexagonal crimp press. For very large cross section the crimp procedure has to be done in several steps to assure good cold-flow of the conductor material and to avoid a brittle connection. 8-Crimp Tool. Adjustable for cross section from mm (AWG8 - AWG0) Table for adjustment and Contact holder = positioner - see page 6/7 Order Number: Crimp Tool. Adjustable for cross section from mm (AWG - AWG1) Table for adjustment and Contact holder = positioner - see page 6/7 Order Number: Crimp Instruction (for above tools) Correct crimp position will be attained by use of different Positioner. By rotating the selector knob to selected number you will get the correct crimp connection. The crimp tool has an internal ratchet which opens only after completing the crimp process. Page 8 ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ ,

39 Crimp Tools 8-Crimp Tool. Adjustable for cross section from mm (AWG8 - AWG1) Gauge on request. Table for adjustment and Contact holder = positioner - see page 6/7 The crimp tool has an internal ratchet which opens only after completing the crimp process. Order Number: Crimp Tool with pneumatic activation. Adjustable for cross section from mm (AWG8 - AWG1) Gauge on request. Table for adjustment and Contact holder = positioner - see page 6/7 Order Number: Crimp Instruction (for above tools) How to set the crimp tool according to the cable cross-section 1. Close crimp tool completely and keep it closed.. Adjust the tool so that the smaller gauge-pin just fits through the hole but not so the bigger one. In order to achieve that you have to adjust the tool with the adjustment bolt. After the tool is set properly you have to secure it with the fastening screw in order to avoid a misadjustment by accident.. Check the proper setting after a while by use of both gauge-pins. ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ , Page 9

40 Crimp Tools Hexagonal Crimp Tool for AWG 1, mm cross sections, with locking system (ratchet). For cross section AWG1: Order Number For cross section,0-6,0 mm : Order Number Hydraulic Crimp Tool for cross sections 10 mm to with safety valve for automatic release when correct pressure is reached. Order Number - Crimp tool: Crimp die: Crimp Instruction (for above tools) How to set the crimp tool according to the cable cross-section 1. Before use insert the proper crimp jaws open the retainer claws by pressing the locking belt.. Now put the crimp jaws on the fixing pins, close the retainer claws and lock them.. Build up the hydraulic pressure by pumping the grip until you hear a click.. The crimp process is finished now and you can open the tool with the set-back trigger and the crimp part will be released. Page 0 ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ ,

41 Crimp-Tools Hexagonal Crimp Tool for coax contacts, with locking system (ratchet). Order Number: ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ , Page 1

42 Technical Information Crimp Termination According to DIN IEC 5 Pull-out forces diagram of a crimp termination according to the wire cross-section (Extract of DIN 5 part ) Wire Cross-section in mm Example: For a.5 mm wire a minimum pull-out force of appr. 0 N is required Page ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ ,

43 Technical Information Application of VDE for the determination of clearance and creepage distances The following factors must be determined for clearance and creepage distance dimensioning: Value of the nominal line voltage ( generally 0 / 00 V see Table 1) Overvoltage Category ( generally Category ) Contamination Level ( generally Level - see Table ) Insulation Class ( at ODU, Class IIIa or IIIb - see Table ) Type of field to which the operating materials are subject ( most disadvantageous: inhomogeneous field ) The following text and tables are excerpts from DIN VDE from April 1997 * Overvoltage categories The fixing of a particular overvoltage category must take place on the basis of the following general description: Overvoltage Category I applies to such devices as are intended for connection to the permanent electric installation of a building. Exterior to the device, either in the permanent installation or between the permanent installation and the device, measures are taken for limiting the transient overvoltages to the value in question. Overvoltage Category II applies to such devices as are intended for connection to the permanent electric installation of a building. Examples: household appliances, portable tools and similar consumers. Overvoltage Category III applies to such devices as are a component of the permanent installation and other devi ces for which a higher degree of availability is expected. Examples: distribution panels, power switches, distributors in the permanent installation and devices for industrial use. Overvoltage Category IV applies to such devices as are intended for the use on or in the vicinity of the feeder in the electric installation of buildings, namely as seen from the main distributor outwards in the direction of the power system. Examples: Electric meters, overvoltage protection switches and ripple control devices. Table 1 Nominal voltage of the electric power supply system according to IEC 8, in V Assessment surge voltage, in V Three-phase systems 0 /00 77 /80 00 /690 Single-phase systems with midpoint 10 to 0 Specially protected operating material Category I Operating material for connection to the permanent installation Category II Operating material as part of the permanent installation Category III Operating material at the installation feeder Category IV * Original DIN VDE of April 1997 remains relevant for all omentioned technical information ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ , Page

44 Technical Information Contamination The micro-environment determines the influence of the contamination on the insulation. However, the macro-environment must be taken into account when examining the micro-environment. Means for reducing the contamination on the insulation being considered can be provided by cladding, encapsulation or hermetic seals. Such means for the reduction of the contamination can be ineffective if the operating material is exposed to dewfall or if it produces the contamination itself under normal operating conditions. Small clearances can be completely bridged by solid pieces, dust or water. Minimum clearance distances are prescribed by the amount of contamination that can be present in the micro-environment. Table Contamination Level Contamination Level Only non-conductive contamination appears. However, occasionally temporary conductivity due to dewfall must be reckoned with. Conductive contamination or dry non-conductive contamination, which becomes conductive because dewfall is to be expected, appears. Insulation The behavior of insulations under different contaminations and voltages is extremely complicated. Experience and tests have shown, however, that insulations with a higher relative quality also have roughly the same ranking according to their tracking reference number (CTI Comparative Tracking Index). The following declared CTI values, applied to the insulation we use, refer to the values according to IEC 11. Table Insulation Class IIIa 175 CTI < 00 Insulation Class IIIb 100 CTI < 175 Page ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ ,

45 Technical Information Clearance Distance Dimensioning As laid down in Table, clearance distances for base and additional insulation must always be calculated according to the assessment surge voltage impulse withstand voltage The clearance distances of the reinforced insulation must be selected from Table corresponding to the assessment surge voltage, however by one level higher in the row of preferred values as compared to the values determined for base insulation. If the impulse withstand voltage required for base insulation doesn t have a value in the row of the preferred values, the reinforced insulation must be dimensioned so that it withstands 160 % of the impulse withstand voltage for base insulation. Table Required impulse withstand voltage 1) KV 0. ) ) ) ).0.5 ).0.0 ) 5.0 Minimum clearance distances in air for installation altitudes up to 000 m above sea level mm 0. ) Condition A (inhomogeneous Field) Contamination Level mm 0.8 ) 1) This voltage is for function insulation: the highest surge voltage to be expected at the clearance; for base insulation, if directly or substantially influenced by transient overvoltage from the low voltage power system: the assessment surge voltage of the operating materials; for other base insulation: the highest surge voltage that can occur in the circuit; for reinforced insulation. ) Preferred values ) The minimum clearance distances are based more on experience than on basic knowledge. ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ , Page 5

46 Technical Information Dimensioning of the creepage distances A creepage distance can not be smaller than the corresponding clearance distance, so that the smallest possible creepage distance is the same as the clearance distance that is called for. The minimum creepage distance is determined with the help of the voltage value, the contamination level and the insulation material class (Table 6). Table 5a Nominal voltage of the power supply system (power system) V 1.5 /5 0 /8 / / Voltages for Table 6 Voltages for Table 6 For conductorground insulations Nominal voltage of the power supply system For conductorconductor insulations -conductor (power system) Three-phase -conductor systems midpoint grounded V All systems systems with For conductorconductor insulations All systems V Table 5b V /10 / ) 08 0 /0 /0 00 ) 80 /00 / / ) 660 / / ) V For conductor-ground insulations grounded neutral ) V Three-phase -conductor systems not grounded 1) or conductor grounded V ) Conductor-ground insulation levels for ungrounded or impedance-grounded systems are the same as those for conductor-conductor since the operating voltage of every conductor to ground can reach the conductor-conductor voltage in practice. This is because the actual voltage compared to ground is determined by the insulation resistance and by the capacitive reactance of every conductor to ground; so one conductor s low (but permissible) insulation resistance can practically ground it and raise the two others to conductor-conductor voltage compared to ground. ) The values for -conductors systems are to be used exclusively for operating material that is intended for use both in three-phase -conductor and in three-phase -conductor systems, grounded and also ungrounded. ) These values correspond to the values in Table 1 Page 6 ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ ,

47 Technical Information Table 6 Voltage effective value 1) V Insulation Class IIIa and IIIb mm Creepage distances Contamination Level Insulation Class III ) mm Insulation Class III ) mm ) This voltage is for function insulation: the working voltage for base and additional insulation, a circuit driven directly from the low voltage power system: the voltage selected from Table 5a or 5b on the basis of the assessment voltage of the operating material or the assessment insulation voltage; for base and additional insulation of systems, operating materials and internal circuits, which are not driven directly from the low voltage power system: the highest effective value of the voltage that can occur in the system, operating material or internal circuit when supplied with assessment voltage and with the unfavorable combination of the operating conditions within the framework of the assessment data. ) Insulation Class IIIb is not recommended for use at Contamination Level at voltages of more than 60 V and at Con tamination Level. ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ , Page 7

48 R R ODU-MAC Application Example ODU-MAC in DIN Housing (Size II), max.160 contacts Available with one piece molding (1) Panel-Mounted Base Housing () Frame for Sockets (With cable shield connections) () 16 Modules, 10 Positions ea. () Springtac Sockets, AWG with AWG 8 Crimp Termination Plug consists of: (1) Plug Housing (Cable Hood) () Cable Strain Relief Pg 1 () Frame for Pins (With cable shield connections) () Module, 10 Positions ea. (5) Pin Contact, AWG with AWG 8 Crimp (6) Pin Contact with Crimp for Conductor Strain Relief Page 8 ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ ,

49 ODU-MAC Application Example ODU-MAC in DIN Housing With locking lever for simple, one-handed operations. Accepts maximum 680 contacts. ca A B C D E F G H J K A B C D E F G H J K Shown is Plug (Example) ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ , Page 9

50 ODU-MAC Application Example ODU-MAC in Aluminium Frame, mixed contact configuration, in Quick-Change-Head Technology for extremely high mating cycles - mating part exchangeable remain connected to wire Changed by plugging remain connected to wire Page 50 ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ ,

51 Technical Article Connection during the testing of mass-produced electronic articles Car radios, video recorders, mobile telephones, fuel injection pumps, motor controllers, printers, printed circuit boards, video screens, frequency converters, microwave ovens, ABS systems, automobile motors, electric scales: all of these products are produced in large-scale manufacturing and must be tested. This requires that the products (test pieces) be connected and attached to a test computer. The test requires: 1. connection to the product and,. in most cases, an interface (a connector) between the test piece and the computer. ODU has developed special products that are being used worldwide for both tasks. 1. Connection to the product Let s take as an example a through-hole plated printed circuit board: it has a huge number of soldering points, i.e., contact points. It can be effectively connected using spring-loaded pins (pogo pins). The pins are usually attached to so-called needle beds, which naturally appear different for different printed circuit board geometries (layouts). Connection of printed circuit boards with spring-loaded pins (pogo-pins) on needle bed. Figure 1 Let s take as an additional example a product from the automobile electronics field, for example, a motor controller. These products usually have flat pins as contacts (for example, 0.8 x.8 mm). The connection could be done using appropriate mating connectors (sockets), as used in series production. But the problem here is that the socket contacts of the mating connectors for the series usually have only a very limited lifetime. ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ , Page 51

52 Technical Article After 500 or at most 1000 insertion/withdrawal cycles, the failure probability rises sharply. A remedy for this is to use special test adaptors with special springwire flat contacts, such as ODU has developed. These contacts tolerate several hundred thousand insertion/withdrawal cycles with a very high degree of reliability. ODU springwire socket for the connection of flat contacts (for example, 0.8 x.8 mm). The socket permit many hundred thousand insertion /withdrawal cycles. Figure Likewise, ODU has developed special springwire contacts for very high insertion / withdrawal cycles for square pins (for example, 0.6 x 0.6) and for round pins (for Ø from 0.7 to over 10 mm). ODU springwire sockets for the connection of round contacts (from Ø= 0.7 to over 10 mm) and square contacts (for example, 0.6 x 0.6). Under ideal conditions, over 1 million insertion/ withdrawal cycles are possible. Figure. The interface Basically, it is possible to connect the product and insert the values directly into the test computer. However it can very quickly be seen that it s expedient to provide an interface (a connector) between the test piece and the computer. This can be explained by an example. Example: Testing car radios an absolutely typical case! Carrier rack for test line with test piece (car radio) and ODU-MAC (socket part) Figure Page 5 ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ ,

53 Technical Article In Figure one sees a carrier rack with an interface connector (ODU-MAC) permanently mounted on it, a car radio and adaptor cables, which produce the connection from the car radio to the ODU-MAC. The adaptor cables are permanently connected to the ODU-MAC while on the side of the car radio they are freshly inserted for every test piece. The interface connector (ODU-MAC) is then docked within the framework of the test step in the test line so that the signals can be transmitted over the mating connector to the computer side and can then be processed in the computer. Total Guiding ODU-MAC Pin Part Socket Part Test line with racks for multiple testing. Docking system with total guiding and ODU-MAC with guiding for the connector. Figure 5 In this case the adapter connenctors are worked with every tested radio. Especially high demands are placed on the ODU-MAC: the connector on the computer side is worked at least 10,000 times for 10,000 radios per day, and proportionately more in the case of multiple tests. This means at least approximately million insertion/withdrawal cycles a year! In addition, in this case the ODU-MAC must be equipped with power contacts, signal contacts and high frequency (HF) contacts with 75 Ω characteristic impedance. Here one can rightfully ask the question: why provide an expensive interface connector when the adaptor cable connector still has to be plugged in usually manually anyway? There are different, mutually independent reasons for this: - Program change Multiple test on the same test piece (Figure 5) Without interface connectors, the adaptor cables would have to be repeatedly plugged by hand, which would mean multiple time required and also that the adaptor connector would wear out earlier. The high number of insertion/withdrawal cycles is shifted to the ODU-MAC, which is suitable for this. - Better utilization of the expensive test computers The attachment of the adaptor cable is often truly time-consuming since several different connectors must be multiply plugged mostly by hand. So it is expedient to plug the adaptor cable to the racks in a decentralized manner at a great distance from the test computer and then to run the racks quickly through the test line. ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ , Page 5

54 Technical Article - Buffer stock This reason is closely related to the one above. With decentralized preperation, the adaptor cables can be plugged in the nd and rd shift, for example, while the test line and test computer run only during the main shift under the presence of the permanent staff. In the following, the use of interface connectors in the case of program changes and for additional examples is explained. Program change Example: Testing printed circuit boards Let s assume that a factory produces the different printed circuit boards Nr. 1, and. Then it needs the needle beds Nr. 1, and as adapters for the connecting the printed cicuit boards. In order to connect needle bed Nr. 1 with the test computer, the interface Nr. 1 is provided, for needle bed Nr. the interface Nr., etc. It s expedient to execute the mating connector on the computer side in such a way that it covers interfaces 1, and. Connection of different printed circuit boards with different needle beds and uniform interface on test computer for program change. Figure 6 Page 5 ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ ,

55 Technical Article In practice, it happens that a special test machine is used, for example, through which the printed circuit boards run on a conveyor. Figure 7 Testing of printed cicuit boards for ICCT and function test The printed circuit boards are thereby pressed against the needle bed from above during a short conveyor stop and the signals run over the interface connector to the computer. If the production program is changed every week, for example, then the interface connector is worked at least once every week. The demands on the ODU-MAC s insertion/withdrawal cycles are not very great here, because the insertion/withdrawal cycles accumulate on the spring-loaded pins on the needle bed. On the other hand, the ODU-MAC, under certain circumstances, must have a very high number of poles (certainly several hundred). As the interface connector for such applications, the ODU-MAC, developed by ODU, has gained acceptance all around the world. ODU-MAC the modularly attachable connector system which can be strung together. Figure 8 Example: Testing mobile telephones In principle, everything is the same as for the testing of auto radios, which was outlined above. The differences are: the connection of the mobile telephones doesn t take place over adaptor cables but instead over their outer connectors in connection beds and telephones are always tested simultaneously. Docking station for testing mobile telephones (demo model). The coaxial contacts for 50 Ω ( GHz), the x 10 signal contacts and the x power contacts can be seen. Figure 9 ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ , Page 55

56 Technical Article Example: Testing electric motors in a testing stand Here the racks don t run along a conveyor, but instead are mounted in a test stand and are pushed back and forth in the test stand. As is the case for the mobile telephones, the adaptor cables are replaced by direct connection on the rack. High voltage testing ( kv) of electric motors. The adapter cable is replaced by direct connection to the rack. Figure 10 Example: Climate and temperature test Figure 11 shows transport wagon with x 9 frames for the seating of 18 racks, each with a test piece. Each rack has an ODU-MAC; the 18 ODU-MAC mating connectors can be seen in the transport wagon. The 18 racks with the test pieces are plugged in the wagon by hand and the wagon is driven in to the climatic chamber. The signal and power contacts are joined together and guided out of the climatic chamber. They are joined together in one ODU-MAC connector in double DIN housing. Climatic test of frequency converters. Figure 11 Page 56 ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ ,

57 Technical Article Example: Testing injection vents The opening and closing of injection vents is today increasingly controlled electrically using magnetic vents. These magnetic vents have flat contacts. Here the ODU springwire flat socket has proven itself for the adapting, and the ODU-MAC has also proven itself as an interface connector. Otherwise the conditions are as described above for the car radio. Testing injection vents for diesel motors. Figure 1 Remarks about the interface connector ODU-MAC In Figure 8, the modularly-built connector ODU-MAC can be recognized: a pin part and a socket part, each made up of an aluminium frame and the module, i.e., the insulating body with the contacts. The aluminium frame is made of an end piece, rails and an end piece. The total length of the assembly can be freely selected up to approximately 5 cm: power contacts, signal contacts, HF contacts up to GHz, fiber optic contacts, pneumatic elements. All together, over 50 different modules are available. The contacts are supplied for crimp, solder and print connection. All contacts are assembled according to the ODU springwire principle and allow many hundred thousand or even a million insertion/withdrawal cycles. In addition, they offer constant contact resistance which is very important in test situations and an extremely high degree of contact reliability. For docking tasks, ODU-MAC is set into aluminium frames as described above. In addition, ODU-MAC is offered in DIN housing for manual connection with locking system. ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ , Page 57

58 Technical Article Remarks about the installation of interface connectors and docking systems Special attention should be given to the guiding system. The guide pins and sockets of the ODU-MAC serve exlusively to guide the connector! The guiding system when docking (between the docking system and the rack) must take place separately! The standard version of the ODU-MAC is intended for a floating mounting of +/- 0.6 mm. This means that the docking system guide must be selected so that the tolerance lies under +/- 0.6 mm. One possible solution for a docking system with a built-in ODU-MAC can be seen in Figure 1. Docking system with total guiding and ODU-MAC. Figure 1 Under some circumstance, several hundred racks are in circulation in test lines. These are usually docked to only a few docking stations in order to produce the connection to the test computer. If 100 racks are in circulation and if every rack is docked to test stations, the result is that the ODU-MAC on the computer side carries out 50 times as many insertion /withdrawal cycles as the ODU-MAC on the racks. It is recommended to provide the pin parts on the racks and the socket parts on the docking station, because the socket parts permit approximately 10 times as many insertion/ withdrawal cycles as the pin parts. Additionally, they are more expensive. As a rule, the working of docking systems in test lines is done using pneumatic cylinders. Although the ODU springwire contacts have low insertion and withdrawal forces, large forces can still result in the case of connectors with a large number of poles; under certain circumstances the forces are greater than 100 N. The theoretically required insertion force according to the catalogue should be raised by a safety factor of three for the layout of the device doing the working. Page 58 ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ ,

59 Technical Article Some remarks about the profitability. References. Test equipment is expensive. The costs must be seen in connection with the use. In no case should costs be saved on the connection! In addition to the costs for the test computers, the test equipment /line and the docking system must be taken into consideration. In addition to the costs for the adaptation, costs for the interface connector ODU-MAC arise as well as, under some circumstances, considerable costs for their mass production. On the other hand it needs to be taken into consideration that not only insufficiently tested products can lead to failure and dissatisfaction. In addition, bad test equipment leads time and time again to error messages, especially due to bad connection. Under some circumstances, flawless products are rejected. This can lead to entire factories being brought to a standstill. Some of the customers who have chosen the adaptor contact from ODU and the ODU-MAC are: Alcatel, Bosch, Daimler-Chrysler, Ericsson, Matsushita, Mitsubishi, Nokia, Oki, Philips, Samsung, Siemens, Sony, Wabco. Approximately 100 million mobile telephones alone are currently being tested with ODU-MAC every year! In addition to testing situations, ODU-MAC is being used in machine construction (pick and place machines, automatic assembly machines) and in medical technology, among other applications. Documentation is available in German, English, French, Japanese and Korean. ODU -Steckverbindungssysteme GmbH & Co. KG, Pregelstr. 11, D-85 Mühldorf/Inn, Tel. +9/86 1/ , Fax +9/86 1/ , Page 59

60 ODU s headquarters and factory are located in Mühldorf, at the river Inn, approximately 50 miles east of Munich, at the foothills of the Bavarian Alps. Photo of City Mühldorf / Inn Mühldorf, an idyllic small town with its typical Inn-Salzach architecture. Steckverbindungssysteme ODU-Steckverbindungssysteme GmbH & Co. KG Otto Dunkel GmbH Werr. 09/01 Pregelstraße 11 D-85 Mühldorf/Inn Telefon +9/86 1/ Fax +9/86 1/ Internet: zentral@odu.de ODU France Téléphone: Télécopie: odu.france@wanadoo.fr ODU-UK Ltd. Tel Fax oduuk@globalnet.co.uk ODU Scandinavia AB Tel. +6/ Fax +6/ peter.biloch@odu.se ODU USA Inc. ODU-Shanghai Tel Tel /16/ 9 86 Fax Fax 00 86/16/ ralfeb@odu-usa.com odujin@sh16.net