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©2013 Tyco Electronics Corporation, a TE Connectivity Ltd. company All Rights Reserved *Trademark TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or company names may be trademarks of their respective owners. 1 of 17TOOLING ASSISTANCE CENTER 1-800-722-1111 PRODUCT INFORMATION 1-800-522-6752 This controlled document is subject to change. For latest revision and Regional Customer Service, visit our website at www.te.com 114-13206 ELCON* Drawer Series Connectors 19 JUL 13 Rev E NOTE All numerical values are in metric units [with U.S. customary units in brackets]. Dimensions are in millimeters [and inches]. Unless otherwise specified, dimensions have a tolerance of ±0.13 [±.005] and angles have a tolerance of ±2°. Figures and illustrations are for identification only and are not drawn to scale. 1. INTRODUCTION This specification covers the requirements for application of ELCON Drawer Series Connectors: True Hot Plug, Blind Mating Mixed Signal and Power Connectors. These connectors are designed for use in pluggable wire-to- board applications of power supplies. The connectors are available in a variety of custom configurations. The pin side connector accepts pin contacts, and the socket side connector accepts socket contacts. The contact cavities on both sides of the connector are marked for circuit identification. The high power connectors are available with or without pre-installed guide pins; mid and low power connectors are designed with molded-in guide posts to ensure positive mating of connectors. The molded-in pin protectors prevent damage to the contacts. These features (including the guide pin holes and guide post cavities) have chamfered edges for ease of mating. The connectors are designed for float-mount and fixed-mount applications to allow blind mating with misalignment. All connectors are also designed with standoffs to allow easy printed circuit (pc) board cleaning after soldering. The contacts accept wire sizes 24 through 1/0 AWG. Contact sizes 20, 16, and 12 are available in crimp type, and solder type terminations. In addition, contact size 12 is available in hot plug, specifically designed for current interruption capability. Contact size 0 and 4 is available in crimp type termination, internal thread and external thread for ring lug mounting and bus bar mounting. Pin contacts (except size 0 and 4) are available in three lengths: standard, pre mate, and post mate for flexibility in contact sequencing. The contacts contain an active element, or crown band, which ensures maximum surface contact area, allows even insertion and withdrawal forces, and provides shock and vibration resistance. The contacts are available in loose piece only. Only crimp type and threaded contacts are removable. When corresponding with TE Connectivity Personnel, use the terminology provided in this specification to facilitate your inquiries for information. Basic terms and features of this product are provided in Figure 1. Figure 1 (Cont’d) NOTE i Top Drawer Guide PostGuide Pin Guide Pin Hole Guide Post Cavity

75 Amp Middle Drawer

Pin Side Socket Side Pin Side Socket SideChamfered Edge Chamfered Edge Mounting Flange Contact Cavities Pin Protector Standoffs

Figure 1 (End) 2. REFERENCE MATERIAL 2.1. Revision Summary

  • Updated document to corporate requirements and added new logo Lower Drawer Mini Drawer Dual Power Quad Power Double Drawer 125 Amp Middle Drawer Pin Side Socket Side Pin Side Socket Side Pin Side Socket Side Chamfered Edge Chamfered Edge Mounting Flange Pin Side Socket Side Contact Cavities Mounting Flange Contact Cavities Pin Protector Standoffs Pin Side Socket Side Pin Protector Guide PostGuide Post Cavity Pin Side Socket Side Mounting Flange Contact Cavities Pin Protector Crimp Type Contact Solder Type Contact Contact Size 0 Crimp Type Internal Thread External Thread

2.2. Customer Assistance Reference Product Base Part Number 1648578 and Product Code D033 are representative of the ELCON Drawer Series Connectors. Use of these numbers will identify the product line and help you to obtain product and tooling information. Such information can be obtained through a local TE Representative, by visiting our website at www.te.com, or by calling PRODUCT INFORMATION or the TOOLING ASSISTANCE CENTER at the numbers at the bottom of page 1. 2.3. Drawings Customer Drawings for product part numbers are available from the service network. If there is a conflict between the information contained in the Customer Drawings and this specification or with any other technical documentation supplied by TE, call Product Information at the number at the bottom of page 1. 2.4. Specifications Product Specification 108-2285 provides product performance and test information. Workmanship Specification 101-654 is a guide for evaluating installed connectors for conditions which effect the cosmetics and/or function of the connector. 2.5. Manuals Manual 402-40 is available upon request and can be used as a guide in soldering. This manual provides information on various flux types and characteristics along with commercial designations and flux removal procedures. A checklist is included in the manual as a guide for information on soldering problems. 2.6. Instructional Material Instruction sheets (408-series) contain detailed assembly instructions and repair procedures for product and tooling. Documents available which pertain to this product are: Document Number Document Title 408-7526 Screw Machine Contacts and Application Tooling 408-10159 Insertion/Extraction Tools for ELCON Circular Contacts 3. REQUIREMENTS 3.1. Material Crimp type contacts are made of copper alloy plated with silver or gold. Solder type contacts are made of brass or copper alloy plated with silver or gold. The crown band is made of copper alloy plated with gold over nickel. Hot plug contacts are made of copper alloy plated with gold. Connector housings are made of polyester, 30% glass filled, UL94-V0. 3.2. Storage A. Ultraviolet Light Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the connector material. B. Shelf Life The connectors should remain in the shipping containers until ready for use to prevent deformation to the contacts. The connectors should be used on a first in, first out basis to avoid storage contamination that could adversely affect signal transmissions. The shelf life is six months from date of shipment. NOTE Silver-plated contacts are shipped in silver-saver packaging to prevent tarnishing until opened. 3.3. Chemical Exposure Do not store connectors near any chemical listed below as they may cause stress corrosion cracking in the contacts. Alkalies Ammonia Citrates Phosphates Citrates Sulfur Compounds Amines Carbonates Nitrites Sulfur Nitrites Tartrates NOTE i

Each crimp dimension represents the functional range of wire and contact combination. The developed crimp configuration is unique for each tool design and is acceptable provided the crimp height is within the functional range. For crimp dimensions relating to a specific tool, refer to the instruction sheet packaged with manual tools and the applicator log packaged with power tools. C. Conductor Location After crimping, the conductor ends must be flush to the end of the wire barrel. In contacts having a sight hole, this can be verified by checking that the conductor ends are visible in the sight hole. See Figure 5. D. Effective Crimp Length The effective crimp length is the area where the crimp pressure is applied over the length of the wire barrel. E. Straightness After crimping the wire to the contact, the contact must be chucked, and rotated a minimum of 360°. The point of TIR (total indicator reading) measurement must not exceed the dimensions shown in Figure 6. Figure 6 3.7. Threaded Contacts and Guide Posts and Threaded Contacts

  • Threaded guide posts should not exceed a torque limit of 1.7 Nm [15 in.-lb]
  • Threaded contacts with M6 threading should not exceed a torque limit of 4.5 Nm [40 in.-lb]
  • Threaded contacts with 1/4-20 threading should not exceed a torque limit of 6.8 Nm [60 in.-lb]
  • Threaded contacts with M5 threading should not exceed a torque limit of 2.9 Nm [26 in-lb] 3.8. Connector Spacing Care must be taken to avoid interference between adjacent connectors and/or other components. There is no required spacing between connectors, however spacing may be dependent on variable hardware used and the clearance required for mating connectors. 3.9. Panel Cutout The pin side connector and socket side connector can be installed or removed from either the back or the front of the panel (front of the panel is recommended). Usually, the socket side connector is mounted in the cabinet (energized) panel, while the pin side connector is mounted in the drawer (passive) panel. Dimensions for mounting holes, guide pins (if applicable), and panel cutouts, and maximum panel thickness for rear mounting are shown in Figure 7. 3.10. Contact Insertion and Extraction Normally an insertion tool is not required to insert contacts into connectors, but if the wire bundle is large or individual wires are fragile, using an insertion tool is recommended. Push contact straight into the contact cavity until it bottoms (an audible click). After inserting contact into connector, pull back lightly on the wire to ensure contact is fully seated. The contacts are rear-insertable and rear-releasable; an extraction tool is needed to disengage the connector retention clips and remove the contact from the back of the connector. Only crimp type and threaded contacts are removable. Refer to Section 5 for tooling information. 3.11. PC Board Connectors A. PC Board Material and Thickness The pc board material shall be glass epoxy (FR-4 or G-10). The pc board thickness range shall be 1.38 NOTE i WIRE SIZE RANGE (AWG) TIR MEASUREMENT (Max) 20 0.279 [.011] 28-12 0.305 [.012] Chucking Area Dial Indicator Probe Placed Here for Measurement of TIR Wire

Contact the Product Information Center at the number listed at the bottom of page 1 for suitability of other board materials and thicknesses. B. PC Board Tolerance Maximum allowable bow of the pc board shall be 0.03 mm [.001 in.] over the length of the connector. C. Connector Placement The connector number one position must be aligned with the number one position board hole. When placing connectors on the pc board, make sure that the contact solder tails are aligned and started into the matching holes before seating the connector onto the pc board. CAUTION Connectors should be handled only by the housing to avoid deformation, contamination, or damage to the contact solder tails. Figure 7 CAUTION For applications using panel mounted threaded fasteners, care must be taken that the threaded hole does not compromise the shoulder area of the shoulder screw used to fasten the float mount connector. C O N N E C T O R ABCDE NOTE i A B C D E Recommended Panel Cutout 6.35 mm [.250 in.] Mounting Hole Dia (4 Places) Threaded Hole for Applicable Shoulder Screw (2 Places) Panel Thickness: 4.76 mm [.188 in.] (Max)

D. PC Board Layout The mounting holes and contact holes in the pc board must be precisely located to ensure proper placement and optimum performance of the connector. Design the pc board using the dimensions provided in Figure 8. Figure 8 (Cont’d)

Figure 8 (Cont’d)

Figure 8 (Cont’d)

Figure 8 (End)

3.15. Mounting Hardware The connectors can be float mounted or fixed mounted to a backplane or chassis. The float mount shoulder screws are designed to secure a connector to a panel. The panel must flex and be of sufficient gauge to support mating loads. These screws allow some movement of the assembly for easier mating. Connectors can be fixed mounted using commercially available screws with a head that will not interfere with connector mating. Washers can also be used to make up the difference for the required hardware diameter. High power connectors are fixed mounted using the mounting flange or, if available, the guide pins (which have internal 6-32 threads). Hardware for specific connector types is shown in Figure 13. NOTE PC board connectors must be fixed mounted. Figure 13 NOTE i Mounting Flange Panel (Ref) Float Mounting Float Mount Shoulder Screw 10-32 or M5 Top Drawer and Double Drawer 6-32, 8-32 or M4 Mini Drawer, Lower Drawer, and 75A/125A Middle Drawer Fixed Mounting Commercially Available Screw and Washer‡ ‡Hardware Diameter 9.52 mm [.375 in.] Top Drawer, Double Drawer 12.7 mm [.500 in.] 75A, 125A Middle Drawer, Lower Drawer and Mini Drawer Internally Threaded (6-32) Guide Pin Commercially Available Screw and Washer‡ Optional Fixed Mounting for High Power Connectors Only

3.16. Connector Mating and Alignment The pre-installed guide pins and molded-in guide posts ensure positive mating of connectors. In addition, because of their symmetrical design, the low power connectors have a polarizing feature: a rib in the guide post cavity that fits into a notch in the guide post. When fully engaged, the dimension between the pin side connector and socket side connector must be within the limit provided to ensure full mating. See Figure 14. When mounted, the float mount design allows blind mating with gatherability up to 2.54 mm [.100 in.]. Figure 14 3.17. Special Assembly Consideration The system into which the connectors are installed must support the weight of the drawer when connectors are engaged (for example, the drawer must bottom on a built-in stop, not on the connector). 3.18. Strain Relief and Wire Dress If required, wires can be bundled together and supported with cable ties. Wires must not be stretched or confined in any way that would restrict the floating action of the connectors. Therefore, the wires must remain perpendicular to the connector and avoid an excessively sharp bend radius. The minimum distance for the cable tie, measured from the wire end of the connector to the cable tie, and the minimum bend radius of a wire bundle is shown in Figure 15. Figure 15 Low Power Connectors Polarizing Feature Rib in Guide Post Cavity Notch in Guide Post “A” CONNECTOR MATING DIMENSION “A” (MAX) Double Drawer, Top Drawer, 75A and 125A Middle Drawer, Mini Drawer 12.70 mm [.500 in] Lower Drawer 10.16 mm [.400 in.]

10 Times Diameter

152.4 [6.0] (Min) Connector Cable Tie

FIGURE 17. VISUAL AID