Modular Interface Connector System Female connectors modules with insulation displacement contacts for singie wires General Tobe abletowire upallthe various types ofround wire eco- nomically, ERN!s Modular Interface Connector System was developed with insulation displacement contacts. These connectors are available for various pin configura- tions (modules). The individual round wires or stranded wires make con- tact via redundant insulation displacement contacts (IDC). Gastightvibrationproofcontactis guaranteed. In conjunction withthe6, 8, 14,21,30, 45,64 and 96pinmod- ules, ERNI has developed the Series KSG MOD connec- tor housing system for most of the popular sizes and styles. The KSG MOD connector housing system is com- prised of a family of cable housings and strain reliefs, backplane shrouds and various panel guides, coding de- vices and spacers. For example, the 64pin fernale connectors, when pro- vided with the mounting flange, can also be fitted into ERNIs Series KSG 173 connector housing. After assembly the female connectors are inserted into the 2 halves simply snap-lock together. To attach the connector housings on the equipment or rack for a particular assembly, there are suitable guide frames for the front-panel and wiring sides. Coding and locking options are available. Series KSG MOD Modular Cable Housing System Series KSG MOD Key features Mating and installation conditions of the female con~ nectors to DIN 41612 e 2-row modules: rows a and c for 6, 8, 14, 30 and 64 pins e 3-row modules: rows a, b and c for 21, 45 and 96 pins e Redundantinsulation displacementcontacts (IDC) for round wires and stranded wires e Precision guidance of the wires in the wire guide Assembly with no risk of twisting e Easy assembly by manual hand tools or semi~auto- mated application equipment e One process for making contact and cutting off the projecting wires e Connector housings suitable for all modules e Guide frame for the front-panel and wiring side of the rack e Connector housings are locked with locking hook on one side or both sides e Coding assisted by locking hook e Further strain relief via cable tie 317Female connectors-modules with insulation displacement contacts for single wires Module sizes: 2-row aandc with 6, 8, 14, 30 and 64 contacts 3-row a,b andc with 21, 45 and 96 contacts Electrical and mechanical characteristics Max. number of contacts 64 96 Max. number of contacts 64 96 Contact row designation ac abc Insulation resistance 2107 Q RRO . . Temperature range 65C. ...4425C Service life to Performance level 1 >500 Current DIN 41 612, Part S Performance level 2 >400 rating at + 20C 2A in mating-cycles Performance level 3 > 50 ambient + 70C 15A temperature + 100C 1A Housing material of female connectors PBTP 30%GV Test voltage, 50Hz,1min Contact/contact 1000 Vims Contact material Contact/ground 1550 Vims of female connectors CuSn6 Permissible Humidity Annual average<80%, Mating and withdrawal 64 pin. < 60 N Applicationclass 65/125/56 max.100% force for the assembled pre 96 pin.s 90 N - - connectors max N Shock and vibration No break of contacts proofness at 20g und 10...2000Hz inflammability non flammable Contact resistance <20 mQ as per UL 94 V-0 Wire specifications Type AWG Rows fitted Wire- @ mm Max. core- @ mm* Round wires: 24 ac 0,5 1,05 26 ac 0,4 1,05 26 abc 0,4 0,65 30 abc 0,25 0,65 7-core stranded wire 26-24 ac - 1,05 to VDE 0881: 30-26 abc - 0,65 * For inserting into the cable guide it is the maximum core diameter which is important. Performance level 107Conforms to the requirements as per DIN 41612 performance level 1 and IEC 603-2 500 mating cycles Contact zone gold plated Terminal zone tinplated 318 207 Conforms to the requirements as per DIN 41 612 performance level 2 and IEC 603-2 400 mating cycles Contact zone gold plated Terminal zone tinplated 307 Conforms to the requirements as per DIN 41 612 performance level 3 and |EC 603-2 50 mating cycles Contact zone gold piated Terminal zone tinplatedDimensions of female connectors Dimensions of wire guide The 64pin female connector is illustrated The 64pin wire guide is illustrated 9 _ a _ | 85.01 pm 3) 4 ed TyuUErtrore 7 oO 66 Oo 6D xf y ! a | PUOdOUoOUoOo : = ! is ASORHORASA HARD af 8.5.04 I c _ b a 2,54 Leisiticinivisicit fries icc i Hh ST gOS U Table of dimensions for female connector modules and matching wire guides 2-row modules Rows a and c 3-row modules Rows a,b and c for ... pins for ... pins Dimension letter 6 8 14 30 64 21 45 96 a 10,1 12,7 20,3 40,6 83,8 20,3 40,6 83,8 b 5,08 7,62 15,24 35,56 78,74 15,24 35,56 78,74 Cc 10,1 12,7 20,3 40,6 85 20,3 40,6 85 319Ordering details for female connector modules with mounted wire guide but without mounting flange (suitable for connector housing system Series KSG-MOD) STV-SKV 64Fac 5 STV-SKV 96Fabc tS af | ! Hi | 107 207 307 | H | | 107 207 307 | | PETP; 423115 423116 PBTP| 013103 STV-SKV 30-F-ac STV-SKV 45Fabc | 107 207 307 UL 107 207 307 PBTP| 423118 423119 PBTP:) 013102 | iE ee [ 1 STV-SKV 14F-ac STV-SKV 21-Fabc | 107 207 307 | Ht | 107 207 307 PBTP| 423121 423 122 PBTP| 013101 | | ] STV-SKV 8F-ac 107 207 307 PBTP| 423351 423352 STV-SKV 6-F-ac 107 207 307 PBTP| 423337 423338 ! Ordering details for female connectors with mounted wire guide and mounting flange (suitable for connector housings Series KSG173) STV-SKV 64-F-ac The dimensions of the 64pin female connector with mounting flange conform to DIN 41612. This means that the female connectors can be built 107 207 307 into the Series KSG 173 connector housings. This interface connector system offers many options PBTP 424 620 for mating interfaces from the frontpanel and wiring | sides of the rack. 96-pin female connectors available on request. 320Dimensions of male connectors for guide frame KSG MOD 87, 5.42 12,5 Ces OJ 5,08 2,54 lit | Pl 2,54 31x2,54=78,74 \ 88,9 + Ot \ Slot for joining to the guide frame Ordering details for male connectors matching guide frame KSG MOD STV-C 64--M-ac 1 mT 107 207 307 423124 423125 PBTP STV-C 96M-abc 107 207 307 PBTP| 013100 Male connectors with straight contacts available on request. 321Modular Cable Housing System Series KSG MOD Module sizes: for number of contacts 96/64, 45/30, 21/14, 8 and 6 installable insulation displacement female connectors without mounting flange Characteristics Module size 96-pin abc 45-pin abc | 21-pin abc 64pin ac 30-pin ac 14pin ac 8pin ac 6pin ac Set contents 2 housing shellhalves 2 housing shell halves 1 plug 1 cable tie 2 cable ties Sizes of pack, 1 connector housing set in a bag packaging units 50 connector housing sets in a bag 100 connector housing sets in a bag Material Standard version PC grey 30% GR Cable outputs Number: 2 1 1 1 1 @ mm: 10,9 10,9 10,9 6,9 5,4 Locking options On both sides with locking hook accessory Dimensions of modular connector housing system Series KSG MOD Connector housing with coding 15 30-0,2 Une | [HHA OO AT Fok s Bs Mol [a By] , | po Front of coding recesses can be extracted Connector housing without coding = Une | 30-0,2 322Ordering details for connector housing sets Series KSG MOD Part No. with coding without coding for ... pins Packaging unit* 96 and 64 1 set 423 127 424 069 50 sets 033 135 033 137 100 sets 033 136 033 138 45 and 30 1 set 423 129 424 071 50 sets 033 139 033 141 100 sets 033 140 033 142 21 and 14 1 set 423 131 424 073 50 sets 033 143 033 145 100 sets 033 144 033 146 8 1 set 594 590 424 076 50 sets 033 147 033 149 100 sets 033 148 033 150 6 1 set 594 589 424 079 50 sets 033 151 033 153 100 sets 033 152 033 154 * In the case of packaging unit comprising 50 and 100 sets we supply assorted individual parts in a card- board box and not packed as individual sets. 323 SMCAccessories for modular cable housings Series KSG MOD Description: Guide frame for front-panel and wiring side Locking hook, coding web, spacers Dimensional drawings for accessories Guide frame for frontpanel, grip version (mounted to rack without front plate, overall width 3 modular units = 15.24 mm) 1284402 CTD Grip locked 7 1 in place aT } 7 : Cort i + = (Pp ESSnInO OR OOOO OOo HT Y | L a A 15,24 16,51 16,51 15,24 p 15,2 -9,2 o Ol oo a7,62 Guide frame for front panel, without grip 108,292 ~ | tT I | ooo} @o IIe ae cI Pn im jj LT 14 15,24 16,51 16,51 15,24 | 15,2 0,2 7,62 0,17 104,14 324EAD) hs - Ss _ / i eda Ra tabhatall! InP habthie pl OA PE ED ) LOE ETE EEE EVLETED LT amar mmr sum sume amma (UTD OUI EL DT POM LL OETA T id re Modular cable connector system with interfacing from the front panel 325Assembly details and installation dimensions for interfacing from the front panel QO ft ! Q ie O iF | | | a: | \ QO rm ' | 2p Pe . O NN | U0 3 0 = QO 3 S| : UL _. = 4 | = | Coding option by removing 10.4 30 the webs ww !4 | r J The coding web accessory is fitted to the contacts on the male connector. This means individual modules can be kept separate. 326Dimensional drawings of the guide frame, wiring side Guide frame for Type C female connectors and inverted Type R male connectors 95.02 s |] pam Mt111! ae ' pit iti i Lobitiit I | po 6.35) 6x5,08=30,48 6x6.08=30,48 995 A y Pp \ / Nw ee 5 so EI SF / 5,08 NA Guide frame for Type M female connectors with dedicated contacts (hybrid type to DIN 41612) 95.0.4 | flr. el frrfvrit S Se Lititittil , HL) J 6,35 30,48 A P L. 30,48 oh oO | . + 5 S| 5,08 6,5 P 7,62 A Currently available for the versions with 2 and 8 dedicated contacts To achieve the correct mating height we supply spacers (for details refer to page 13)[S555 {) = fms aie fellelialils ime LEE LL eS, Lah a Pee , eet he , Wf 4] PSE) y Uf, VUES. PTTL CL LD EE y VY Yi Qo.0 Koo d _ _ Modular cable connector system with interfacing from the wiring side 328Assembly instructions and installation dimensions for interfacing from the wiring side 95 83.8 | | Guide frame | =! { Spacer __ \ in 4 6 \ \ \ \ ~ 3.6 \ Female connector C_ or maie connector R Interfacing examples: for ordering details of accessories refer to page 14 Spacer Dimensions of connecting elements Wiring rack Interface to: (not included in the scope of supply) Hmm On guide frame On female connector L = post length C or maie connector R Mounting rail Female connector Type C, D = 2 mm thick M Male connector Type R Cheesehead screw Hexagon nut L=13mm 2,5 M2,5x16 DIN 84 M2,5 DIN 934 Cheese-head screw L=17mm 6,0 M2,5x5 DIN 84 M2,5x8 DIN 84 L=20mm 9,0 M2,5x5 DIN 84 M2,5x8 DIN 84 PC board Female connector Type C, D=3.2 mm thick |M Male connector Type R L=17mm 5,0 M2,5x8 DIN 84 L=20mm 8,0 M2,5x8 DIN 84 PC board Female connector Type C, D = 2.4 mm thick M Male connector Type R Cheesehead screw Hexagon nut L=13mm 2,5 M2,5x5 DIN 84 M2,5 DIN 934 Cheesehead screw L=17mm 6,0 M2,5x8 DIN 84 L=20mm 9,0 M2,5x8 DIN 84 PC board Female connector Type C, D = 1.6 mm thick M Male connector Type R Cheese-head screw Hexagon nut L=13mm 2,5 M2,5x5 DIN 84 M2,5 DIN 934 Cheesehead screw L=17mm 6,0 M2,5x8 DIN 84 L=20mm 9,0 M2,5x8 DIN 84 Mounting rail Wiring element VE64 6,0 Set up in backplane For installation example refer to page 10 Mounting rail Set up in marginal | Wiring element VE64 8,0 plane 329 ro) osOrdering details for accessories Series KSG MOD Description Cat. no. Material Remarks Part. Guide frame for front panel With grip 414 945 PC 30% GR grey Fastening screws not included With grip 424 324 PC 30% GR grey Fastening screws not included Without grip 414 934 PC 30% GR grey Fastening screws not included Female Type C Male Type R 414 962 PC 30% GR | Also order matching grey spacers Fastening screws not included 2 dedicated Female Type M contacts 424 384 PC 30% GR | Also order matching 8 dedicated grey spacers contacts Fastening screws 424 387 not included Locking hook 414 933 PC 30% GR | Locking hooks also = black serve coding purposes Coding web Coding webs are 014 690 PC 30% GR | mounted on the free grey contact pins between the modules. Cable entry reducer Matching module 003 510 PC 30% GR | sizes 14/21, 30/45 black and 64/96 Spacers 2,5mm 423 185 Eor use with 5,0 mm 083 532 guide frame on the [ 6,0 mm 083 529 Al Mg Si__| wiring side. 8,0 mm 083 531 For dimensions 9,0 mm 083 525 see page 13 330installation options of the various modules Guide frame (front panel or wiring sid eT Ty with male connector similar ~ L441 i to Type C96 or 64-pin A er oeer enema Comment Mer eee MeN Ne AMMAN MAMAN eee ee wee pate ee ee eT Tin Us {To TT? | CL 1 moduie 96/64pin Nr On Dron stn Ko Aw@ Rete BON Ome AMMAN AN Ae eee ee 2 modules _| ~~] 45/30pin | A 8 C 2 E E ~ A 6 c o E F 4 modules 21/14 pin 6 modules 8&pin 8 modules 6pin PCI IL LIC The 45/30, 21/14, 8 and 6pin modules can be combined in a variety of ways. No contact at pos. 16 or 17 No contact at pos. 8, 16, 17 or 25 No contact at pos. 5,10, 15, 16, 17, 18, 23 or 28 No contact at pos. 4, 8, 12, 16, 17, 21, 25 or 29 331Handling details for female connectors with insulation displacement contacts for single wires 1. Preparing the wires Strip outer cable sheathing to approx. 30 mm. 2. Inserting the wires The wire ends are inserted into the cable guide and then bent into the guide slots. 3. Mounting the wire guide When the wire guide has been prepared it is mounted on the fe- male connector. Please ensure there is no twisting (red mark). 3324. Pressfitting Slide the female connector and mounted wire guide into the guide slot of the hand tool. The wire ends must not project by more than 5/6 mm. 5. The completely assembled connector will now fit into the ERNI connector housings of Series KSG MOD.334 Assembly tool for wiring and cutting off the wires in one process. The tool is supplied in a plastic case withfoaminsertand Assembly equipment for installation can also be various assembly tools, oilcanandapairofreplacement supplied. blades. Part no. 424268Customer Driven meeting the needs of the marketplace. This data sheet includes the various details about our standard offering of ERNI's KSG MOD products. In addi- tion to this offering, we have developed many other vari- ations in response to customer application require- ments. An example of such a custom KSG MOD product is shown below. Please contact us if your application re- quires any customization. An efficient wiring method is essential in most all elec- tronic or electrical systems. ERNI female connectors with insulation displacement contacts for connecting up single wires, used in conjunc- tion with the connector housing system Series KSG MOD products, is the basis for such an efficient method. With clearly arranged wire guides the wires can be as- signed quickly and reliably. With the aid of the easy-to-use hand tool you can as- semble quickly and neatly and cut off the projecting wire ends at the same time. The advantages in assembly and the high precision of ERNI insulation displacement contacts, including the re- dundant insulation displacement terminais and the double-sided female contact which both guarantee a re- liable connection, have established the KSG MOD product as a standard in the telecommunications indus- try and others as well. The above application required the development of spe- cial wire guides and frames for a standard female con- nector. This example shows ERNIs ability to provide the optimum, customized solution. In partnering with our customers, ERNi strives to find the optimum, cost effi- cient solution through standard products or in conjunc- tion with custom designed products. Please contact our sales engineers and representatives or call ERN! directly at our offices to discuss your particu- lar application. 335