Accessories
Cassette Style Mating Connectors
BCD20022 Rev AH, 12-Nov-2014 Page 1 of 10
MELCHER
The Power Partners.
Description
All 19" cassette style converters are equipped with either
H11, H15 , H15S4, or H15S2 male connectors. Mating
female connectors are available as accessories. The four H-
type connector versions are especially designed for power
supply application s, capable of handling high operating
currents. The connectors have an integrated code key
system allowing many coding possibilities. Converters with
high output current normally use two contacts in parallel to
keep the voltage drop across the connector as low as
possible. In case of very high currents, the connectors are
fitted with round high current contacts.
Note: Parts ending with -G are RoHS-compliant for all 6 substances.
H11 Connectors
This connector has 11 contacts in one vertical column
marked 2 to 32. Mating and mounting conditions are
according to IEC 60603-2 and DIN 41612. The connector
contacts are hard-silver plated and correspond to quality
class 1, allowing for 500 mating cycles.
Note: H11 connectors (male version) are used in the converter
series (case size): H (H02), M (M02), and PSL (L04).
Table 1: H11 Connector Survey
Female connector Part number Description of terminals Fig. Integrated
(former designation) coding
STV-H11-F/CO HZZ00101-G Faston terminals 6.3 × 0.8 mm 2 yes
STV-H11-FG/CO 2 HZZ00196 2 Faston terminals 6.3 × 0.8 mm, gold-plated contacts 2 yes
STV-H11-FS/CO-G HZZ00104-G Faston terminals 6.3 × 0.8 mm, solderable (short moulding) 3 yes
STV-H11-FSR/CO-G HZZ00102-G Screw terminals, 90°, 2.5 mm2 (AWG 13), torque ≤ 26.6 Ncm 4 yes
STV-H11-FB/CO-G 1HZZ00103-G 1Solder pin 5.2 mm, ∅ 1.6 mm 5 yes
STV-H11-FBG/CO 3 HZZ00199 3 Solder pin 5.2 mm, ∅ 1.6 mm, gold-plated contacts 5 yes
STV-H11-FBER/CO 3 HZZ00113 3 Solder pin 4.3 mm, ∅ 1.0 mm 5 yes
STV-H11-FP/CO HZZ00111-G Press fit 6.5 mm, ∅ 1.0 mm 5 yes
1See also matching Flexi-PCB (HZZ01208-G) for PCB-mounting of converters, fig. 6.
2Obsolete; use HZZ00101-G
3Obsolete; use HZZ00103-G (STV-H11-FB/CO-G)! Obsolete parts Preferred for new designs
84.8
7.62
10 x 7.62 = 76.2
90
95
10.7
8.5
12042
Description ........................................................................... 1
H11 Connectors ................................................................... 1
H15 Connectors ................................................................... 3
H15S4, H15S2 Connectors ................................................. 6
Technical Data ..................................................................... 8
Code Key System ................................................................. 8
Connector Retention Clips .................................................. 9
Connector Retention Brackets CRB ................................... 9
Cable Hood ........................................................................ 10
Cage Clamp Adapter ......................................................... 10
Table of Contents Page Page
Fig. 1
H11 front view, relating to
figures 2 to 5
Mechanical Dimensions (in mm)
Accessories
Cassette Style Mating Connectors
BCD20022 Rev AH, 12-Nov-2014 Page 2 of 10
MELCHER
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5.63
10 x 7.62 = 76.2 Y
0.3
2.8±0.1
2 5 8 1114172023262932
11.5
X
5.08
2.9±0.3
5.08
90±0.1
Footprint for PCB-layout
12045a
11.5
31.3
2.9
±0.3
7.4
6.3 x 0.8
6.5
Coding wedge
KI H G F
2 5 8 11 14 17 20 23 26
4
5.5
12038a
11.5
25.8
2.9±0.3
7.3
6.3 x 0.8
K I H G F
12043a
232
11.5
2 5 8 1114172023262932
2.9
±0.3
19.8
K I H G F
10.9
12044
Fig. 2
HZZ00101-G (STV-H11-F/CO), faston terminals 6.3 × 0.8 mm
HZZ00196 (STV-H11-FG/CO), faston terminals 6.3
×
0.8 mm with gold plated contacts, obsolete
Fig. 4
HZZ00102-G (STV-H11-FSR/CO), screw terminals,
max. 2.6 mm2 (AWG 13), max torque 26.6 Ncm.
Fig. 3
HZZ00104-G (STV-H11-FS/CO),
faston terminals 6.3 × 0.8 mm, solderable (short moulding)
European
Projection
Fig. 5
HZZ00103-G (STV-H11-FB/CO),
solder pins, X = 5.2, Y = Ø 1.6
HZZ00199 (STV-H11-FBG/CO),
solder pins, X = 5.2, Y = Ø 1.6, obsolete
HZZ00113 (STV-H11-FBER/CO),
solder pins, X = 4.3, Y = Ø 1.0, obsolete
HZZ00111-G (STV-H11-FP/CO),
press insert pins, X = 6.5, Y = Ø 1.0
Accessories
Cassette Style Mating Connectors
BCD20022 Rev AH, 12-Nov-2014 Page 3 of 10
MELCHER
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3.81 7.62
83.82
5.08
21.3
24,5
12034
95
14.8
90
12.4
12046
H15 Connectors
This connector has 15 contacts in two vertical columns,
marked with 4 to 32 and is designed to meet DIN 41612. The
connector contacts are hard-silver plated and correspond to
Table 2: H15 Connector Survey
Female connector Part number Description of terminals Fig. Integrated
former designation coding
STV-H15-FSR-G HZZ00107-G Screw terminals, 90°, 2.5 mm2 (AWG 13), torque ≤ 26.6 Ncm 8 yes
STV-H15-F/CO-G HZZ00106-G Faston terminals 6.3 × 0.8 mm (8) y e s
STV-H15-FB/CO HZZ00112-G Solder pin 4.0 mm, ∅ 1.6 mm 9 a ye s
STV-H15-FBG/CO 1HZZ00197 1Solder pin 4.0 mm, ∅ 1.6 mm, gold-plated contacts 9 a yes
STV-H15-FWS/CO HZZ00114-G Solder pin 10.1 mm, ∅ 1.6 mm, 90° bent contacts 9b ye s
STV-H15-FP/CO HZZ00117-G Press fit 4.5 mm, square 0.6 mm (double-pin version) 9 c y e s
H 15 cage clamp HZZ00118-G Cage clamp contacts, wire gauge ∅ 0.14 – 1.5 mm 10 no
1 Obsolete; use HZZ00112-G !
Mechanical Dimensions (in mm)
Fig. 7
H15 front view, relating to the next figures
Flexible H11 PCB
If cassette style converters with H11 male connectors are
mounted on a PCB board, the connection can be made
using the H11 flexible PCB (fig. 6) together with the female
connector HZZ00103-G (STV-H11-FB/CO-G).
Part number: HZZ01208-G
European
Projection
Fig. 6
Flexible H11 flexible PCB board HZZ01208-G
quality class 1, allowing for 500 mating cycles.
Note: This connector type (male version) is used in the
following converter series (case size): Q, P, LPC, PSK, PSS, K,
S, T.
Obsolete parts Preferred for new designs
Accessories
Cassette Style Mating Connectors
BCD20022 Rev AH, 12-Nov-2014 Page 4 of 10
MELCHER
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Fig. 8
HZZ00107-G
screw terminals, max. torque 26.6 Ncm,
material LPC E130 i
HZZ00106-G (STV-H15-F/CO-G),
Faston terminals 6.3 × 0.8 mm (similar
dimensions, but not shown). The orientation
of the faston terminals can be horizontal or
vertical, depending on supplier.
Fig. 9a
HZZ00112-G (STV-H15-FB/CO),
solder pins, foot print.
HZZ00197 (STV-H15-FBG/CO),
solder pins, foot print, obsolete
3.5
90
14 × 5.08 = 71.12 8.17
10.16
0.3
1.6
2.8
10.1
3
5.08
Footprint for PCB-layout
12047
4 32
European
Projection
Fig. 9b
HZZ00114-G (STV-H15-FWS/CO,
solder pins for PCB mounting
14 x 5.08
2.54
3
7.62
88.9
14.9
3
12053a
3.5 6
min.
10.1
32 4
Fig. 9c
HZZ00117-G (STV-H15-FP/CO),
press fit pins, foot print
3.5
90
15 × 5.08 = 76.2 8.17
10.16
0.3
1.6
2.8
10.1
3
5.08
Footprint for PCB-layout
JM074
z
d
2
32
29.1
84
10.1
14.8
8.0
3.3
432
12039b
84.9
access screws M2 -15
12.4
95
1.9
Accessories
Cassette Style Mating Connectors
BCD20022 Rev AH, 12-Nov-2014 Page 6 of 10
MELCHER
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H15S4, H15S2 Connectors
These special connectors derive from the H15 connectors
having standard contacts like the standard connectors,
combined with 4 (H15S4) or 2 (H15S2) high-current contacts
(jacks) according to DIN 41626. These jacks are specially
designed to handle currents up to 40 A. They correspond to
quality class 2, allowing for 400 mating cycles. The contact
material is high-quality Phosphor Bronze.
The high-current jacks are joined separately to the
connectors. To install them, carefully follow the assembly
instructions. It is extremely important to solder cables, screw
cable terminals or heat shrink sleeves to high-current jacks
first, before inserting them into the moulding. Paralleled
converters should preferably be interconnected on current
bars or at a star point.
Using screw versions, the two outer high-current jacks may
be inserted at a 90° angle in order to prevent possible short
circuits between the cable terminals, especially in
applications with high vibration environment. Heat shrink
sleeves might be necessary for further isolation purposes or
to keep clearances and creepage distances at specified
levels.
An extraction tool allows removal of the high-current jacks for
replacement (see fig. 18).
Caution: The use of an adequate cable strain relief device (e.g.
Cable Hood etc.) is essential, in order to protect the high-current
contact jacks from damage. Do not screw, solder or manipulate
these contacts, when the connector is plugged into the male
connector! The use of highly flexible cables is strongly recom-
mended.
Note: H15S4 connectors (male version) are used in the
following converter series (case size): K, PSK with line currents
≥20 A.
Note: H15S2 connectors (male version) are used in the
following converter series (case size): P1000, K4000 with line
currents ≥20 A. H15S2 connectors are not for new designs.
Please consult the product data sheets for replacing models.
95
14.8
90
12.4
12054b
10.1
13
84.9
30.3
32 28 24 20 16 12
30 26 22 18 14 8/10 4/6
Table 3: H15S2 and H15S4 connector survey
Female connector Part number Description of terminals Fig. Integrated
former designation coding
STV-H15S2-FSF/CO 3 HZZ00116 3 11 faston terminals 6.3 × 0.8 mm, 2 screw jacks 1 12 + 11b yes
STV-H15S2-F/CO 3 HZZ00115 3 11 faston terminals 6.3 × 0.8 mm, 2 solder jacks 1 (12) + 11a yes
STV-H15S4-FSF/CO HZZ00110-G 7 faston terminals 6.3 × 0.8 mm, 4 screw jacks 1 14 yes
STV-H15S4-F/CO HZZ00105-G 7 faston terminals 6.3 × 0.8 mm, 4 solder jacks 1 (14) yes
STV-H15S4-FLS/CO 2 HZZ00109 7 screw terminals 90°, 2.5 mm2, torque ≤ 26.6 Ncm, 4 solder jacks 1 15 yes
STV-H15S4-FSR/CO 2 HZZ00108 7 screw terminals, 90°, 2.5 mm2, torque ≤ 26.6 Ncm, 4 screw jacks 1 (15) yes
Fig. 12
HZZ00116 (STV-H15 S2-FSF/CO)
11 faston terminals and two screw jacks.
HZZ00115 (STV-H15 S2-F/CO)
11 faston terminals and two solder jacks
(solder jacks are shown in fig. 15).
European
Projection
Fig. 11a
Solder jack XMB045
Fig. 11b
Screw jack YVM002-G
for screws M4.
1Spare jacks are available on request: screw version YVM002-G,
solder version XMB045; see fig. 11a and 11b.
2Obsolete; use female connectors with faston terminals instead!
3H15S2 connectors are not for new designs.
Delivery content: H15S4 (S2) moulding, 4 (2) high current jacks
and assembly instructions. Screw versions also include four M4
screws with washers and heat shrink sleeves.
Mechanical Dimensions (in mm)
Accessories
Cassette Style Mating Connectors
BCD20022 Rev AH, 12-Nov-2014 Page 7 of 10
MELCHER
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95
14.8
90
12048a
24
2
0 16 12
30/32
26/28
22 18 14 8/10 4/6
Fig. 14
HZZ00110-G (STV-H15 S4-FSF/CO),
7 faston terminals and 4 screw jacks
HZZ00105-G (STV-H15 S4-F/CO),
7 faston terminals and 4 solder jacks (solder jacks, fig. 11a, are shown in fig. 15)
84.9
30.3
41.6
12.4
13
10.1
3
7.6
8
4
12049
84.9
30.6
40.5
12.4
10.1
14.8
Ø 3.5
3
12040
Fig. 15
HZZ00109 (STV-H15 S4-FLS/CO), obsolete,
7 screw terminals (max torque 26.6 Ncm) and 4 solder jacks
HZZ00108 (STV-H15 S4-FSR/CO), obsolete,
7 screw terminals (max torque 26.6 Ncm) and 4 screw jacks (screw jacks, fig. 11b, are shown
in fig. 14)
The connectors shown in fig. 15 with 7 screw terminals are obsolete. Use connectors with 7
faston terminals instead, HZZ00110-G or HZZ00105-G; see fig. 14.
Fig. 13
H15S4 front view, relating to figures below
European
Projection
Accessories
Cassette Style Mating Connectors
BCD20022 Rev AH, 12-Nov-2014 Page 8 of 10
MELCHER
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Extraction Tool for High Current Contacts
High current plugs and jacks can be disassembled from the
moulding by means of a special extraction tool (H15S2 and
H15S4 connectors). Holding the extraction tool over the
center of the connector's female contact the outer part of the
extraction tool should be fed between the moulding and the
outside of the female contact itself. This releases the spring
clip fixing the contacts, in order to pull the contacts out of their
moulding for replacement. If the operation is performed
correctly, very little force is required. Extreme care should be
taken since incorrect procedure and excessive force could
damage the tool and/or the connector.
This tool is available as an accessory for high-current solder
and high-current screw contacts.
Fig. 16
Extraction tool HZZ00150-G
Technical Data of Connectors
Table 4: Connector data
H11 H15 H15S2 / H15S4
Mechanical data Fastons High current
Number of poles 11 15 11/ 7 2/4
Mating cycles 500 500 400
Insertion/withdrawal forces max. 80 N 90 N 90 N 10 /1.6 N
Electrical data
Clearances and creepage distances ≥4.5 mm ≥4.5 mm ≥4.0 mm
contact to ground
Clearances and creepage distances ≥8.0 mm ≥8.0 mm ≥4.0 mm
between contacts
Test voltage 3100 VAC 3100 VAC 3100 VAC
Operation voltage 500 VAC 500 VAC 500 VAC
Operation current TA = 20 °C 20 A 15 A 15 A 40 A
per contact TA = 70 °C 17 A 12 A 12 A 35 A
TA = 95 °C 14 A 9 A 9 A 25 A
Contact resistance ≤8 mΩ≤8 mΩ≤8 m Ω≤1 mΩ
Insulation resistance at 100 VDC ≥1000 MΩ≥1000 MΩ≥1000 MΩ
Miscellaneous data
Operating temperature –55 to 125 °C – 55 to 125 °C –55 to 105 °C
Contact surface 6 µ Ag 6 µ Ag 6 µ Ag over 2 µ Ni 0.8 µ Au over 2 µ Ni
Moulding material of the female PBTP black Arnite TV4 264 SN Lyquid Cristal Polymer, Vectra E130i
connector (not all models) Crastin SK 645FR (E41938) (E47960) (former material: Glass filled PBT)
Flammability UL 94 V-0/UL 94 V-1 UL 94 V-0/UL 94 V-1 UL 94 V-0
Code Key System
An efficient coding system is of great importance in complex
electronic systems. Since power supplies handle high
currents and voltages, any false connection could be
dangerous and quite costly.
This integrated polarizing system allows effortless coding by
the simple insertion of coding wedges (HZZ00202-G) into
the female connector mouldings. The corresponding counter-
parts, i.e. the coding tabs of the male moulding, just have to
be broken off to match the right female part. Major
advantages are high mechanical stability and easy handling.
The H11 connectors have 10 and the H15 connectors 8
coding positions. The use of coding wedges allows for many
different coding possibilities. Coding wedges are available
as accessories to female connectors with the following item
number (fig. 17):
Note: In order to avoid damage, never manipulate high-current
contacts when plugged-in!
Part number: HZZ00150-G
Description: Extraction tool
Accessories
Cassette Style Mating Connectors
BCD20022 Rev AH, 12-Nov-2014 Page 9 of 10
MELCHER
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Connector retention clips (unlocked)
Connector retention clips (locked)
12050
Connector Retention Clips
The retention clip V is an accessory, which guarantees
secure connection even under severe vibration, as for
example in mobile applications. One connector retention
system fits to almost all converters and all of the mentioned
connector types.
The following converter series are delivered with pre-
punched holes in the back plate for fast field-mounting of
retention clips:
Note: Suitable for H, M, K, S, PSK, PSS, PSL, R, and T Series.
Q, P, LPC Series only in combination with HZZ01215-G (Mounting
Plate Q)
Part number: HZZ01209-G
Description: Retentionclip (2x)
Delivery content: 2 pcs. in a plastic beg
Fig. 19
Connector retention clips HZZ01209-G and their application
Fig. 20
Connector retention brackets HZZ01216-G (left-hand side)
and HZZ01217-G (right-hand side)
232
5811 14 17 20 23 26 29
KIHGF
K I H G F
2 5 8 11 14 17 20 23 26 29 32
Coding tab
4
6.5
12041a
Coding wedge
AB C D E
Bottom side:
Fig. 18
Integrated code key system (H11 connector)
Fig. 17
Integrated code key system for a H11 connector
Part number: HZZ00202-G
Description: Codierkeil XKN031-G
Delivery content: 5 pcs.
Connector Retention Brackets
An alternative to the above mentioned retention clip V is the
connector retention bracket. They are attached to the back
plate by one screw each with a torque of 20 to 30 Ncm.
Table 5: Connector Retention Bracket Survey
Series Part number Delivery
Description content
K, R, S, HZZ01216-G 2 brackets, 2 screws,
PSK, PSS, PSL, CRB-HKMS 2 washers
H, M, T
Q, P, HZZ01217-G 2 brackets, 2 screws,
LPC CRB-Q 2 washers, 2 springs
Accessories
Cassette Style Mating Connectors
BCD20022 Rev AH, 12-Nov-2014 Page 10 of 10
MELCHER
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Cable Hood
A cable connector housing (cable hood) is available for all
female H15, H15S2, and H15S4 type connectors with faston
terminals (not suitable for screw terminals). It serves as a
strain relief, isolates connections and protects cables.
Part number: HZZ00141-G
Description: Cable hood for H15, H15S2, H15S4
Delivery content: Connector housing, blanc label
for K, S, R, T, PSK, PSS Series converters, the cable hood
can be fixed to the converter case with a pair of U-shaped
cable hood retention brackets; see fig. 21.
Fig. 21
Cable hood HZZ00141-G fixed with retention brackets
HZZ01218-G
Fig. 23
Metallic cable hood
HZZ00143-G providing
fire protection
Part number: HZZ01218-G
Description: Retention brackets CHRB-KSG
Delivery content: 2 brackets XMK187-G
2 screws XMM003-G (M2.5 x 6)
Install. instruction BZM20006, blank label.
For fixing the cable hood with a pair of retention clips
HZZ01209-G, a special version HZZ00142-G is available
where both sides of the cable hood are slightly modified in
order to allow for insertion of the clips. The cable hood fixed
with the clips has been tested to withstand vibrations
according to IEC/EN 60068-2-6: 5 g, 7.5 h (2.5 h per axis).
See fig. 22.
Part number: HZZ00142-G
Description: Cable hood for H15/H15S2/S4
Delivery content: Connector housing, blanc label
JM156
A metalic version of the cable hood provides fire protection;
see fig. 23
Part number: HZZ00143-G
Description: Metallic cable hood for H15/H15S2/S4
Delivery content: Connector housing, blanc label
Cage Clamp Adapter
The adapter HZZ00144-G allows for connecting a converter
with cage clamp technique; see fig. 24.
Fig. 24
Cage clamp
adapter HZZ00144-G
110
20.2
68
Modification for use with retension clip
12051
Fig. 22
Cable hood HZZ00142-G for fastening with
retention clips HZZ01209-G
European
Projection
NUCLEAR AND MEDICAL APPLICATIONS - These products are not designed or intended for use as critical components in life support systems,
equipment used in hazardous environments, or nuclear control systems.
TECHNICAL REVISIONS - The appearance of products, including safety agency certifications pictured on labels, may change depending on
the date manufactured. Specifications are subject to change without notice.
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