HOW TO

Choose the Right Connector

Choosing the right power connector for your application may be one of the most important interconnection choices to make in a product's design. The appropriate connector can provide a reliable means to modularize, downsize, or improve manufacturability and field maintenance. There are several criteria to consider in selecting the power interconnection system. These include: Current rating (current density) Connector size (circuit density) Engagement force Wire size Configuration and circuit size Operating voltage Agency approvals (listings) Price per circuit POWER CONNECTOR SELECTION CRITERIA Current Rating is the most important criterion in the selection of a power interconnection system. It is stated in amperes per circuit and is a measure of the amount of current that can be passed through a mated terminal that will give no more than a 30 degrees C (85 F) temperature rise over ambient 22 degrees C (72 F). This current level is then derated or adjusted for the number of circuits in a given housing (2 to 15 circuits per housing typically) due to the heat (temperature rise) of the adjacent terminals. For example, a typical power connector can carry up to 12 amperes/circuit on a 2- or 3-circuit housing, but only 7.5 amperes/circuit on a 12- or 15-circuit housing. Note that the current rating for a particular circuit size assumes all circuits of the housing are carrying the rated maximum current. The current rating also assumes that the maximum wire gauge for that connector family is used. For example, if a standard connector family has a maximum current rating of 12 amperes/circuit, the use of 14 AWG wire is assumed. If a smaller wire is used (larger AWG number), the maximum current carrying capacity should be derated by 1.0 to 1.5 amperes/ circuit for each AWG gauge range less than the maximum. Connector Size or Circuit Density Connector size is becoming more important in the connector selection process with the trend of downsizing equipment. Circuit density is a relative measure of the number of circuits (lines) a connector can accommodate per square inch. It is relative in that using this measure, one can objectively determine the space requirements or size of one connector family versus another.
Molex XRC Connectors

Amphenol AT Connectors

Engagement Force The force or effort required (stated in pounds/circuit) to connect, mate, or engage the two populated connector halves. If the application required a 10-circuit housing, the total engagement force for the connector would be equal to the total number of circuits (10) times the engagement force per circuit**. The engagement force is of major concern in primarily two areas. The first is with high circuit count connectors (typically greater than 9 circuits), while the second is in applications where the connectors will be mated to a printed circuit (PC) board via a header.

There when you need it.

www.waytekwire.com

WAYTEK, INC. Toll-Free I 800.328.2724 Fax I 800.858.0319 sales@waytekwire.com

In the high circuit count application, total engagement forces for some connector families can be as high as 50 lbs., a force which may be considered excessive for some assembly operators or in applications where the connectors are difficult to reach. In the second case, when mating to a header or to a connector mounted on a PC board, high mating forces may damage the board. In both cases, a "low force" terminal within the chosen connector family or a connector family with a lower engagement force/circuit should be used. The configuration of the connector and circuit size required are generally defined by the architecture of the application. The number of lines or circuits one should specify in a given housing depends on four key factors: Maximum current rating of the housing Number of module-to-module interconnects needed Total connector engagement force Packard Metri-Pack Size of connector.
480 Connectors

Wire size Is an important criterion, especially in applications where the current rating required is near the maximum for the chosen connector family or where mechanical strength in the wire is required. In both cases, a heavier wire gauge (a smaller AWG number) should be chosen. Most power connectors will accommodate wire gauges of 16 to 22 AWG. Note that the Metri-Pack 480 connector line can accommodate up to a 10 AWG wire. Operating Voltage Most applications are within the 250V rating to the standard power connectors, although some connector families, such as the MX150L Connectors, offer a 600 V rating. The voltage ratings are RMS values and, therefore apply to both AC and DC voltages. Generally, the higher voltage ratings are obtained by fully enclosing both the male and female terminals individually in the housing. Shrouded housings or fully isolated contacts also offer protection to the metal terminals during the assembly and handling of the product. Agency Approvals or Listings Assure that the interconnection system has been tested to a consistent specification with respect to other connector systems. Most connectors meet the requirements of UL (USA) and CSA (Canadian) agencies. IP ratings and salt spray tests are indicators Of the connectors resistance to moisture and contaminants.

Molex MX150L Connectors

Housing Lock Type Either positive or passive appropriate for a given application can best be determined by the degree of stress to which the mated connectors will be subjected. A connector system having a positive lock requires the operator to deactivate a locking device before the connector halves can be separated, whereas a passive locking system will allow the connector halves to disengage by simply pulling the two halves apart with a moderate force. In high-vibration applications or where the wire or cable is subjected to axial loads, by design or by accident, a positive locking connector system should be specified. Strain Reliefs Strain reliefs or backshells for the power connector can be a major criteria in the extra degree of safety that the non-conductive strain relief housing provides. Should a terminal or wire become dislodged from its seated position in the connector housing due to being mechanically over-stressed (that's a technical term for "pulling on the wire too hard"), the strain relief can prevent the "live" wire from contacting other components or "neutral" conductive members. The one-piece strain relief shown in figure 1 features an integrally molded tie strap to firmly grip the wires. This design does not require any additional assembly hardware (screws) and it will work with either half of the connector, thus minimizing inventory requirements. It also has a removable strap holding the top cover to the base, again reducing the number of pieces to order, track, and inventory.

There when you need it.

www.waytekwire.com

WAYTEK, INC. Toll-Free I 800.328.2724 Fax I 800.858.0319 sales@waytekwire.com

Housing and Terminal Materials and Terminated Platings Are the last major decisions to be made. Most power connectors are made from a nylon plastic. This nylon can have flammability rating of typically UL94V-2 or 94V-0. The higher 94V-0 rating indicates that the nylon will extinguish itself (in case of fire) more rapidly than the 94V-2 nylon. A 94V-0 rating does not infer a higher operating temperature rating, but rather a higher resistance to flame continuance. For most applications, the 94V-2 material is adequate. The standard terminal plating options available for most power connectors are tin, tin/lead and overall or select gold. Tin or tin/lead platings are appropriate for most applications where per circuit currents are above 0.5 A. Gold plating should generally be specified in signal or low current applications where high mating cycles (>30 cycles) are likely or within harsh environments. Terminal base materials are either brass or phosphor bronze. Brass is the standard material and affords an excellent combination of strength and current-carrying capabilities. Phosphor bronze is recommended where a thinner base material is used to obtain a lower engagement force, high engagement/disengagement cycles (>100 cycles) are likely, or where prolonged exposure to high ambient temperature (>85C/29F) are likely. Price The price of the connector system should be calculated on the basis of total applied cost, i.e., the cost of the housing (both plug and receptacle), the cost of the terminals, plus the cost of the labor to attach the wire to the terminal and to insert the terminal into the housing. Most connector companies offer a full range of application tooling equipment from simple plier-like hand tools (please do not use common pliers, it won't work) for low volume production and repair to semi-automatic bench presses that are capable of terminating as many as 3,000 terminals/hour (operator dependent). There are also fully automated wire processing machines that will cut wires to the proper length, strip off insulation on wire ends, and crimp the wire to the terminal. A few connector and wire processing machine manufacturers offer "block stuffing" equipment that can automatically insert the terminated wire into the housing as well. For this discussion of price, let's assume (reasonably so) that most connectors can be terminated equally well and inserted into housings equally well, and concentrate on the pricing as it relates to the cost of the housings and terminals. The unit of measure used in this analysis is cost per circuit on a loaded, mated pair. For an interconnection system requiring four lines or circuits, each of the four circuits of both the plug and receptacle housing (mated pair) would be populated (loaded) with either a male or female terminal. If a price curve were to be drawn for various power connector families, it would show only a small difference between each family, which is why the price is the least important criterion. This is especially true if the other criteria are compromised to save a fraction of a cent at the cost of the reliability and integrity of the design. Conclusion So which criterion is the most important? After current rating, your specific application will dictate whether connector size, engagement force, wire size, configuration and circuit size, operating voltage, agency approvals, or price is the criterion which defines the right power connector for your application.

* Or the rated maximum, whichever is the lower rating, specified by the wire manufacturer. ** The actual total force may be greater due to housing-to-housing frictional forces.

There when you need it.

www.waytekwire.com

WAYTEK, INC. Toll-Free I 800.328.2724 Fax I 800.858.0319 sales@waytekwire.com