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PCB connectors

Posted: Tuesday 27th July 2010

Weidmüller PCB Connectors: Omnimate Power SL/BL 7.62 IT, SV/BV 7.62 IT and SU/BU 10.16 IT for IT mains systems – The compatible power level to fit each power variant in a device series – Scalable up to 50 kVA – Uncompromised safety – Designed with the application in mind, for easy international IEC and UL device approvals.

Weidmüller offers optimized PCB connectors for devices that are using an IT-type mains power supply. This includes three product lines: SL/BL 7.62 IT MF, SV/BVZ 7.62 IT MF and SU/BUZ 10.16 IT MF; scalable from 24.5 A/2.5 mm2 to 41 A/ 6 mm2 and all the way up to 76 A/16 mm2. This range is suited for devices in the 16-kVA, 28-kVA and 52 kVA power classes. The connectors fulfil the expanded requirements for 5.5 mm of finger safety with IT systems (400 V phase-to-ground voltage in case of error), according to IEC 61800-5-1. Even the SU 10.16 IT male PCB pin header in 10.16-mm pitch features sufficient finger safety with its insulated contact tips. The single flange saves space and serves as a one-hand, safety interlock mechanism. This ensures that the male and female headers snap together safely and automatically. The creepage and clearance distances on the PCB connector have been enhanced, so that there is no limitation for UL approval with 600-V applications – even under difficult design requirements. The female headers are available with clamping yoke (screw) connections. Even the BVF 7.62 HP PCB connector with PUSH IN spring connection technology fulfils the requirements for IT-system use. The Weidmüller PCB connectors with screw connection technology are always delivered with "wire-ready" clampingpoints. That means the user must not unscrew the yoke before inserting the wire – this saves time and thus saves money. The PCB connectors for IT mains systems are presently available only from Weidmüller.

IT mains supply systems (also referred to as 3-wire systems) are primarily used for hospitals (surgery wings), railway locomotives, portable generators and specialized industrial facilities (such as those used in high-risk explosive zones in mining). IT mains systems have several special characteristics. Weidmüller took these into account when designing its PCB connectors. One of these characteristics is that a single fault in the insulation of an IT mains system does not cause a dangerous contact voltage. The earthing reference potential is thus at the same voltage level as the fault phase. A fuse is triggered only after a second insulation fault (on another phase) occurs. For this reason, specialized fault-alarm systems are implemented which issue an alert when the first earth fault occurs. This allows for troubleshooting before the system shuts down from the second fault. The makes the system "first-fault protected". In order to comply with IEC 61800-5-1:2007, an IT mains system must account for 400 volts relative to earth. The touch protection gap thus increases from 3.3 mm (for 400-V TN systems) to 5.5 mm (for 400-V IT systems).

Weidmüller has implemented this requirement for increased touch protection in three of its product lines: the SL/BL 7.62 IT MF, SV/BVZ 7.62 IT MF and SU/BUZ 10.16 IT MF. All of the PCB connectors in these three product lines provide 5.5 mm of touch protection in compliance with IEC 61800-5-1:2007 for 400 V relative to earth. The male pin headers feature a leading-pin PE contact. In combination with the corresponding female header, they fulfil the requirements of UL 1059, 600 V Class C. All IT variants of the connectors comply with the IEC 61800-5-1 requirement of 400 volts relative to earth in event of fault. When not plugged in, the male headers provide a basic touch protection of over 1 mm with 20 N pressure applied by the test finger. The ends of the pins on the large 10.16-pitch male headers are moulded with insulation. This ensures dependable touch protection. The easy-to-use, auto-interlock, one-handed security flange provides you with one more safety feature. The middle flange decreases the space required by one pitch width when compared to other standard solutions. Operational reliability is guaranteed by the automatic interlock feature during the plug-in process. Depending on the application, the one-handed security flange can be positioned differently on either the male or female side of the connection. Versions are available with the one-handed security flange in position 2, 3 or 4 within the connector. The clamping yoke (screw) connection system is used for all three product lines. The SV/BV 7.62 IT MF line is also available with the PUSH IN connection method. The clamping yoke system requires no servicing, is resistant to vibrations and enables a gas-tight connection. The Weidmüller PCB connectors with screw connection technology are always delivered "wire ready" with opened clamping points. You do not need to pre-loosen the clamping point. The pre-opened connection saves time and money during installation. It also allows you to establish a safe and proper contact with a test adapter during a functional inspection. There’s no need to connect a wire in order to perform a performance test. The PUSH IN connection is safe and easy to use. It shortens wiring times and thus reduces your costs. A solid wire (or flexible stranded wire with wire-end ferrule) need only be inserted into the contact area and it is ready to go.

Omnimate Power SL/BL 7.62 IT MF for the 16-kVA power class

The SL/BL product line offers the smallest PCB connector available for IT mains systems. The female headers are designed in 7.62-mm pitch. They have the following technical specifications: voltage 400 V (IEC) / 600V (UL), current 29 A (IEC) / 20 A (UL). The male headers are available in 90° or 180° variants. The female headers are available as 180° variants. Wires sizes ranging from 0.08 to 4.00 mm2 (IEC) / AWG 28 to 12 (UL) can be safely connected to the female header.

Omnimate Power SV/BV 7.62 IT MF for the 28-kVA power class

The SV/BV 7.62 IT MF product line in 7.62-mm pitch is designed for IT mains systems. The male headers are available in 90°, 180° and 270° versions. The BVZ female header is available in the 180° version. Technical specifications: voltage 1000 V (IEC) / 300 V (UL), current 41 A (IEC) / 35 A (UL). Wires sizes ranging from 0.2 to 6.0 mm2 (IEC) / AWG 28 to 10 (UL) can be safely connected to the clamping yoke (screw) connection on the female header.

Omnimate Power SU/BU 7.62 IT MF for the 52-kVA power class

The SU/BU 10.16 IT MF product line in designed for IT mains systems and is available in 10.16-mm PCB pitch. The male headers are available in 90°, 180° and 270° versions. The female header is available in the 180° version. Technical specifications: voltage 1000 V (IEC) / 300 V (UL), current 76 A (IEC) / 54 A (UL). The pin tips on the male headers are insulated. The mating profile ensures (even without a plugged-in female header) that more than 1 mm of touch safety is present with a finger pressure of 20 N. Wires sizes ranging from 0.2 to 16.0 mm2 (IEC) / AWG 28 to 6 (UL) can be safely connected to the clamping yoke (screw) connection on the female header. An extension to AWG 4 is pending.

The insulation material

The three product lines designed for IT mains systems (the SL/BL 7.62 IT MF, SV/BVZ 7.62 IT MF and SU/BUZ 10.16 IT MF) are manufactured with PBT (thermoplastic polyester), PBT GF (glass-fibre reinforced thermoplastic polyester) or PA GF (glass-fibre reinforced polyamide) insulating material. In each case, the flammability class is UL 94 V-0.

Software Galaxy

Engineers and developers can take advantage of Software Galaxywww.galaxy.weidmueller.com – to custom design their own Omnimate Power connectors: including colour coding, application-oriented labelling and specialized modifications or design.




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