DIN 41612 IEC 60603-2 Connectors

Types & Selection Guide

DIN 41612 connectors are primarily divided into signal and power series to meet different application requirements. The table below summarizes the most common types and their key specifications:

Key Technical Details

• Performance Levels: Connectors are available in different performance grades (e.g., Levels 1, 2, and 3 per IEC 60603-2). Higher grades require more stringent material and testing standards and offer greater durability. For example, a Level 3 connector typically guarantees at least 500 mating cycles, while a Level 1 product may be rated for 50 cycles.

• Termination Methods: Various PCB attachment methods are available, including wave soldering, press-fit (e.g., ACTION PIN – solderless), and wire wrapping.

• Coding / Keying: Connectors feature polarization mechanisms, such as coding keys or side coding, to prevent incorrect insertion of different functional boards. This is critical in complex rack systems.

Typical Applications

Thanks to its high reliability and rugged construction, the DIN 41612 connector is widely used across multiple industries:

• Industrial Automation: Backplane and module connections in manufacturing machinery and factory control systems.

• Railway & Transportation: High-speed trains, passenger information systems, and other environments with stringent vibration and reliability requirements.

• Telecommunications & Data Communications: Base stations, servers, data storage equipment, and switching systems.

• Medical & Measurement Equipment: Diagnostic, analytical, and testing instruments.

FAQ:

I. Standards & Basic Concepts

Q1: What is a DIN 41612 connector?

A1: DIN 41612 is a standardized rectangular electrical connector widely used in rack-based electronic systems for connecting daughterboards to backplanes. It is also known as the Eurocard Connector and is commonly found in bus systems such as VMEbus, NuBus, STEbus, and Multibus II.

Q2: Is the DIN 41612 standard still valid?

A2: The DIN 41612 standard has been superseded by the international standard IEC 60603-2 and the European standard EN 60603-2. However, the name "DIN 41612" remains widely used within the industry.

Q3: What is the difference between "normal" and "reversed" connectors?

A3: In a daughtercard/backplane configuration:

• Normal: The male connector is mounted with right-angle pins on the PCB, while the female connector uses straight pins.

• Reversed: The male connector uses straight pins, while the female connector uses right-angle pins.

Reversed connectors use the same pin numbering scheme as normal types, but the row and pin sequences are mirrored – male pin a1 connects to female socket a32 (rather than a1).

II. Mechanical & Electrical Specifications

Q4: How many pin configurations are available for DIN 41612 connectors?

A4: Connectors can have 1, 2, or 3 rows of contacts (labeled rows a, b, and c), with 16 or 32 columns per row, offering configurations with 16, 32, 48, 64, or 96 contacts. Two-row connectors typically use rows a+b or a+c combinations. Some manufacturers also offer configurations beyond the standard definition (e.g., R120 type).

Q5: What are the contact pitch and current ratings?

A5: Standard signal connectors use a 2.54mm (0.1 inch) contact pitch, with a typical current rating of 2A per contact. Power connectors feature a larger pitch (5.08mm) and can handle higher currents (e.g., D/E/F/G types up to 5.6A, H type up to 15A). It is important to note that current ratings decrease with increasing ambient temperature – for example, a 5.6A-rated connector may drop to approximately 2.5A at +100°C.

Q6: What are the operating voltage and test voltage ratings?

A6: The typical operating voltage is 500V. Test voltage (50Hz, 1 minute) varies by type. For B/C types, the test voltage between contacts is 1000V, and between contacts and ground is 1550V. Other types (e.g., power types) have higher test voltages, up to 3100V.

Q7: What are the typical contact resistance and insulation resistance values?

A7: Contact resistance is typically less than 20mΩ, and insulation resistance is greater than 10³MΩ.

III. Performance Levels & Reliability

Q8: What do performance levels mean?

A8: The standard defines three performance levels corresponding to different testing requirements and durability:

Note that some suppliers may use slightly different labeling (e.g., Level II rated for 500 cycles). Always refer to the specific product datasheet for exact specifications.

Q9: What are the insertion and withdrawal forces?

A9: Insertion/withdrawal forces depend on the pin count. Typical values for fully assembled connectors:

• 64-pin connector: Insertion force < 60N

• 96-pin connector: Insertion force < 90N

• VME 160-pin connector: Insertion force < 160N

The individual contact separation force (test value) should be greater than 0.15N.

IV. Termination Methods & Processing

Q10: What termination methods are available for DIN 41612 connectors?

A10: The main termination methods include:

• Wave Soldering: Traditional through-hole soldering process.

• Reflow Soldering (THTR – Through-Hole Reflow): Connectors made with high-temperature materials that can withstand 260°C reflow soldering temperatures. This allows them to be processed alongside SMD components in a reflow oven, eliminating the need for a separate wave soldering step.

• Press-fit: Solderless termination using compliant press-fit pins that are pressed into plated through-holes, avoiding thermal stress.

• Wire Wrapping: Suitable for cable terminations.

Q11: What are the PCB hole diameter requirements for press-fit termination?

A11: According to IEC 60352-5:

• Standard signal pins (B/C/D/R types): Nominal hole diameter 1.0mm, finished hole 1.0 +0.08/-0.00mm

• High-current pins (D/E/F/G types): Nominal hole diameter 1.6mm, finished hole 1.6 +0.08/-0.00mm

PCB thickness must be at least 1.6mm, with a minimum copper plating thickness of 25μm. The upper operating temperature limit for press-fit connections is typically 85°C; applications exceeding this temperature require specific validation.

V. Selection Guide

Q12: How do I select the right DIN 41612 connector type?

A12: Consider the following factors when selecting:

1. Pin Count Requirements: Choose based on the number of signal and power lines (16/32/48/64/96 pins).

2. Current Carrying Capacity: Signal applications require 2A rating; power applications require 5.6A or 15A ratings.

3. Connector Type:

• B Type: 2 rows, 64 pins

• C Type: 3 rows, 96 pins (most common signal connector)

• D/E/F/G Types: Power connectors

• H Type: 15A high-current

• M Type: Mixed (signal + power/coaxial)

• Q/R Types: High-density or special configurations

4. Termination Method: Choose soldering, press-fit, or THTR based on production process.

5. Environmental Conditions: Operating temperature range, corrosion resistance requirements, etc.

6. Mounting Style: Straight, right-angle, or backplane mounting.

Q13: What is a Type M hybrid connector?

A13: The M-type connector integrates signal contacts and special contacts (power or coaxial) within the same housing, offering flexible hybrid configurations. Examples include:

• 24+8 configuration: 24 signal contacts + 8 special contacts

• 42+6, 60+4, 78+2, and other combinations

M-type connectors are widely used in complex applications requiring simultaneous transmission of signal and power.

Q14: How can incorrect mating be prevented?

A14: DIN 41612 connectors can be keyed to prevent incorrect insertion through:

• Coding Keys: Installed at specific positions on the connector; different board functions use different coding keys.

• Side Coding: Coding marks applied to the side of the connector.

• Polarization Features: Asymmetric housing designs that prevent reverse insertion.

VI. Typical Applications

Q15: Where are DIN 41612 connectors used?

A15: This connector family is widely used in:

• Industrial Automation: PLCs, industrial PCs, equipment backplanes.

• Telecommunications: Base stations, switching systems.

• Computers & Servers: VMEbus, Multibus II, and other bus systems.

• Measurement Instruments: Test equipment, data acquisition systems.

• Railway & Transportation: On-board systems with high reliability requirements.