picomax Connectors A Small Revolution Cost-Effective Universal Simple picomax The Connection System Compact Shock-Proof Vibration-Proof

Transcription

1 picomax Connectors A Small Revolution Cost-Effective Simple Universal picomax The Connection System Compact Shock-Proof Vibration-Proof

2 The Revolution has Begun WAGO engineers set out to challenge established technologies. Innovation and determination have enabled them to change wiring with a radically new electrical connection design: picomax and picomax ecom Connectors This catalog introduces the picomax families and their ability to streamline plug-in modules. picomax will lower project costs, reduce labor and provide greater reliability via CAGE CLAMP S and a WAGO-exclusive, ultra-compact design that optimizes vibration-resistance. picomax, creating big change from a small connector.

3 CONTENTS picomax Pin Spacing: 3.5 mm/0.138 in; 5.0 mm/0.197 in; 7.5 mm/0.295 in Versatile Connectors for a Wide Range of Applications 3.5 Female Connectors with Conductor Terminations Male Headers with Solder Pins Male Connectors with Conductor Terminations Female Headers with Solder Pins Panel Feedthrough Male Connectors Female Connectors with Conductor Terminations Male Headers with Solder Pins Male Connectors with Conductor Terminations Female Headers with Solder Pins Panel Feedthrough Male Connectors Female Connectors with Conductor Terminations Male Headers with Solder Pins Male Connectors with Conductor Terminations Female Headers with Solder Pins picomax 7.5 ecom The Easiest Way to Make PCBs Pluggable 3.5 Pluggable Connectors with Conductor Terminations, for Direct Soldering to PCB 5.0 Pluggable Connectors with Conductor Terminations, for Direct Soldering to PCB 7.5 Pluggable Connectors with Conductor Terminations, for Direct Soldering to PCB

4 2 picomax A connector system in a class of its own Female Connectors with CAGE CLAMP S Termination for All Conductor Types Standard female connector design consists of a clamping spring (e.g., CAGE CLAMP ) on the conductor entry side. A two-leg, spring-loaded socket connects to the header pin on the other side. This design requires contact material made of high-strength copper alloy, which is substantially less conductive than copper. Increasing the contact cross-section compensates for lower conductivity, but also reduces socket contact elasticity. Thus, longer sockets are needed to maintain elasticity, requiring more space for standard female connectors. The revolutionary approach taken by picomax uses the contact force of a single stainless steel spring to clamp the conductor and connect the header pin. Unlike copper-alloy sockets, the contact force of stainless steel remains constant - even in higher temperatures. The new, extremely short contact bridge essentially floats toward the contact force, separating the termination unit from the header pin. The picomax socket design yields extremely short female connector and current path, creating a new generation of headers with industry-leading features. Headers with Locking Latches

5 Connectors radically simplified Push-button Locking latches Test port Electrolytic copper (E-Cu), tin-plated contact bridge High-alloy, stainless steel (CrNi) clamping spring Locking latch Original size 3.5 mm pin spacing Straight or angled E-Cu, tin-plated solder pins for both wave and THR soldering Protected by patent No. EP A2

6 4 picomax A connector system in a class of its own The majority of the female connector inserts into the male header s housing, and automatically locks with one firm push. The clamping point of the terminated conductor and the contact point of the inserted header pin are on opposing sides of the contact bridge. This configuration optimizes mass distribution, making it ideal for vibration-prone applications. Essentially, the contact force between conductor, bridge and contact pin automatically adjusts to the conductor size and mass according to the spring characteristic, ensuring a robust connection is always made. This allows picomax connectors to achieve high contact reliability when subjected to vibrations of up to 16 g according to IEC The protruding locking latch of the male header interlocks with the locking latches of the female connector, for secure connection. Designed for safety, releasing the orange latches takes deliberate effort via screwdriver or fingernail. Extremely short current path from conductor to contact pin minimizes voltage drop. Dynamic contact force on both the conductor and contact pin automatically adjusts to the conductor cross section. E-Cu, tin-plated contact bridge E-Cu, tin-plated contact pin Straight or angled, E-Cu, tin-plated solder pins for both wave and THR soldering. Pin spacing: 3.5 mm, 5 mm and 7.5 mm

7 Perfection down to the last detail Male Header with Mated Female Connector The female connector is fully shrouded by the male header s housing. This significantly reduces the overall height of the component. Test port for 1 mm test pin High-alloy, stainless steel (CrNi) clamping spring Insulating material: Male headers and female connectors are made of a durable, high-performance and high-temperature resistant, glass fiber-reinforced PPA; in light gray or in black for THR soldering. Protected by patent No. EP A2

8 6 picomax Application examples Touch-Proof PCB Output Touch-proof female header on the PCB Locking latch with release lever Male connector with CAGE CLAMP S Wire-to-Wire Flying Lead Locking latch with release lever Optional gripping plate Male connector with CAGE CLAMP S Female connector with CAGE CLAMP S

9 Wire-to-Board Panel Feedthrough Panel feedthrough male connector with fixing flanges Female connector with CAGE CLAMP S Touch-protected PCB output Wire-to-Wire Panel Feedthrough Female connector with CAGE CLAMP S Female connector with CAGE CLAMP S Panel feedthrough male connector with fixing flanges

10 Handling picomax Pin Spacing 3.5 mm, 5 mm and 7.5 mm 8 Inserting fine-stranded conductor into unmated female connector via push-button. Inserting fine-stranded conductor into mated female connector via push-button. Inserting solid and ferruled conductors via push-in termination. Male connector with snap-in mounting feet on mounting adapter for DIN 35 rail. Male and female headers with solder pins for THR soldering ("Through-Hole Reflow"). Easy-to-identify PCB inputs and outputs. Flying leads. Male connectors with snap-in mounting feet for panel mounting. CAGE CLAMP S clamps the following copper conductors: solid stranded fine-stranded, also with tinned single strands

11 ! > > 1 1 Disconnection via screwdriver: 1 Release orange locking latch via screwdriver. 2 Pull up to disconnect the connector. Disconnection via finger tip. 1 Release orange locking latch with your finger. 2 Pull up to disconnect the connector. Coding a female connector (coding key carrier with two keys for male header and two keys for female connector). Coding a male header (coding key carrier with two keys for male header and two keys for female connector). Pole marking via direct printing upon request. Male connector for panel feedthrough application. Optional gripping plate for factory or in-the-field assembly. fine-stranded, tip-bonded fine-stranded, with crimped ferrule (gas-tight)

12 10 Female Connectors with Conductor Terminations picomax 3.5 Universal connection of all conductor types Simple, push-in termination of solid and ferruled conductors Easy-to-use design does not require specialty tools Ability to wire while mated or unmated Testing parallel to conductor entry tip contact Also available with gripping plates Integrated locking latches prevent accidental disconnection Technical data: Pin Spacing 3.5 mm in Rating per IEC/EN Overvoltage category III III II Pollution degree Rated voltage 160 V 160 V 320 V Rated surge voltage 2.5 kv 2.5 kv 2.5 kv Nominal current 10 A 10 A 10 A Approvals per UL/CSA* Use group UL 1059 B C D Rated voltage Nominal current UL Nominal current CSA Conductor data: Connection technology CAGE CLAMP S Conductor size: solid mm 2 Conductor size: fine-stranded mm 2 Conductor size: fine-stranded mm 2 (with insulated ferrule) Conductor size: fine-stranded mm 2 (with uninsulated ferrule) AWG : THHN, THWN Strip length 8 9 mm / in Material data: Material group I Insulating material Glass fiber-reinforced polyphthalamide (PPA-GF) Temperature stability 60 C to +85 C Flammability rating per UL 94 V0 Clamping spring material Chrome nickel spring steel (CrNi) Contact material Electrolytic copper (E Cu ) Contact plating tin-plated Accessories for picomax : Page: Operating tools 54 Gripping plates 55 Coding pins 55 Test pin 54 picomax connectors are designed without breaking capacity for compliance with DIN EN When used as intended, these connectors shall not be connected/disconnected when live or under load. The circuit design should ensure male header pins, which can be touched, are not live in unmated condition. Approvals are available online at: *UL/CSA approval pending

13 Female Connectors with Conductor Terminations picomax 3.5! Pin spacing 3.5 mm / in With gripping plate Pin spacing 3.5 mm / in mm 2 AWG mm 2 AWG V/2.5 kv/2 10 A 300 V DC / 10 A 160 V/2.5 kv/2 10 A 300 V/10 A 3.5 < L < 14 < 13 1,1 > < < L 3,5 1,75 _ < < 9,5 > < 10,3 > 1,1 3,5 1,75 _ < 1,1 < 9,5> < 10,3> > < 1,1 < ØC > > E < A B < D L = (pole no. 1 ) x pin spacing mm Pole No. Item No. Pack. Unit Pole No. Item No. Pack. Unit Female connector, light gray Female connector with gripping plate, light gray Available March 2011 Available March 2011 Gripping plate dimensions (in mm): Pole No. A B C D E For other pole numbers, please contact factory.

14 Male Headers with Solder Pins picomax Male headers may be mounted horizontally or vertically via straight or angled solder pins Assembly of female connectors without loss of poles, allowing different functions to be divided within one header Coding pins inserted into the header interface prevent mismating, allowing subsequent coding in panel feedthrough applications The female connector is fully shrouded by the male header's housing, providing vibration resistance up to 16 g*** Technical data: Pin Spacing 3.5 mm in Rating per IEC/EN Overvoltage category III III II Pollution degree Rated voltage 160 V 160 V 320 V Rated surge voltage 2.5 kv 2.5 kv 2.5 kv Nominal current 10 A 10 A 10 A Approvals per UL/CSA* Use group UL 1059 B C D Rated voltage Nominal current UL Nominal current CSA Solder pin data for THT (wave soldering): Solder pin: length/width Solder pin: drilled hole diameter 3.6 mm / 1.0 mm Ø mm Solder pin data for THR** (reflow soldering): Solder pin: length/width 2.4 mm / 1.0 mm Ø Solder pin: metal-plated hole diameter mm Material data: Material group I Insulating material Glass fiber-reinforced polyphthalamide (PPA-GF) Temperature stability 60 C to +85 C Flammability rating per UL 94 V0 Contact material Electrolytic copper (E Cu ) Contact plating tin-plated Accessories for picomax : Page: Coding pins 55 picomax connectors are designed without breaking capacity for compliance with DIN EN When used as intended, these connectors shall not be connected/disconnected when live or under load. The circuit design should ensure male header pins, which can be touched, are not live in unmated condition. Approvals are available online at: *UL/CSA approval pending **For THR soldering, see page 39 ***Testing based on IEC

15 Male Headers with Solder Pins picomax 3.5 With straight solder pins Pin spacing 3.5 mm / in With angled solder pins Pin spacing 3.5 mm / in V/2.5 kv/2 10 A 300 V/10 A 160 V/2.5 kv/2 10 A 300 V/10 A 3.5 > A < 17,5 < L 3,5 < 2,75 3,05 _ < 12,4 > < 13,4 > < 15,5 < 16,5 2,75 _ < L 3,5 < < 3,05 > A < 13,4 > < 15,5 < 17,5 < 12,4 > 0,8 12,6min 14,7max < 16,5 L = (pole no. 1 ) x pin spacing mm A = 3.6 mm THT solder pin A = 2.4 mm THR solder pin THR male headers with solder pins in tape-and-reel packaging available upon request Pole No. Item No. Pack. Unit Pole No. Item No. Pack. Unit Male header with straight solder pins, light gray Male header with angled solder pins, light gray Available March 2011 Available March 2011 Item no. suffix for colored THR version: black / Ordering example: THR male header with straight solder pins, 3.5 mm pin spacing, 8-pole, black: / For other pole numbers, please contact factory.

16 Male Headers with Solder Pins and Fixing Flanges picomax With straight solder pins and fixing flanges Pin spacing 3.5 mm / in With angled solder pins and fixing flanges Pin spacing 3.5 mm / in 160 V/2.5 kv/2 10 A 300 V/10 A 160 V/2.5 kv/2 10 A 300 V/10 A 2,6 > < 3,8 2,6 > < 3,5 < < L 1 < L _ 6 < < < L 3,5 2,75 _ < L 2 2,1 6 > 7 > < < < 12,4 > > A < 17,5 > <_ 3 < 13,4 > <_ 15,5 _> <_ 16,5 _> > < < 2,6 > < 2,6 2,1 < > 3,5 _ 2,75 < 3,5 < L 2 > < 3,8 < L 1 < > 7 < ( 12,4 ) _> A 6 > <_ ( 13,4 ) < 15,5 > < 17,5 > 0,8 12,6 < 14,7> < 16,5> L = (pole no. x pin spacing) mm L 1 = (pole no. x pin spacing) mm L 2 = (pole no. x pin spacing) mm A = 3.6 mm THT solder pin A = 2.4 mm THR solder pin Pole No. Item No. Pack. Unit Pole No. Item No. Pack. Unit Male header with straight solder pins and fixing flanges, light gray Male header with angled solder pins and fixing flanges, light gray / / / / / / / / Available June 2011 Available June 2011 Item no. suffix for colored THR version: black / Ordering example: THR male header with straight solder pins and fixing flanges, 3.5 mm pin spacing 5-pole, black: / For other pole numbers, please contact factory.

17 15 3.5

18 Male Connectors with Conductor Terminations picomax Universal connection of all conductor types Simple, push-in termination of solid and ferruled conductors Easy-to-use design does not require specialty tools Testing parallel to conductor entry tip contact For wire-to-wire and board-to-wire connections Integrated release lever Also available with gripping plates Technical data: Pin Spacing 3.5 mm in Rating per IEC/EN Overvoltage category III III II Pollution degree Rated voltage 160 V 160 V 320 V Rated surge voltage 2.5 kv 2.5 kv 2.5 kv Nominal current 10 A 10 A 10 A Approvals per UL/CSA* Use group UL 1059 B C D Rated voltage Nominal current UL Nominal current CSA Conductor data: Connection technology CAGE CLAMP S Conductor size: solid mm 2 Conductor size: fine-stranded mm 2 Conductor size: fine-stranded mm 2 (with insulated ferrule) Conductor size: fine-stranded mm 2 (with uninsulated ferrule) AWG : THHN, THWN Strip length 8 9 mm / in Material data: Material group I Insulating material Glass fiber-reinforced polyphthalamide (PPA-GF) Temperature stability 60 C to +85 C Flammability rating per UL 94 V0 Clamping spring material Chrome nickel spring steel (CrNi) Contact material Electrolytic copper (E Cu ) Contact plating tin-plated Accessories for picomax : Page: Operating tools 54 Gripping plates 55 Coding pins 55 Test pin 54 picomax connectors are designed without breaking capacity for compliance with DIN EN When used as intended, these connectors shall not be connected/disconnected when live or under load. The circuit design should ensure male header pins, which can be touched, are not live in unmated condition. Approvals are available online at: *UL/CSA approval pending

19 Male Connectors with Conductor Terminations picomax 3.5! Pin spacing 3.5 mm / in With gripping plate Pin spacing 3.5 mm / in With snap-in mounting feet Pin spacing 3.5 mm / in mm 2 AWG mm 2 AWG mm 2 AWG V/2.5 kv/2 10 A 160 V/2.5 kv/2 10 A 160 V/2.5 kv/2 10 A 3.5 ( 9 )( R) 3,5 < 2,75 < L 2 ( 11,6 ) < 2,1 < 25,9 < 15,9 > 3,1 < ( 9 )( R ) 3,5 < 2,75 < L > ( 9 )( R) ( 11,6 ) 2 < 3,3 < >4,5< 2,1 > 7 3,5 7 < _ < 2,75 < < 13,5 > < 28 < L < 15,9 > < D _ > ØC < > E < 3,1 < 2 <_ > Ø1,4 < 3,5 > < L = (pole no. 1 ) x pin spacing mm Even pole number R = (L 9 mm) : 2 Odd pole number R = (L 12.5 mm) : 2 Pole No. Item No. Pack. Unit Pole No. Item No. Pack. Unit Pole No. Item No. Pack. Unit Male connector, light gray Male connector with gripping plate, light gray Male connector with snap-in mounting feet, for mm plate thickness light gray / / / / / / / / / / / / Available June 2011 Available June 2011 Available June 2011 Accessories Mounting adapter for DIN 35 rail, min. length 3 poles ( ) Page 54 Gripping plate dimensions (in mm): Pole No. A B C D E Drilled hole pattern for panel mounting Ø3,5 +0,1 < > > < Ø3,5 +0,1 Ø1,5 +0,1 > < > ( 7 )( 7 ) 3,5 < 2 poles 3 or more poles For other pole numbers, please contact factory.

20 Female Headers with Solder Pins picomax Female headers may be mounted horizontally or vertically via straight or angled solder pins Touch-proof PCB outputs Easy-to-identify PCB inputs and outputs Coding via coding pins Black THR version** Technical data: Pin Spacing 3.5 mm in Rating per IEC/EN Overvoltage category III III II Pollution degree Rated voltage 160 V 160 V 320 V Rated surge voltage 2.5 kv 2.5 kv 2.5 kv Nominal current 10 A 10 A 10 A Approvals per UL/CSA* Use group UL 1059 B C D Rated voltage Nominal current UL Nominal current CSA Solder pin data for THT (wave soldering): Solder pin: length/width Solder pin: drilled hole diameter 3.6 mm / 0.4 x 0.9 mm mm Solder pin data for THR** (reflow soldering): Solder pin: length/width 2.4 mm / 0.4 x 0.9 mm Solder pin: metal-plated hole diameter mm Material data: Material group Insulating material Temperature stability Flammability rating per UL 94 Contact material Contact plating I Glass fiber-reinforced polyphthalamide (PPA-GF) 60 C to +85 C V0 Copper alloy tin-plated Accessories for picomax : Page: Coding pins 55 picomax connectors are designed without breaking capacity for compliance with DIN EN When used as intended, these connectors shall not be connected/disconnected when live or under load. The circuit design should ensure male header pins, which can be touched, are not live in unmated condition. Approvals are available online at: *UL/CSA approval pending **For THR soldering, see page 39

21 Female Headers with Solder Pins picomax 3.5 With straight solder pins Pin spacing 3.5 mm / in With angled solder pins Pin spacing 3.5 mm / in V/2.5 kv/2 10 A 160 V/2.5 kv/2 10 A 3.5 > A <_ 13 _> < L 3,5 < 1,75 <10,5> 0,4 1,1 > < < 6 > < 1,75 < L < 3,5 A ( 10,5 ) <_ 13 _> > < 13,6 > 1,1 < 2,8 10,2 ( ) < 28 L = pole no. x pin spacing A = 3.6 mm THT solder pin A = 2.4 mm THR solder pin Pole No. Item No. Pack. Unit Pole No. Item No. Pack. Unit Female header with straight solder pins, light gray Female header with angled solder pins, light gray Available June 2011 Available June 2011 Item no. suffix for colored THR version: black / Ordering example: THR female header with straight solder pins, 3.5 mm pin spacing, 8-pole, black: / For other pole numbers, please contact factory.

22 Panel Feedthrough Male Connectors with Fixing Flanges picomax Male connectors for screw mounting in device or enclosure panels External plug-in connection via locking latch to female connectors with conductor terminations Internal plug-in connection to female headers with solder pins or female connectors with conductor terminations Also available with pre-assembled female connectors on both sides Fixing flanges also suitable for panel mounting Technical data: Pin Spacing 3.5 mm in Rating per IEC/EN Overvoltage category III III II Pollution degree Rated voltage 160 V 160 V 320 V Rated surge voltage 2.5 kv 2.5 kv 2.5 kv Nominal current 10 A 10 A 10 A Approvals per UL/CSA* Use group UL 1059 B C D Rated voltage Nominal current UL Nominal current CSA Conductor data: Connection technology CAGE CLAMP S Conductor size: solid mm 2 Conductor size: fine-stranded mm 2 Conductor size: fine-stranded mm 2 (with insulated ferrule) Conductor size: fine-stranded mm 2 (with uninsulated ferrule) AWG : THHN, THWN Strip length 8 9 mm / in Material data: Material group I Insulating material Glass fiber-reinforced polyphthalamide (PPA-GF) Temperature stability 60 C to +85 C Flammability rating per UL 94 V0 Clamping spring material Chrome nickel spring steel (CrNi) Contact material Electrolytic copper (E Cu ) Contact plating tin-plated Accessories for picomax : Page: Operating tools 54 Coding pins 55 Test pin 54 picomax connectors are designed without breaking capacity for compliance with DIN EN When used as intended, these connectors shall not be connected/disconnected when live or under load. The circuit design should ensure male header pins, which can be touched, are not live in unmated condition. Approvals are available online at: *UL/CSA approval pending

23 ! Panel Feedthrough Male Connectors with Fixing Flanges picomax 3.5 With internal and external female connector Pin spacing 3.5 mm / in With external female connector Pin spacing 3.5 mm / in Pin spacing 3.5 mm / in mm2 160 V/2.5 kv/2 10 A 160 V/2.5 kv/2 10 A AWG mm2 160 V/2.5 kv/2 10 A 21 AWG ,8 < < L1 <Ø _2 3,8 <,6 < < < L1 > min 13 2,6 > < 2 < _> <_ 16 _> 3,5 > 7 < < <Ø _2 3,8 <,6 < ( 12,4 ) < L2 min L+0,6 ( 12,4 ) < 27 < 30 < L1 (12,4 ) < L1 > < L 6 < 3,5 2,75 < > 6 < 2,6 > < < < min 13 2,6 > < < L2 2 < _> <_ 16 _> 3,5 > 7 < 2,2 < > < ( <Ø _ 3,8 _ < 2_,6 _ 3,8 < L 6 < 3,5 2,75 min L+0,6 < < 29 < L1 < L1 > > 6 < 2,6 > < < < min 13 < L2 min L+0,6 < 29 6 < 2,6> < 3,8 _ < L _ 6 < 3,5 2,75 _ < 2 _> < 2,6 < 16 > _> < 3,5 > 7 < 2,2 < > < 3.5 L = (pole no. x pin spacing) mm L1 = (pole no. x pin spacing) mm L2 = (pole no. x pin spacing) mm Pole No. Item No. Pack. Unit Panel feedthrough male connector with fixing flanges, light gray / / / / Available June 2011 Wire-to-wire panel feedthrough connection Notice: Male connectors shall not be live when disconnected! For other pole numbers, please contact factory. Pole No. Item No. Pack. Unit Panel feedthrough male connector with fixing flanges and pre-assembled female connector, external, light gray / / / / Available June 2011 Wire-to-board panel feedthrough connection Pole No. Item No. Pack. Unit Panel feedthrough male connector with fixing flanges and pre-assembled female connectors, external and internal, light gray / / / / Available June

24 Female Connectors with Conductor Terminations picomax Universal connection for all conductor types Simple, push-in termination of solid and ferruled conductors Easy-to-use design does not require specialty tools Ability to wire while mated or unmated Testing parallel to conductor entry tip contact Also available with gripping plates Integrated locking latches prevent accidental disconnection Technical data: Pin Spacing 5 mm in Rating per IEC/EN Overvoltage category III III II Pollution degree Rated voltage 250 V 320 V 630 V Rated surge voltage 4 kv 4 kv 4 kv Nominal current 16 A 16 A 16 A Approvals per UL/CSA* Use group UL 1059 B C D Rated voltage Nominal current UL Nominal current CSA Conductor data: Connection technology CAGE CLAMP S Conductor size: solid mm 2 Conductor size: fine-stranded mm 2 Conductor size: fine-stranded mm 2 (with insulated ferrule) Conductor size: fine-stranded mm 2 (with uninsulated ferrule) AWG : THHN, THWN Strip length 9 10 mm / in Material data: Material group I Insulating material Glass fiber-reinforced polyphthalamide (PPA-GF) Temperature stability 60 C to +85 C Flammability rating per UL 94 V0 Clamping spring material Chrome nickel spring steel (CrNi) Contact material Electrolytic copper (E Cu ) Contact plating tin-plated Accessories for picomax : Page: Operating tools 54 Gripping plates 55 Coding pins 55 Test pin 54 picomax connectors are designed without breaking capacity for compliance with DIN EN When used as intended, these connectors shall not be connected/disconnected when live or under load. The circuit design should be such that male header pins, which can be touched, are not live in unmated condition. Approvals are available online at: *UL/CSA approval pending

25 Female Connectors with Conductor Terminations picomax 5.0! Pin spacing 5 mm / in With gripping plate Pin spacing 5 mm / in mm 2 AWG mm 2 AWG V/4 kv/2 16 A 320 V/4 kv/2 16 A < L 5 2,5 _> < < 16,2 <_ 14 _> < 1,4 1,1 < 12,3 > < L < ØC > > 5 _> E < 2,5 < 1,1 < 12,3> < 11,5> > < 1,4 < D 5.0 L = (pole no. 1 ) x pin spacing + 5 mm Pole No. Item No. Pack. Unit Pole No. Item No. Pack. Unit Female connector, light gray Female connector with gripping plate, light gray Available March 2011 Available March 2011 Gripping plate dimensions (in mm): Pole No. A B C D E For other pole numbers, please contact factory.

26 Male Headers with Solder Pins picomax Male headers may be mounted horizontally or vertically via straight or angled solder pins Assembly of female connectors without loss of poles, allowing different functions to be divided within one header Coding pins inserted into the header interface prevent mismating, allowing subsequent coding in panel feedthrough applications The female connector is fully shrouded by the male header's housing, providing vibration resistance up to 16 g*** Technical data: Pin Spacing 5 mm in Rating per IEC/EN Overvoltage category III III II Pollution degree Rated voltage 250 V 320 V 630 V Rated surge voltage 4 kv 4 kv 4 kv Nominal current 16 A 16 A 16 A Approvals per UL/CSA* Use group UL 1059 B C D Rated voltage Nominal current UL Nominal current CSA Solder pin data for THT (wave soldering): Solder pin: length/width Solder pin: drilled hole diameter 3.6 mm / 1.4 mm Ø mm Solder pin data for THR** (reflow soldering): Solder pin: length/width 2.4 mm / 1.4 mm Ø Solder pin: metal-plated hole diameter mm Material data: Material group I Insulating material Glass fiber-reinforced polyphthalamide (PPA-GF) Temperature stability 60 C to +85 C Flammability rating per UL 94 V0 Contact material Electrolytic copper (E Cu ) Contact plating tin-plated Accessories for picomax : Page: Coding pins 55 picomax connectors are designed without breaking capacity for compliance with DIN EN When used as intended, these connectors shall not be connected/disconnected when live or under load. The circuit design should be such that male header pins, which can be touched, are not live in unmated condition. Approvals are available online at: *UL/CSA approval pending **For THR soldering, see page 39 ***Testing based on IEC

27 Male Headers with Solder Pins picomax 5.0 With straight solder pins Pin spacing 5 mm / in With angled solder pins Pin spacing 5 mm / in V/4 kv/2 16 A 320 V/4 kv/2 16 A < L > 5 3,6< > A < 19,5 _ 3,35 _ <_ 14,4 _> <_ 15,4 _> < 17,9 _ < 18,6 _ 3,6 < L <_ 5 < 3,35 <_ 14,4 _> > A <_ 15,4 _> < 17,9 _ 1,2 14,2min < 16,7max > < 18,6 < 19,5 _ 5.0 L = (pole no. 1 ) x pin spacing mm A = 3.6 mm THT solder pin A = 2.4 mm THR solder pin THR male headers with solder pins in tape-and-reel packaging available upon request Pole No. Item No. Pack. Unit Pole No. Item No. Pack. Unit Pole No. Item No. Pack. Unit Male header with straight solder pins, light gray Male header with angled solder pins, light gray Available March 2011 Available March 2011 Item no. suffix for colored THR version: black / Ordering example: THR male header with straight solder pins, 5 mm pin spacing, 8-pole, black: / For other pole numbers, please contact factory.

28 Male Headers with Solder Pins and Fixing Flanges picomax With straight solder pins and fixing flanges Pin spacing 5 mm / in With angled solder pins and fixing flanges Pin spacing 5 mm / in 320 V/4 kv/2 16 A 320 V/4 kv/2 16 A < L 1 > < 2,6 2,1 >3,8< < L 6 < 5 < 3,6 _> < 3,5 < L 2 > 7 > 6 < < 14,4 > 2,6 > < < > A < 19,5 > < 3,4 <_ 13,6 _> < 16,1 < 16,8 < > 3,5 2,1 > < < 2,6 < L 6 < 3,6 <_ 5 < L 2 > < 3,8 < L 1 ( > ( 14,4 < 7 < 2,6 _> A ) > <_ < 15,4 > <_ 17,9 _> <_ 19,5 _> 6 1,2 14,2 < 16,7> <_ 18,6_> L = (pole no. x pin spacing) mm L 1 = (pole no. x pin spacing) + 8 mm L 2 = (pole no. x pin spacing) + 7 mm A = 3.6 mm THT solder pin A = 2.4 mm THR solder pin Pole No. Item No. Pack. Unit Pole No. Item No. Pack. Unit Male header with straight solder pins and fixing flanges, light gray Male header with angled solder pins and fixing flanges, light gray / / / / / / / / Available June 2011 Available June 2011 Item no. suffix for colored THR version: black / Ordering example: THR male header with straight solder pins and fixing flanges, 5 mm pin spacing 5-pole, black: / For other pole numbers, please contact factory.

29 27 5.0

30 Male Connectors with Conductor Terminations picomax Universal connection of all conductor types Simple, push-in termination of solid and ferruled conductors Easy-to-use design does not require specialty tools Testing parallel to conductor entry tip contact For wire-to-wire and board-to-wire connections Integrated release lever Also available with gripping plates Technical data: Pin Spacing 5 mm in Rating per IEC/EN Overvoltage category III III II Pollution degree Rated voltage 250 V 320 V 630 V Rated surge voltage 4 kv 4 kv 4 kv Nominal current 16 A 16 A 16 A Approvals per UL/CSA* Use group UL 1059 B C D Rated voltage Nominal current UL Nominal current CSA Conductor data: Connection technology CAGE CLAMP S Conductor size: solid mm 2 Conductor size: fine-stranded mm 2 Conductor size: fine-stranded mm 2 (with insulated ferrule) Conductor size: fine-stranded mm 2 (with uninsulated ferrule) AWG : THHN, THWN Strip length 9 10 mm / in Material data: Material group I Insulating material Glass fiber-reinforced polyphthalamide (PPA-GF) Temperature stability 60 C to +85 C Flammability rating per UL 94 V0 Clamping spring material Chrome nickel spring steel (CrNi) Contact material Electrolytic copper (E Cu ) Contact plating tin-plated Accessories for picomax : Page: Operating tools 54 Gripping plates 55 Coding pins 55 Test pin 54 picomax connectors are designed without breaking capacity for compliance with DIN EN When used as intended, these connectors shall not be connected/disconnected when live or under load. The circuit design should be such that male header pins, which can be touched, are not live in unmated condition. Approvals are available online at: *UL/CSA approval pending

31 < 3,2 Male Connectors with Conductor Terminations picomax 5.0! Pin spacing 5 mm / in With gripping plate Pin spacing 5 mm / in With snap-in mounting feet Pin spacing 5 mm / in mm 2 AWG mm 2 AWG mm 2 AWG V/4 kv/2 16 A 320 V/4 kv/2 16 A 320 V/4 kv/2 16 A ( 12 )( R ) _> 5 < 3,6 < L 2,1 ( 13,6 ) < 2,5 < 30 < 18,2 > 3,2 < ( 12 )( R ) _> 5 < 3,6 < L > ( 12 )( R ) 15,7 > 2,1 _> < < 3,3 2,5 > 10 5 < 3,6 < < < 15,9 > < L < 32,6 < >4,5 < < 18,2 > 5.0 < D ØC < > > E < L = (pole no. 1 ) x pin spacing mm Even pole number R = (L 12 mm) : 2 Odd pole number R = (L 17 mm) : 2 Pole No. Item No. Pack. Unit Pole No. Item No. Pack. Unit Pole No. Item No. Pack. Unit Male connector, light gray Male connector with gripping plate, light gray Male connector with snap-in mounting feet, for mm plate thickness, light gray / / / / / / / / / / / / / / / Available June 2011 Available June 2011 Available June 2011 Gripping plate dimensions (in mm): Pole No. A B C D E Accessories Mounting adapter for DIN 35 rail, min. length 3 poles ( ) Drilled hole pattern for panel mounting > 5 < Ø3,5 +0,1 < Ø3,5 +0,1 < > 2 poles Page 54 3 or more poles ( 10 )( 10 ) For other pole numbers, please contact factory.

32 Female Headers with Solder Pins picomax Female headers may be mounted horizontally or vertically via straight or angled solder pins Touch-proof PCB outputs Easy-to-identify PCB inputs and outputs Coding via coding pins Black THR version** Technical data: Pin Spacing 5 mm in Rating per IEC/EN Overvoltage category III III II Pollution degree Rated voltage 250 V 320 V 630 V Rated surge voltage 4 kv 4 kv 4 kv Nominal current 16 A 16 A 16 A Approvals per UL/CSA* Use group UL 1059 B C D Rated voltage Nominal current UL Nominal current CSA Solder pin data for THT (wave soldering): Solder pin: length/width Solder pin: drilled hole diameter 3.6 mm / 0.4 x 1.3 mm mm Solder pin data for THR** (reflow soldering): Solder pin: length/width 2.4 mm / 0.4 x 1.3 mm Solder pin: metal-plated hole diameter mm Material data: Material group Insulating material Temperature stability Flammability rating per UL 94 Contact material Contact plating I Glass fiber-reinforced polyphthalamide (PPA-GF) 60 C to +85 C V0 Copper alloy tin-plated Accessories for picomax : Page: Coding pins 55 picomax connectors are designed without breaking capacity for compliance with DIN EN When used as intended, these connectors shall not be connected/disconnected when live or under load. The circuit design should be such that male header pins, which can be touched, are not live in unmated condition. Approvals are available online at: *UL/CSA approval pending **For THR soldering, see page 39

33 Female Headers with Solder Pins picomax 5.0 With straight solder pins Pin spacing 5 mm / in With angled solder pins Pin spacing 5 mm / in V/4 kv/2 16 A 320 V/4 kv/2 16 A < 12,5 > > A <_ 15,4 _> < L > 5 < 2,5 0,4 1,1 > < < 7,3 > < < L 2,5 5 < > A < 12,5 > <_ 15,4 _> <_ 15,7 _> 1,1 < 3,8 11,6 ( ) 5.0 < 32,6 L = pole no. x pin spacing A = 3.6 mm THT solder pin A = 2.4 mm THR solder pin Pole No. Item No. Pack. Unit Pole No. Item No. Pack. Unit Female header with straight solder pins, light gray Female header with angled solder pins, light gray Available June 2011 Available June 2011 Item no. suffix for colored THR version: black / Ordering example: THR female header with straight solder pins, 5 mm pin spacing, 6-pole, black: / For other pole numbers, please contact factory.

34 Panel Feedthrough Male Connectors with Fixing Flanges picomax Male connectors for screw mounting in device or enclosure panels External plug-in connection via locking latch to female connectors with conductor terminations Internal plug-in connection to female headers with solder pins or female connectors with conductor terminations Also available with pre-assembled female connectors on both sides Fixing flanges also suitable for panel mounting Technical data: Pin Spacing 5 mm in Rating per IEC/EN Overvoltage category III III II Pollution degree Rated voltage 250 V 320 V 630 V Rated surge voltage 4 kv 4 kv 4 kv Nominal current 16 A 16 A 16 A Approvals per UL/CSA* Use group UL 1059 B C D Rated voltage Nominal current UL Nominal current CSA Conductor data: Connection technology CAGE CLAMP S Conductor size: solid mm 2 Conductor size: fine-stranded mm 2 Conductor size: fine-stranded mm 2 (with insulated ferrule) Conductor size: fine-stranded mm 2 (with uninsulated ferrule) AWG : THHN, THWN Strip length 9 10 mm / in Material data: Material group I Insulating material Glass fiber-reinforced polyphthalamide (PPA-GF) Temperature stability 60 C to +85 C Flammability rating per UL 94 V0 Clamping spring material Chrome nickel spring steel (CrNi) Contact material Electrolytic copper (E Cu ) Contact plating tin-plated Accessories for picomax : Page: Operating tools 54 Coding pins 55 Test pin 54 picomax connectors are designed without breaking capacity for compliance with DIN EN When used as intended, these connectors shall not be connected/disconnected when live or under load. The circuit design should be such that male header pins, which can be touched, are not live in unmated condition. Approvals are available online at: *UL/CSA approval pending

35 ! Panel Feedthrough Male Connectors with Fixing Flanges picomax 5.0 3,8 < <Ø _2 3,8 <,6 < <_ L1 _> min 15 3,5 > 7 < < <Ø _2 3,8 <,6 < L1 < L2 > min L+0,6 < <14,4> < 33,4 ( 14,4 ) < <14,4> 1,6 < 2,6 < 18 > < 3,8 <_ L1 _> L = (pole no. 1 ) x pin spacing mm L1 = (pole no. x pin spacing) + 8 mm L2 = (pole no. x pin spacing) + 7 mm Pole No. Item No. Pack. Unit Panel feedthrough male connector with fixing flanges, light gray / / / / / Available June 2011 Wire-to-wire panel feedthrough connection Notice: Male connectors shall not be live when disconnected! For other pole numbers, please contact factory. Pole No. Item No. Pack. Unit Panel feedthrough male connector with fixing flanges and pre-assembled female connector, external, light gray / / / / / Available June 2011 Wire-to-board panel feedthrough connection Pole No. Item No. Pack. Unit Panel feedthrough male connector with fixing flanges and pre-assembled female connectors, external and internal, light gray / / / / / Available June AWG < L 6 < 5 3,6 _> < > 6 < 2,6 > < < L mm2 320 V/4 kv/2 16 A > min L+0,6 < < < L 6 < 5 3,6 _> < 1,6 < 2,6 < 18 > < <Ø 3,8 < 2, 6 _ ( min 15 AWG < 33,4 < L1 < L1 > > 6 < 2,6 > < < < < 33,4 6 < 2,6> < 3,8 _ < L2 min L+0,6 1,6 < 2,6 <_ 21 _> _> < 3,5 > 7 < 2,6 < > < 320 V/4 kv/2 16 A 3,5 > 7 < < 2,6 > < mm2 320 V/4 kv/2 16 A min 15 Pin spacing 5 mm / in < L 6 < 5 3,6 < With internal and external female connector Pin spacing 5 mm / in With external female connector Pin spacing 5 mm / in

36 Female Connectors with Conductor Terminations picomax Universal connection for all conductor types Simple, push-in termination of solid and ferruled conductors Easy-to-use design does not require specialty tools Ability to wire while mated or unmated Testing parallel to conductor entry tip contact Also available with gripping plates Integrated locking latches prevent accidental disconnection Technical data: Pin Spacing 7.5 mm in Rating per IEC/EN Overvoltage category III III II Pollution degree Rated voltage 400 V 630 V 1000 V Rated surge voltage 6 kv 6 kv 6 kv Nominal current 16 A 16 A 16 A Approvals per UL/CSA* Use group UL 1059 B C D Rated voltage Nominal current UL Nominal current CSA Conductor data: Connection technology CAGE CLAMP S Conductor size: solid mm 2 Conductor size: fine-stranded mm 2 Conductor size: fine-stranded mm 2 (with insulated ferrule) Conductor size: fine-stranded mm 2 (with uninsulated ferrule) AWG : THHN, THWN Strip length 9 10 mm / in Material data: Material group I Insulating material Glass fiber-reinforced polyphthalamide (PPA-GF) Temperature stability 60 C to +85 C Flammability rating per UL 94 V0 Clamping spring material Chrome nickel spring steel (CrNi) Contact material Electrolytic copper (E Cu ) Contact plating tin-plated Accessories for picomax : Page: Operating tools 54 Gripping plates 55 Coding pins 55 Test pin 54 picomax connectors are designed without breaking capacity for compliance with DIN EN When used as intended, these connectors shall not be connected/disconnected when live or under load. The circuit design should ensure male header pins, which can be touched, are not live in unmated condition. Approvals are available online at: *UL/CSA approval pending

37 Female Connectors with Conductor Terminations picomax 7.5! Pin spacing 7.5 mm / in With gripping plate Pin spacing 7.5 mm / in mm 2 AWG mm 2 AWG V/6 kv/2 16 A 630 V/6 kv/2 16 A < L < 16,2 < 14 1,4 > < < L 7,5 _ 2,5 < L = (pole no. 1 ) x pin spacing + 5 mm 1,1 < 12,3 > < ØC > > 7,5 _ E < 2,5 < 1,1 < 12,3> < 11,5> > < 1,4 < D 7. 5 Pole No. Item No. Pack. Unit Pole No. Item No. Pack. Unit Female connector, light gray Female connector with gripping plate, light gray Available March 2011 Available March 2011 Gripping plate dimensions (in mm): Pole No. A B C D E For other pole numbers, please contact factory.

38 Male Headers with Solder Pins picomax Horizontal or vertical PCB mounting via straight or angled solder pins Assembly of female connectors without loss of poles, allowing different functions to be divided within one male header Coding pins inserted into the header interface prevent mismating, allowing subsequent coding in panel feedthrough applications The female connector is fully shrouded by the male header's housing, providing vibration resistance up to 16 g*** Technical data: Pin Spacing 7.5 mm in Rating per IEC/EN Overvoltage category III III II Pollution degree Rated voltage 400 V 630 V 1000 V Rated surge voltage 6 kv 6 kv 6 kv Nominal current 16 A 16 A 16 A Approvals per UL/CSA* Use group UL 1059 B C D Rated voltage Nominal current UL Nominal current CSA Solder pin data for THT (wave soldering): Solder pin: length/width Solder pin: drilled hole diameter 3.6 mm / 1.4 mm Ø mm Solder pin data for THR** (reflow soldering): Solder pin: length/width 2.4 mm / 1.4 mm Ø Solder pin: metal-plated hole diameter mm Material data: Material group I Insulating material Glass fiber-reinforced polyphthalamide (PPA-GF) Temperature stability 60 C to +85 C Flammability rating per UL 94 V0 Contact material Electrolytic copper (E Cu ) Contact plating tin-plated Accessories for picomax : Page: Coding pins 55 picomax connectors are designed without breaking capacity for compliance with DIN EN When used as intended, these connectors shall not be connected/disconnected when live or under load. The circuit design should ensure male header pins, which can be touched, are not live in unmated condition. Approvals are available online at: *UL/CSA approval pending **For THR soldering, see page 39 ***Testing based on IEC

39 Male Headers with Solder Pins picomax 7.5 With straight solder pins Pin spacing 7.5 mm / in With angled solder pins Pin spacing 7.5 mm / in V/6 kv/2 16 A 630 V/6 kv/2 16 A < L < L > 7,5 3,6< < 3,35 _ > A < 19,5 _ <_ 14,4 _> L = (pole no. 1 ) x pin spacing mm A = 3.6 mm THT solder pin A = 2.4 mm THR solder pin <_ 15,4 _> < 17,9 < 18,6 7,5 >3,6 < < 3,35 <_ 14,4 _> > A <_ 15,4 _> < 17,9 _ 1,2 <_ 14,2_> < 16,7 < 18,65 < 19,5 _ THR male headers with solder pins in tape-and-reel packaging available upon request 7. 5 Pole No. Item No. Pack. Unit Pole No. Item No. Pack. Unit Male header with straight solder pins, light gray Male header with angled solder pins, light gray Available March 2011 Available March 2011 Item no. suffix for colored THR version: black / Ordering example: THR male header with straight solder pins, 7.5 mm pin spacing, 5-pole, black: / For other pole numbers, please contact factory.

40 Male Headers with Solder Pins and Fixing Flanges picomax With straight solder pins and fixing flanges Pin spacing 7.5 mm / in With angled solder pins and fixing flanges Pin spacing 7.5 mm / in 630 V/6 kv/2 16 A 630 V/6 kv/2 16 A < 3,5 < L 1 < L 6 < _> 7,5 3,6< < L 2 > < 2,6 > 6 < 2,1 > A < 19,5 > 2,6 < < > 7 14,4 > < > < 3,4 <_ 13,6 _> < 16,1 < 16,8 < > 3,5 2,1 > < < 2,6 < L 6 < 3,6 < 7,5 < L 2 > < 3,8 < L 1 < > 7 < ( 14,4 ) _> A <_ 6 > < 15,4 > <_ 17,9 _> 1,2 < 14,2> < 16,7> <_ 19,5 _> <_ 18,6_> L = (pole no. 1) x pin spacing) mm L 1 = (pole no. x pin spacing) mm L 2 = (pole no. x pin spacing) mm A = 3.6 mm THT solder pin A = 2.4 mm THR solder pin Pole No. Item No. Pack. Unit Pole No. Item No. Pack. Unit Male header with straight solder pins and fixing flanges, light gray Male header with angled solder pins and fixing flanges, light gray / / / / / / / / Available June 2011 Available June 2011 Item no. suffix for colored THR version: black / Ordering example: THR male header with straight solder pins and fixing flanges, 7.5 mm pin spacing 5-pole, black: / For other pole numbers, please contact factory.

41 THR (Through-Hole Reflow) Soldering Process 39 By using high-temperature-resistant plastic and a streamlined pin design, the WAGO Through-Hole Reflow headers and PCB terminal blocks meet requirements for SMT process capability while maintaining the necessary stability. Male headers and THR PCB terminal blocks are simply pushed into the solder paste-filled PCB holes and then soldered along with the SMT components via reflow soldering. This eliminates wave soldering. The result is a perfect connection both mechanically and electrically. picomax THR male headers in tape-and-reel packaging acc. to IEC upon request ( d i ) < H < d S D S > < > < d A _ Metal-plated PCB bore hole SMD positioning pattern Application of solder paste < 7. 5 Component assembly, automatic/by hand Reflow soldering process THR soldering joint Series d i (mm) d A (mm) H(mm) d s (mm) D s (μm) d(mm) L(mm) ,1 1.9 < Ø ,1 1.9 < x ,1 2.3 < Ø ,1 2.2 < x WAGO recommends both a temperature profile that adheres to EN and the use of forced convection ovens for processing THR components. < d _ d i : Inner diameter of metal-plated PCB bore hole d A : Outer diameter of metal-plated PCB hole* H: PCB thickness d s : Pattern hole diameter D s : Pattern thickness d: Pin cross section L: Pin length * When laying out the metal-plated bore holes, the clearance and creepage distance requirements as specified in the equipment standards must be considered.

42 Male Connectors with Conductor Terminations picomax Universal connection for all conductor types Simple, push-in termination of solid and ferruled conductors Easy-to-use design does not require specialty tools Testing parallel to conductor entry tip contact For wire-to-wire and board-to-wire connections Integrated release lever Also available with gripping plates Technical data: Pin Spacing 7.5 mm in Rating per IEC/EN Overvoltage category III III II Pollution degree Rated voltage 400 V 630 V 1000 V Rated surge voltage 6 kv 6 kv 6 kv Nominal current 16 A 16 A 16 A Approvals per UL/CSA* Use group UL 1059 B C D Rated voltage Nominal current UL Nominal current CSA Conductor data: Connection technology CAGE CLAMP S Conductor size: solid mm 2 Conductor size: fine-stranded mm 2 Conductor size: fine-stranded mm 2 (with insulated ferrule) Conductor size: fine-stranded mm 2 (with uninsulated ferrule) AWG : THHN, THWN Strip length 9 10 mm / in Material data: Material group I Insulating material Glass fiber-reinforced polyphthalamide (PPA-GF) Temperature stability 60 C to +85 C Flammability rating per UL 94 V0 Clamping spring material Chrome nickel spring steel (CrNi) Contact material Electrolytic copper (E Cu ) Contact plating tin-plated Accessories for picomax : Page: Operating tools 54 Gripping plates 55 Coding pins 55 Test pin 54 picomax connectors are designed without breaking capacity for compliance with DIN EN When used as intended, these connectors shall not be connected/disconnected when live or under load. The circuit design should ensure male connector pins, which can be touched, are not live in unmated condition. Approvals are available online at: *UL/CSA approval pending