PowerPlus Torque + Original POWER ELEMENT Intelligent Systems 400A reliable established low weight maximum torque PowerPlus high current terminal blocks and spacers are made of a brass base body and a stainless steel screw/nut element offering very low weight and a maximum torque. The special design of the base body allows a double-sided assembling on the same position. Depending on the pin arrangement and the layout, currents of up to 400 ampere are possible. That is the reason why Power Elements perfectly qualify as connecting elements for fuses and cables to the circuit board or as mounting elements whenever a high torque is required. Various lengths of threaded pins are available. Application Possibilities Board-to-board Wire-to-board screw connection of ring terminals Retainers / fastenings, fuses For mounting with high torques Technical Data Current carrying capacity per pin at 20 °C Current carrying capacity per pin at 85 °C see table on the back see table on the back Material base body: CuZn37 screw / nut: stainless steel V2A Surfaces base body: tin-plated (standard) screw / nut: w / o Dimensions Length x width Height Height above PCB Pin length Pin diagonal from 9,22 x 9,22 to 22,44 x 22,44 mm from 21,5 to 45,8 mm from 16,5 to 40,8 mm 5 mm from 1,60 to 2,45 mm Processing Würth Elektronik PowerPlus Power Elements are pressed in into the circuit board. Soldering is not necessary. Therefore, the PCBs are not exposed to temperature stress. This processing step easily blends in to the processing chain and is highly cost efficient. With the aid of the corresponding Press Fit tools, several Power Elements can be pressed in simultaneously. For assembling prototypes, no special equipment is needed for pressing in, a simple toggle press is sufficient The circuit board needs support during the pressing procedure The pressing force must be executed in a 90° angle to the circuit board After the pressing process the pins should stand out of the drillhole (approx. 0.2 – 0.5 mm) Plated through holes of the circuit board must be executed according to our indications Only for use with adequate pressing tools In case of double-sided use, the smallest Power Element must be pressed in first www.we-online.com/pe Circuit Board Base material PCB thickness Drilling diameter Final diameter HAL surface chemical surface Copper in hole thickness FR4 (EP-GC-) from 1,5 mm see table on the back see table on the back see table on the back min. 25 µm, max. 80 µm Processing Parameters Press-in force min. 40 N per Pin max. 250 N per Pin Retention force Press-in speed 60 - 80% of the press-in force 100 - 250 mm/min Compliant PowerPlus Torque + Circuit Board Design For the massive Press Fit Technology the PCBs are to be finished according to the Würth Elektronik ICS Press Fit specifications (see table below). Particular attention should be paid to the drill diameter and the copper thickness. Due to the different layer thicknesses of Hot Air Levelling compared to chemical surfaces, the final diameters vary. Würth Elektronik ICS – Press Fit Specification 5.1 Drill Ø see table below Cu-H Cu A End Ø The torques indicated in the table are based on DIN 267 part 25. Different material combinations or different thread lengths of the connectors are not regarded here. Current Carrying Capacity The current carrying capacity of a Press Fit connection needs to be seen in the context of the overall system. The Press Fit zone has a very low electrical contact resistance of 100 – 200 µOhm. The limiting factor therefore usually lies in the circuit board layout or in the connection of a feed line. Reference values for a pre-dimensioning can be found in the table below. min. 25 µm, max. 80 µm min. 125 µm depends on surface HAL chem. surfaces see table below Torques for Stainless Steel Thread M4 M5 M6 M8 M 10 M 12 (Nm) 1.8 3.9 5.9 16 31 42 Derating Curve current A Torques Cu - in Hole Annular Ring 200 180 160 140 120 100 80 60 40 20 0 Measured Derating Curve PowerPlus current values 30 % reduced trend line 60 65 70 75 80 85 90 95 100 105 110 115 120 125 ambient temperature °C example: 2-layer 105µm final copper Overview of Standard Products Bolt Part-No. Bush Part-No. Current carrying capacity at 20 °C Current carrying capacity at 85 °C Drill Ø (in mm) End Ø (in mm) HAL End Ø (in mm) chemical Pins circumferential number / grid M4 93512 93511 ~ 180 A ~ 120 A 1.60 +/- 0.025 1.45 +/- 0.05 1.475 +/- 0.05 12 / 2.60 M5 93514 93513 ~ 192 A ~ 132 A 1.90 +/- 0.025 1.75 +/- 0.05 1.775 +/- 0.05 12 / 3.00 M6 93516 93515 ~ 272 A ~ 192 A 1.90 +/- 0.025 1.75 +/- 0.05 1.775 +/- 0.05 16 / 2.80 M8 93518 93517 ~ 360 A ~ 260 A 2.00 +/- 0.025 1.85 +/- 0.05 1.875 +/- 0.05 20 / 2.84 M10 93520 93519 ~ 380 A ~ 280 A 2.30 +/- 0.025 2.15 +/- 0.05 2.175 +/- 0.05 20 / 3.70 M12 93522 93521 ~ 400 A ~ 300 A 2.45 +/- 0.025 2.30 +/- 0.05 2.325 +/- 0.05 20 / 4.10 Supplies Under the product category PowerCover, we offer a large choice of twist and contact protection elements. Press Fit tools and die plates for the prototype assembling with small Press Fit systems and also for serial production with automats, are available on demand. www.we-online.com/pe For more information visit us at: www.we-online.com/pe or call our Hotline: +49 7941 9205-4444