COOL. CUSTOMIZED. RELIABLE.

COOL.
CUSTOMIZED.
RELIABLE.
BLUEcontactTM Solutions
BLUEcontactTM Solutions
The most reliable Power Connection for automotive electronics.
Engineered and manufactured by ERNI Germany.
The reliability of the central electrical systems,
fuse and powerboards is top priority for utility
vehicles.
That is why ERNI developed BLUEcontact™
technology for the harsh requirements in the
automotive sector: printed circuit boards and its
connections do not thermally overload with high
current. They are also very secure, durable and
robust.
ERNI takes it one step further with BLUEcontact™
Solutions: we offer you the entire workflow from
project management, customer specific secure
electronic development to series production in
Germany.
Stay cool and benefit from our decades of experience – Please feel free to get to know us at
www.erni.com
— BLUEcontactTM Solutions
COOL.
CUSTOMIZED.
RELIABLE.
Example central electrical system
ERNI provides widespread services and key components for utility vehicles.
Development services and compact, reliable components for central electrical
systems, security systems and power supply.
Based on their extensive expertise in the field of connectors and board-design, ERNI is expanding their services and
the portfolio on key components for automotive customers. The
company is focussing on the areas driver’s cab, exter-ior and
motor periphery of buses, construction equipment, trucks, tractors or towing vehicles, etc. ERNI offers its wide-spread expertise in pressfit systems, in pcb assembly and as an EMS service
provider to ensure secure connection also at high currents.
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Experienced and highly qualified electronic designers have already successfully implemented numerous projects. The service
portfolio offered under the slogan BLUEcontact™ Solutions
comprises of the entire project management from the initial
sample all the way to the final product, the unbundling of pcb’s,
development and supply of mechanical components as well as
the pcb assembly integration. Serial production occurs at ERNI
Germany and includes assembly, soldering, pressfit and pcb assembly as well as pcb integration into its corresponding housing.
More security with flexible pressfit system
In working closely with the customer in making the optimised
BLUEcontact™ Solutions available, the main issues raised have
already been clarified: How much space is allocated for the device? Is the installation limited? Is any housing required? Can devices be located in the passenger cabin or does it need to be
placed in harsh environment? Is there danger of condensation?
How high is shock and vibration stress?
Within the scope of BLUEcontact™ Solutions, ERNI also
provides various power components with combined elastic and
massive pressfit zones. While the massive pressfit zone guarantees torque support and secure fixture, the flexible pressfit zone
provides optimal power transmission. In addition a comprehensive range of fuse bases, relay sockets, as well as pcb connectors for automotive and industrial applications is available with
elastic pressfit zones. The company utilises its across-the-board
internal tailor made tool designs and manufacturing resources for
this in-house development. These robust components are characterized by a modular construction, high number of contact
points and reliable pressfit contacts.
The soft pressfit prevents damage to the pcb thanks to the
elastic pressfit zone. Moreover, a shock and vibration free
connection with higher current is achieved. ERNI provides
the use of modern components in superior quality with
numerous processing advantages:
no tearing of the circuit paths caused by the “jet effect”
during pressfit
minimal swarf formation during pressfit
less danger of delamination and therefore undesired
shorts due to moisture trapped in the pcb
greater reliability during temperature change and vibration
improved process safety of the press in/out process
greater hole tolerance with lower cost for the pcb
improved pressfit force adjustment application
less pressfit force for high number of poles,
less stress on the pcb
general stress minimisation of pcb
Extract from the performance portfolio
BLUEcontactTM components
PowerElements
Connectors
Relay Sockets
Fuse Sockets
Customer Specific
Connectors
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BLUEcontactTM Central electrics
The new generation electronic central unit for commercial vehicles is tougher, securer and
more powerful. BLUEcontact™ incorporates the advantages of ERNI Electronics flexible
press fit technology.
Almost all general vehicle functions from A to Z are ­controlled
by central electrics. The advantages of PCB based c
­entral
­electronic units as opposed to cable harnesses pays off ­indeed
- for e
­ xample, the minimisation of cabling and circuit faults,
cost ­efficiency and less space required. This also applies to
the c
­ommercial ­
vehicle segment where secure ­
connection
and ­
simultaneously high c
­urrent is especially important.
BLUEcontact™ S
­
­ olutions d
­ eveloped central electronic units
specifically for the high ­
demands of this segment. Representing a new level of shock and vibration resistance and a
significantly securer ­
­
connection with ­
higher current carrying
capability. In this new generation of central electronics, ERNI
combines ­efficient modular design with flexible pressfit tech-
nology. A ­technical p
­ rinciple with clear advantages compared
to conventional m
­ ethods, beginning with low power loss and
ending with high resistance to thermal and mechanical stress.
Over 30 years of know-how and experience in pressfit
technology backs the high performance of BLUEcontact™
­
central e
­
­lectronics. Upheld by the comprehensive q
­uality
service concept of ERNI Electronics. For you, this means
­
­obtaining ­everything from one source; consultation on selecting
the c
­ orrect interface c
­ onnectors, placement recommendations,
3D ­integration of central electrics in the vehicle, connection of
­remaining cable harness connector and dummy samples, to
central electric series production. This you can expect from the
technological leader of pressfit technology.
Examples of application
Headlamps
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Hydraulic valves
Radios
Hybrid distributers
Air conditioning
systems
BLUEcontactTM Central electrics
Standard module with 16 ATO fuses
Part Number 175261
Technical Data
Operational temperature
-40° C to +85° C
Max. power supply
Max. 80 A at 65° C ambient temperature
Max. 70 A at 80° C ambient temperature
Output
Connector 3 row, 21 pin, JPT/MCP compatible
Input
Power element socket M5, max. torque: 2.2 Nm
(other designs on request)
Recommended cable crosssection
Current I ≤ 15 A: 7.5 A per mm²
for connector
Current I > 15 A: 5 A per mm²
(Note derating of connector)
Dimensions
102 x 60 x 36.8 mm (unequipped)
Characteristics
Suitable for 12 V and 24 V applications
Power supply via M5 power elements up to max. 80 A
16 fuse sockets for ATO fuses up to max. 25 A
Rear connector 21 pin, 3 rows – JPT and MCP compatible
High thermal load
Shock and vibration resistant
Also available with populated board (relays, fuses resp. automatic circuit breakers)
Applications
Power distribution within the automotive segment, such as alternators, control and indication devices, radio,
accessories etc.
Applicable individually or modular
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BLUEcontactTM Central electrics
Standard module with 11 ATO fuses, 1 mini fuse, 1 mini relay
Part Number 175263
Technical Data
Operational temperature
-40° C to +85° C
Max. power supply
Max. 70 A at 65° C ambient temperature
Max. 65 A at 80° C ambient temperature
Output
Connector 3 row, 18 pin, JPT/MCP compatible
Input
Power element socket M5, max. torque: 2.2 Nm
(other designs on request)
Recommended cable crosssection
Current I ≤ 15 A: 7.5 A per mm²
for connector
Current I > 15 A: 5 A per mm²
(Note derating of connector)
Dimensions
102 x 60 x 36.8 mm (unequipped)
Characteristics
Suitable for 12 V and 24 V applications
Power supply via M5 power elements up to max. 100 A
10 fuse sockets for ATO fuses up to max. 25 A
1 additional socket for ATO fuse up to max. 30 A for relay protection
1 fuse socket for mini fuse up to max. 7.5 A
1 mini relay socket 5 pin
Rear connector 18 pin, 3 rows – JPT and MCP compatible
High thermal load
Shock and vibration resistant
Also available with populated board (relays, fuses resp. automatic circuit breakers supressor diodes)
Applications
Power distribution within the automotive segment, such as alternators, control and indication devices, radio, a
­ ccessories etc.­
Applicable individually or modular
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BLUEcontactTM Central electrics
Standard module with 9 ATO fuses, 2 mini relays
Part Number 175259
Technical Data
Operational temperature
-40° C to +85° C
Max. power supply
Max. 70 A at 65° C ambient temperature
Max. 65 A at 80° C ambient temperature
Output
Connector 3 row, 18 pin, JPT/MCP compatible
Input
Power element socket M5, max. torque: 2.2 Nm
(other designs on request)
Recommended cable crosssection
Current I ≤ 15 A: 7.5 A per mm²
for connector
Current I > 15 A: 5 A per mm²
(Note derating of connector)
Dimensions
102 x 60 x 36.8 mm (unequipped)
Characteristics
Suitable for 12 V and 24 V applications
Power supply via power elements up to max. 70 A
7 fuse sockets for ATO fuses up to max. 15 A
2 additional sockets for ATO fuses up to max. 30 A for relay protection
2 mini relay sockets 5 pin
Rear connector 18 pin, 3 rows – JPT and MCP compatible
High thermal load
Shock and vibration resistant
Also available with populated board (relays, fuses resp. automatic circuit breakers supressor diodes)
Applications
Power distribution within the automotive segment, such as alternators, control and indication devices, radio, a
­ ccessories etc.
Applicable individually or modular
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BLUEcontactTM Central electrics
Standard module with 2 maxi fuses, 2 maxi relays
Part Number 175265
Technical Data
Operational temperature
-40° C to +85° C
Max. power supply
Max. 2 x 70 A at 30° C ambient temperature
Max. 2 x 50 A at 60° C ambient temperature
Output
Connector 3 row, 6 pin, JPT/MCP compatible
Input
Power element M5, max. torque: 2.2 Nm
(other designs on request)
Recommended cable crosssection
Current I ≤ 15 A: 7.5 A per mm²
for connector
Current I > 15 A: 5 A per mm²
(Note derating of connector)
Dimensions
102 x 60 x 44.6 mm (unequipped)
Characteristics
Suitable for 12 V and 24 V applications
2 isolated electrical circuits, therefore dual usage of 12 V and 24 V possible
Power supply via power elements up to max. 70 A
Outputs via power elements
2 fuse sockets for maxi fuses
2 maxi relay sockets 4 pin
Rear connector 6 pin, 3 rows – JPT and MCP compatible
Also available with populated board (relays, fuses, supressor diodes)
Applications
Power distribution within the automotive segment, such as alternators, control and indication devices, radio, a
­ ccessories etc.
Applicable individually or modular
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ERNI Electronics GmbH & Co. KG
Europe South America Africa Japan
Seestrasse 9
73099 Adelberg
Germany
Tel +49 7166 50-0
Fax +49 7166 50-282
[email protected]
www.erni.com
ERNI Electronics, Inc.
North America Canada Mexico
2201 Westwood Ave
Richmond, VA 23230/USA
Tel +1 804 228-4100
Fax +1 804 228-4099
[email protected]
ERNI Asia Holding Pte Ltd.
Asia Australia New Zealand
Blk 4008 Ang Mo Kio Avenue 10
#04-01/02 Techplace I
Singapore 569625
Tel +65 6 555 5885
Fax +65 6 555 5995
[email protected]
© ERNI Electronics GmbH & Co. KG 2014 • Printed in Germany • A policy of continuous improvement is followed and the right to alter
any published data without notice is reserved.
ERNI ®, ERNI WoR&D ®, Act. Connect. Perfect ®, MicroCon ®, MicroStac ®, MicroSpeed ®, MiniBridge ®, MiniMez ®, MaxiBridge ®, ERmet ®,
ERmet ZD ®, ERmet ZDplus ®, ERmet ZD HD ®, ERbic ®, ERNIPRESS ®, INTERact ®, BLUEcontact ® and WHITEspeed ® are trademarks (registered or applied for in various countries) of ERNI Electronics GmbH & Co. KG.
Catalog E 07461301/14 Edition 4