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ODU-MAC® Blue-Line

ODU-MAC® Blue-Line
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ODU-MAC® Blue-Line

Product catalog summary
Overview: The ODU-MAC® Blue-Line is a versatile modular connector system suitable for medical, industrial, military, and automotive applications. It features fast assembly, modularity, and flexibility, supporting over 10,000 mating cycles.
Specifications: Certified under UL 1977:2022/CSA C22.2 No. 182.3-16:2016 and tested to MIL/SAE/EIA standards, these connectors meet electrical specifications for standard data transmission protocols. A protective conductor connection is required if touchable parts exceed safety limits.
Features: The system supports various transmission types, including signals, power, high-current, high-voltage, coaxial, compressed air, fluid, vacuum, data, and fiber optics. Locking options include spindle, lever, transverse, and push-pull mechanisms.
Product Information: Available in plastic and metal housings, the ODU-MAC® Blue-Line offers manual mating and automatic docking options. Its modular design allows easy assembly and removal of modules without tools.
Applications: Suitable for environments requiring high chemical resistance and mechanical robustness, these connectors support up to 100,000 mating cycles in both manual and automatic docking systems.
Best Practices: Users should employ correct crimping tools and ensure proper strain relief for cables. A configurator tool is available for customizing connections to specific requirements.
Technical Information: Detailed assembly instructions and additional technical information are available on the ODU website. The connectors boast a contact density of up to 370 contacts per single-row connector.
Key Features:
  • User-friendly assembly and removal of modules without tools.
  • Available in four frame sizes with a maximum of 370 contacts per connector.
  • High-performance with over 10,000 mating cycles.
  • Customizable solutions for specific requirements.
Contact Technology:
  • ODU TURNTAC®: Economical slotted contacts with high durability.
  • ODU LAMTAC®: Lamella technology for high contact safety and low wear.
Assembly and Handling:
  • Contacts retained using a clip principle for easy removal and replacement.
  • Modules can be assembled with or without contacts at any process step.
  • PCB termination modules offer a quick-change system for parts subject to wear.
Technical Specifications:
  • Operating temperature range: −40 °C to +125 °C.
  • Protection class: IP67 for certain models.
  • EMC shielding according to IEC standards.
Additional Features:
  • Spindle locking systems for secure connections with over 10,000 locking cycles.
  • Various housing options including metal and plastic with different locking mechanisms.
Technical Specifications Overview:
  • Contact Finishing: Gold-plated.
  • Materials: Insulator made of thermoplastic according to UL 94, contact made of copper alloy.
Voltage Data:
  • IEC 60664-1:2020: Operating voltage varies between 160 V to 550 V, with pollution degrees 2 and 3, and rated surge voltage up to 4,000 V.
  • MIL Standards: Operating voltage up to 800 V, test voltage up to 2,400 V.
  • IEC 61010-1:2010: Supply voltage from grid supply circuit (CAT.2) ranges from 150 V to 300 V, with test voltages up to 2,394 V AC.
Mechanical Specifications:
  • Mating Cycles: Minimum 10,000 cycles.
  • Current-Carrying Capacity: Up to 25 A for certain modules.
  • Solder Temperature: +260 °C for 30 seconds for PCB termination module.
High-Frequency Characteristics:
  • Frequency Range: 0 – 12 GHz for certain coax contacts.
  • Insertion Loss: Detailed graphs provided for loss in dB across frequency ranges.
  • Voltage Standing-Wave Ratio (VSWR): Graphs provided for VSWR across frequency ranges.
Module and Contact Information:
  • Various modules and contacts are specified with part numbers, nominal and maximum continuous currents, and contact resistances.
  • Modules are compatible with specific PCB termination modules and have detailed mechanical dimensions provided.
Technical Notes:
  • Current load information is valid for single contacts or fully equipped modules, with load reduction recommended for connector systems.
  • Crimping and removal tools are specified for various contact types.
Crimping Tool Specifications: Detailed specifications for crimping tools, including crimping jaws and positioners, are provided. The document lists wire gauges (AWG) and corresponding crimping dimensions, highlighting compatibility with different wire classes and sizes.
Positioner and Adjusting Dimensions: Positioners are specified with part numbers and adjusting dimensions for precise crimping operations.
Coax Crimp Information: Details on positioners and crimp dies for coaxial cables are provided, including specific part numbers for inner and outer conductors.
Thermocontact Crimp Information: Specifications for crimp tools used with thermocontacts are outlined, including part numbers and applicable contact types.
Tools and Assembly Aids: A comprehensive list of tools, including torque wrenches and assembly aids, is provided with part numbers and recommended torque settings.
Removal Tools: Information on removal tools for coax and compressed-air contacts is included, emphasizing the necessity of using specific ODU tools for contact removal.
Cleaning and Maintenance: The document advises on contact lubrication and cleaning to enhance mechanical properties and reduce wear.
Technical Information: International Protection (IP) classes are explained, detailing protection levels against solid objects and water ingress.
Rated Surge Voltage: The rated surge voltage is the impulse withstand voltage specified by the manufacturer, indicating the insulation's endurance against transient overvoltages.
Pollution Degree: Pollution degree affects insulation capacity and is categorized into four levels.
Clearance and Creepage Distances: Clearance distance is the shortest air distance between conductive parts, while creepage distance is the shortest path along the surface of an insulating material.
Test Voltages: Test voltages confirm dielectric strength according to rated surge voltage.
Color Code for Cables: The document provides a detailed color code for cables according to DIN 47100 and international standards.
Voltage Data and Testing Standards: The document references various standards for voltage testing, including EIA-364-20F:2019 and IEC 60512-4-1:2003.
American Wire Gauge (AWG): AWG is a standard for wire diameter, where the cross-section changes by 26% between gauge numbers.
Current-Carrying Capacity: The capacity is determined by measurement, considering self-heating and ambient temperature.
Derating Factors: For multi-position connectors and cables, heating is greater than single contacts, requiring a derating factor.
Specifications: The document outlines the current-carrying capacity of connectors and cables, specifying a maximum load of 15.6 A/contact.
Procedures: The document describes the measurement methods for current-carrying capacity, including the derating measurement method in accordance with IEC 60512-5-2:2002.
Norms and Standards: Several standards are referenced, including IEC 60664-1:2020 for clearance and creepage distances, and IEC 61984:2008 for connector specifications.
Recommendations: It is recommended to verify designs with a heating test due to potential variations in module wiring.
Technical Terms: The document provides definitions for various technical terms such as ambient temperature, chemical resistance, contact resistance, and more.
Key Data from Tables and Diagrams: The tables provide derating factors for different numbers of live cores and nominal current loads for various conductor cross-sections.
General Notes: The document emphasizes that connectors are generally designed without breaking capacity unless stated otherwise.
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Catalog excerpts

ODU-MAC® Blue-Line-2

• Universal solution: fast, modular and flexible • Variety of locking options for plastic and metal housings • > 10,000 mating cycles • Clip-in assembly / removal of the modules without tools • Easy replacement of crimp-clip contacts, even when assembled • Wide range of transmission types • Ultra-compact connector Medical Test and measurement Military, security and communications Industrial Automotive ATTENTION: All shown connectors and cable assemblies are defined without breaking capacity (COC) according to IEC 61984:2008 (VDE 0627:2009-11). The majority of ODU-MAC® modules and contacts have...

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ODU-MAC® Blue-Line-3

Clickable page numbers

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ODU-MAC® Blue-Line-4

CONFIGURE THE ODU-MAC® BLUE-LINE EASILY ONLINE AT: WWW.ODU-MAC.COM/EN/ ODU-MAC® Table of contents

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ODU-MAC® Blue-Line-5

PRODUCT INFORMATION Your hybrid connection . . 18

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ODU-MAC® Blue-Line-6

• Easy assembly using crimp contacts, which are clipped into the insulators • Quick assembly and removal of the modules in the frame without using tools • Removal of the contacts from the pin side • Centering, guiding, and grounding via guiding sockets and pins • Numerous housing versions in metal and plastic available with spindle, lever or push-pull locking

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ODU-MAC® Blue-Line-7

• Transmission of signals, power, high-current, high-voltage, HF signals (coax), compressed air, fluid, vacuum, data, and fiber optic • Additional option for the transmission of signals: separate PCB termination modules for effective contacting in the termination area • Very high contact density via the 2.4 mm grid (1 unit) • Up to 370 contacts per single-row connector • Proven ODU contact technology (turned / slotted contacts and contacts with lamella technology)

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ODU-MAC® Blue-Line-8

PRODUCT INFORMATION A MODULAR ALL-ROUNDER The flexible modular design of the ODU-MAC® Blue-Line enables the combination of different transmission types within one connector. Whether signal, power, high-current, high-voltage, HF signals (coax), compressed air, fluid, data, or fiber optic are being transmitted – all of the contact inserts can be integrated into the individual connector solution. For signal transmission, there is also a simple contacting option using PCB termination modules. The individual parts are supplied loose. There are various applications possible: from installation with...

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ODU-MAC® Blue-Line-9

possible areas of application: manual mating or automatic docking PRODUCT INFORMATION THE MODULAR SYSTEM AT A GLANCE 2 10,000 mating cycles and more wide range of cable hood versions strain-relief plate contacts for solder, crimp, and PCB termination types of locking: spindle, lever, transverse or push-pull locking modules to choose from: signal, power, high-current, high-voltage, HF signals (coax), compressed air, fluid, vacuum, data, fiber optic, thermocouple and PCB termination spindle locking different spindle geometries pin frame Contacts with the clip principle that can be dismantled (see...

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ODU-MAC® Blue-Line-10

PRODUCT INFORMATION Use correct crimping tools! Never insert test probes into the contact sockets!

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ODU-MAC® Blue-Line-11

SELECT THE BEST SUITABLE CABLE OUTLET FOR YOUR INDIVIDUAL SOLUTION! BEST PRACTICE Use the ODU-MAC® strain relief! PRODUCT INFORMATION

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ODU-MAC® Blue-Line-12

PRODUCT INFORMATION DOS AND DON’TS BEST PRACTICE Balancing is needed to avoid uneven mating and demating force! SELECT OUT OF A WIDE RANGE OF PRE-ASSEMBLED MODULES AND CONTACTS

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ODU-MAC® Blue-Line-13

IDEAS Safety measurement solution! PARKING POSITION SEVERAL FIRST MATE, LAST BREAK OPTIONS ORDER ADDITIONAL SPARE PARTS! PRODUCT INFORMATION PRODUCT INFORMATION

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ODU-MAC® Blue-Line-14

PRODUCT INFORMATION CONFIGURATOR Individual configuration of your ODU-MAC ® Blue-Line connection With the Product Finder it’s possible to configure your connection simply according to your requirements. The Product Finder guides you through the different choices step by step and offers many continuative information. CONFIGURE YOUR ODU-MAC ® BLUE-LINE HERE: GO TO CONFIGURATOR www.odu-mac.com takes you directly to the Product Finder, allowing you to start to configurate your ODU-MAC ® immediately. SELECT & REQUEST OFFERS You will receive a drawing and a detailed offer within one working day of...

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ODU-MAC® Blue-Line-15

CABLE ASSEMBLY In addition to high quality connectors, ODU also offers complete system solutions including cable assembly. The advantage is that you receive the cable harness in an all-in-one solution from a single source. This greatly minimizes effort and installation time. C omplete solution from ODU with years of expertise State-of-the-art production facilities with 100 % end testing, high-voltage testing and component testing C ustomer-specific labeling P rototype, small series and high volume production W ide range of standard cables and accessories available PRODUCT INFORMATION PRODUCT...

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ODU-MAC® Blue-Line-16

PRODUCT INFORMATION THE ODU-MAC® THE MASS INTERCONNECT SOLUTION with ODU-MAC ® Blue-Line modules More information: odu-interconnect.com 16

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ODU-MAC® Blue-Line-17

Easy assembly and removal of contacts C onstantly low transition resistance F lexibility through easy and fast configuration Free combination of the different modules High packing density PRODUCT INFORMATION PRODUCT INFORMATION

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ODU-MAC® Blue-Line-18

PRODUCT INFORMATION MANUAL MATING AUTOMATIC DOCKING © 4 TYPES OF LOCKING © 4 DOCKING FRAMES TO CHOOSE FROM Size Tolerance compensation radial: +/- 0.6 mm Tolerance compensation axial: min. 0.1 mm First, select your locking type by choosing between spindle, lever, transverse or push-pull locking. Then select the plastic or metal housing best suited to your requirements: cable hood, cable hood XXL, cable hood wide, RAPID or PUSH-LOCK housing. Depending on your requirements you choose between bulkhead mounted housing, surface mounted housing, cable-to-cable hood, PUSH-LOCK receptacles or recessed...

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ODU-MAC® Blue-Line-19

VARIOUS LOCKING OPTIONS SPINDLE LOCKING TRANSVERSE LOCKING LEVER LOCKING PUSH-PULL LOCKING (for ODU-MAC ® PUSH-LOCK housing) SPINDLE LOCKING Quick-action locking system with 10,000 locking cycles. If required, the simple front replacement set (spindle exchange set) enables a simple adjustment of the spindle geometry. The spindle locking is integrated in a module for installation in ODU-MAC® Blue-Line frames for housings. 360° 180° PRODUCT INFORMATION PRODUCT INFORMATI

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