A KYOCERA GROUP COMPANY
ELCO
Varicon
Varicon
®
Contents
The Varicon Range
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Introduction to Varicon
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Input/Output Rack and Panel Connectors
Series 8014
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Series 8016
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Varilok
®
Loose Contacts – Connector Polarization
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Series 8017
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Series 8026
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Series 8223
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
In-line Two Piece Plug and Receptacles
Series 8020
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Series 8022
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Two Piece Printed Circuit Board Plug and Receptacles
Series 8218
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Series 8219
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Series 7008
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Series 7022
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Series 7023
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Series 7024
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Series 7038
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Contact Strips
Series 7000
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Series 5101
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Series 5203
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Series 5204
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Series 5208
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Series 5301
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Series 5304
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Installation Equipment
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Military Cross Reference
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
ELCO
1
The Varicon Range
Pitch
0.050"
0.050"
Number of
Contacts
2 to 152
18, 30, 36, 42, 54, 72
Body
Style
Plugs and Receptacles
Plugs and Receptacles
Termination
Types
Staggered, Fixed:
Solder, Eyelet
Staggered, Fixed: Straight &
Right Angle Solder, Eyelet
Staggered,
Removable: Taper Tab,
Eyelet,
Wire Wrap,
Crimp
As Series 7024
Staggered,
Fixed: Solder
Staggered,
Fixed: Solder
Staggered,
Fixed: Solder,
Taper Tab,
Eyelet,
Wire Wrap,
Bus Line
Staggered,
Removable: Taper Tab,
Eyelet,
Wire Wrap,
Crimp
Wire Wrap,
Crimp
Square Grid Dual Row,
Fixed: Straight and Right
Angle Solder,
Eyelet,
Wire Wrap, Crimp
Wrappable Removable
Crimp
In-line
Fixed: Solder
Crimp
In-line
Fixed: Solder
Crimp
Current
Rating
(Amps)
5
5
Series
Number
8218
8219
0.075" x 0.130"
&
0.075" x 0.150"
0.100"
0.100"
0.100"
20, 38, 56, 90, 120
75, 100, 130
17, 23, 29, 35, 41
17, 23, 29, 35, 41, 47
17, 23, 29, 35, 41, 47
Plugs and Receptacles
8
8016
8017
Receptacles
Plugs
Receptacles
8
6
6
7008
7022
7023
0.100"
17, 23, 29, 35, 41
Receptacles
8
7024
0.100"
17, 23, 29, 35, 41, 47
Receptacles
8
7038
0.100"
33, 75, 117, 165
Plugs and Receptacles
5
8026
0.100"
24, 48, 72, 96
Plugs and Receptacles
5
8223
4mm
0.200"
50, 64
2, 3
Plug and Receptacle
Plugs and Receptacles
2
8.5
8014
8020
0.200"
3
Plug and Receptacle
8.5
8022
2
ELCO
Varicon
®
Introduction
Elco’s Varicon product range is available as two-piece input /
output and board level connectors (intermateable plugs and
receptacles). Varicon contacts are also available in strips, on
disposable carriers, ready for staking to p.c. cards. They all
use the famous, fork-like Varicon
®
(fixed) or Varilok
®
(insertable / removable) hermaphroditic contact design.
VARICON DESIGN ADVANTAGES
Elco’s hermaphroditic Varicon contact utilizes a fork-like
design incorporating four large mating surfaces that are
coined to achieve exceptional hardness and smoothness.
The mating surfaces are wedged together by the spring-like
design of the contact and by the innate properties of the
contact material. The Varicon contact has proven its reliabil-
ity in innumerable applications and with over one-million con-
tacts being produced daily, billions of successful, trouble-free
operating hours have been logged.
SHOCK AND VIBRATION RESISTANCE
Should external forces cause any decrease in contact pres-
sure between two of the four mating surfaces, it is automat-
ically compensated by redistributing the contact pressure
between the other two mating surfaces.
FEATURES
•
Four intimate contact areas, electrically parallel
•
High current carrying capability, excellent heat dissipation
•
Self-cleaning, wiping action burnishes contacting surfaces
reducing constrictive resistance
•
Low contact resistance 3 to 4 milliohms
•
Stable in vibration and adverse environments
•
High contact normal pressure achieved at low stress
levels
ECONOMY
Varicon contacts are stamped from sheet stock instead of
screw-machined. Consequently, this production method not
only increases the production capacity but decreases pro-
duction cost as there is little waste.
VERSATILITY
The Varicon concept can be used in a card-mounted plug
that mates with a receptacle, or Varicon contacts can be
staked directly to a pc board and soldered into place. This
latter method eliminates the need for a conventional plug
reducing the cost of the connection system while retaining
the proven reliability of the Varicon interconnection.
HIGH RELIABILITY
The mating surfaces provide a gas-tight connection and
resists corrosion caused by adverse environments. This seal
is made possible by the spring-like properties of the Varicon
contact and by the smoothness of the coined mating
surfaces. After being mated for years, the contacts still retain
clean, unoxidized mating surfaces.
CONTACT TYPES
Two basic sizes of our Varicon contact are available: stan-
dard and miniature Varicon. And each size has two major
variations: the fixed Varicon contact and the Varilok
insertable / removable version. The standard size is rated at
8 amps and has a withdrawal force range of 2 to 16 ounces
per contact. The miniature size is specifically for high densi-
ty applications and is rated at 5 amps with a withdrawal force
of 2 to 8 ounces per contact. (For exact specifications, check
the individual series listing.)
LOW RESISTANCE
Because of the spring-like properties of the Varicon contact,
both sides of the contact are always under considerable
pressure when mated. Their sliding and wiping action
burnishes the surfaces in a self-cleaning action reducing any
constrictive resistance. The low contact resistance remains
a permanent feature of the Varicon contact even after thou-
sands of mating and unmating cycles.
HIGH CURRENT CAPACITY
The low contact resistance contributes substantially to
Varicon’s high current-carrying capacitor. Also, its heat-dissi-
pating characteristics are enhanced by its flat configuration.
Miniature Varicon
®
Approx. 2X Actual Size
Standard Varicon
®
ELCO
3
Varicon
®
Introduction
CONTACT MATERIAL
The primary contact material used is phosphor bronze. The
electrical conductivity of copper alloys are extremely good.
Within the Varicon concept, the contacts must also perform
as springs and these alloys offer the elastic properties and
the endurance required by today’s rugged applications.
VARILOK CRIMP-AND-INSERT
CONTACTS
The crimp-termination, insertable / removable Varilok contact
offers a solderless connection between wire and contact as
well as strain relief for the wire. This contact snaps into the
insulator quickly and easily. With our simple tool it can be
removed without difficulty, yet it locks securely into place and
cannot twist or bend out of alignment.
CONTACT PLATING
A nickel underplate of 50 to 100 microinches, followed by a
minimum of 10 microinches of gold plate is Elco’s standard
contact plating. The gold plate prevents the formation of
insulating oxide films while the nickel plate provides a hard
backing. It, in turn, reduces wear on the gold and prevents
diffusion between the gold and base metal. Other plating
thicknesses, such as those required by military specifica-
tions, can be supplied on request.
Loose Varilok Contacts
Reel-Mounted Varilok Contacts
Varilok contacts also are available with wire-wrappable, solder
and taper-tab tail configurations. Available loose for small
scale production and replacement purposes, the Varilok
contact is also supplied on reels for use with fast, economi-
cal automatic crimping machines reducing man-hour
requirements and production costs in medium and large-
scale production runs. Because the contact can be crimped
to the wire and installed into the insulator at any point during
the manufacturing operation, it offers the user convenience
and flexibility. Reels contain 1800 standard contacts or 3000
miniature contacts.
4
ELCO
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