Pogo Contacts for Board Test, Battery Interconnects, Medical Devices and other Momentary Electrical Contacts

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1 P Y L O N P O G O C O N T A C T S Pogo Contacts for Board Test, Battery Interconnects, Medical Devices and other Momentary Electrical Contacts

2 The Pylon Advantage The Pylon Pogo Contact advantage comes in two unique design features that enable our Pogo Contacts to achieve the lowest, most consistent contact resistance available in the marketplace. These features are: The biasing ball construction of the Pogo Plunger Gold lined nickel silver tubing material for the Pogo body on selected series F 1 ø F F 2 Pylon s Biasing Ball Plungers Biasing-Ball Construction* creates a radial component force insuring a positive and uniform electrical junction between the contact plunger and gold-alloy lining of the contact body. The figure above depicts the biasing angle (ø), spring force (F), radial or side force (F 1 ) and plunger force (F 2 ) of Biasing-Ball Pogo Contacts. Contact Resistance In evaluating contact resistance, low levels of resistance are important. However, the more critical performance measurement is the consistency of the low contact resistance. Resistance measured as 8 milliohms at 1000 cycles must also measure 8 milliohms at 200K, 500K and 1,000,000 cycles. The Biasing Ball design ensures that our Pogo Contacts achieve consistent, low contact resistance. The graph below plots the resistance of our P2663 Pogo series. Note the consistency even to 3 sigma RESISTANCE MΩ ,000 CYCLES (x 1,000) _ x _ +3s x_ x -3s

3 Considerations When Specifying Pogo Contacts The following list details common mechanical, electrical and economic considerations when specifying Pogo Contacts and Receptacles: Centerline spacing Plunger shape Plunger travel Plunger force Cleanliness of surface to be contacted What the Pogo will contact Resistance Current to be carried Part Numbering Scheme As a means to allow our customers to easily specify Pogo Contacts that meet specific application requirements, a new part number scheme has been adopted. The scheme is easy to follow and utilizes the long-standing Pylon numerical Pogo family design. PXXXX Example: P2663G-1P1S S Materials and plating Replaceable or nonreplaceable Temperature Termination method Life required Quantity Cost Other ambient conditions STRAIGHT BODY STANDARD SPRING FORCE ALTERNATE SPRING FORCE ALTERNATE SPRING FORCE XX HEAD (TIP) STYLE G GOLD PLATED PLUNGER This would be a P2663 Series probe, gold-plated plunger, with a chisel tip, having a standard spring, and a straight body configuration. Table of Contents P2662A Series (1.27) centers P2662B Series (1.27) centers P2663 Series (1.91) centers P2664 Series - centers P3158 Series - centers P5160 Series - centers P2665 Series (3.18) centers P2757 Series (4.75) centers Nonreplaceable Pogo Contacts Pogo Contact A-A-S/A-S Series Pogo Contact C-S/E-S Series Pogo Contact F/G Series Pogo Contact P2550/P2532 Series Pogo Contact Low Ω/P2447/HC125A-TT Pogo Contact P3325 Series/P4301-1F Tools Custom-designed Pogo Contacts and Sockets Pylon has been designing custom Pogo contacts for more than 25 years. Pogo contacts have been designed to withstand harsh environmental conditions. Put our dedicated engineering team to work on your custom requirements. Specifications subject to change without notice. Drawings may not be to scale.

4 .050 (1.27) TEST CENTERS P2662A Series.021 (0.53) typ..027 (0.69) 1C.130 (3.30).710 (18.03) 1Q.013R (0.33) Specifications Plunger Hardened BeCu Body Gold-plated phosphorous bronze Spring Silver-plated BeCu Ball Stainless steel Electrical Resistance <30mΩ Maximum Current amps Working Travel (1.7) 1R Standard: (20) 1.7 (48) Alternate: (17) 2.5 (72) 2V.040 (1.02) 120 Pogo Receptacle The P2662A Series is designed to be used with the S2662A Series receptacle below. The recommended mounting hole is.0395/ (0.76) S2662A-3ED.022 (0.56).036 (0.91).041 (1.04).0285 (0.72).110 (2.79).690 (17.53).025 (0.64) Receptacle with Probe.040 (1.02) 2 P2662A S STRAIGHT BODY 1 STANDARD SPRING FORCE 2 ALTERNATE SPRING FORCE* XX HEAD (TIP) STYLE G GOLD PLATED PLUNGER *Make to Order

5 .050 (1.27) TEST CENTERS P2662B Series.027 (0.69).021 (0.53) 1C.105 (2.67).575 (14.60) Specifications Plunger Hardened BeCu Body Gold-plated phosphorous bronze Spring Silver-plated BeCu Ball Stainless steel Electrical Resistance <30mΩ Maximum Current amps Working Travel (1.27) 1R.013R (0.33) Standard: (28) 1.8 (51) Alternate: (14) 2.5 (71) 1Q Pogo Receptacle The P2662B Series is designed to be used with the PR261 Series receptacles below. The recommended mounting hole is.035/.0365 (0.89/0.93mm). The recommended drill is a #64 or 0.92mm. Use tool T261-0 for installation. 2V.040 (1.02) 120 PR261-O Crimp.180 (4.57) MIN.034 (0.86).027 (0.68).022 (0.56).690 (17.53).040 (1.02) PR261-OF (Flush Mount) PR261-1 Solder PR261-1F (Flush Mount) Solder Cup.037 (0.94) Press Ring.040 (1.02) Receptacle with Probe.040 (1.02) P2662B S STRAIGHT BODY 1 STANDARD SPRING FORCE 2 ALTERNATE SPRING FORCE* XX HEAD (TIP) STYLE G GOLD PLATED PLUNGER *Make to Order 3

6 .075 (1.91) TEST CENTERS P2663 Series.030 (0.76).042 (1.07) 1C.810 (20.57).140 (3.56) 1R 3R O.A.L (19.56).018R (0.46).019R (0.48) Specifications Plunger Hardened BeCu Body Gold-plated phosphorous bronze Spring Stainless steel Ball Stainless steel Electrical Resistance <10mΩ Maximum Current amps Working Travel (1.70) Standard: (42) 3.3 (94) Alternate: (28) 2.0 (57) 1P.060 (1.52) 90 Pogo Receptacle The P2663 Series is designed to be used with the S2663 Series receptacles below. The recommended mounting hole is.0576/ (1.02) S2663-1ED.043 (1.09).038 (0.97).054 (1.37).059 (1.50) 1V.050 (1.27) (2.13) S2663-1ETD.026 DIA (0.66).025 (0.64).760 (19.30).230 (5.84).990 (25.15) 1W S2663-1EWWD.025 SQ. (0.64).380 (9.65) (28.96) Receptacle with Probe.050 (1.27) 4 P2663 S STRAIGHT BODY 1 STANDARD SPRING FORCE 2 ALTERNATE SPRING FORCE* XX HEAD (TIP) STYLE G GOLD PLATED PLUNGER *Make to Order

7 TEST CENTERS P2664 Series.054 (1.37).040 (1.02).895 (22.73) Specifications Plunger Hardened BeCu Body Gold-plated phosphorous bronze Spring Stainless steel Ball Stainless steel Electrical Resistance <10mΩ Maximum Current amps Working Travel (2.13) Standard: (57) 3.6 (102) Alternate: (85) 5.7 (162).175 (4.44) 1C 1R 2R O.A.L (21.46).023R (0.58).050 (1.27).029R (0.74).090 (2.29) O.A.L (23.75) Pogo Receptacle The P2664 Series is designed to be used with the PR541 Series receptacles below. The recommended mounting hole is.069 (1.75mm). The recommended drill is 1.75mm. Use ARIT54 tool for installation. 4V 120 PR541-O Crimp.20 (5.08) MIN.066 (1.68).240 (6.09).058 (1.47).048 (1.22).070 (1.78).930 (23.62).060 (1.52) 1W PR541-OF (Flush Mount).050 (1.27) PR541-1 Solder PR541-1F (Flush Mount) Solder Cup.070 (1.78) Press Ring PR541-2 Wire Wrap PR541-2F (Flush Mount).025 SQUARE PR541-3 Round Post PR541-3F (Flush Mount).025 DIA 1.32 (33.53) 1.32 (33.53) P2664 S STRAIGHT BODY 1 STANDARD SPRING FORCE 2 ALTERNATE SPRING FORCE* XX HEAD (TIP) STYLE G GOLD PLATED PLUNGER *Make to Order 5

8 TEST CENTERS P3158 Series.040 (1.02).054 (1.37) 3C 34 STEEL PLUNGER.970 (24.64).260 (6.35) 1R.060 (1.52).023R (0.58) Specifications Plunger Hardened BeCu (except as noted) Body Gold-plated phosphorous bronze Spring Music wire Ball Stainless steel Electrical Resistance <10mΩ Maximum Current amps Working Travel (2.90) 1Q.080 (2.03) Standard: (77) 6.9 (196) Alternate: (37) 2.8 (79) 2Q.025 (0.64) Pogo Receptacle The P3158 Series is designed to be used with the PR541 Series receptacles below. The recommended mounting hole is.069 (1.75mm). The recommended drill is 1.75mm. Use ARIT54 tool for installation..070 (1.78) PR541-O Crimp.20 (5.08) MIN.066 (1.68).240 (6.09).058 (1.47).048 (1.22) 1V (23.62).060 (1.52) PR541-OF (Flush Mount) 1W PR541-1 Solder PR541-1F (Flush Mount) Solder Cup.070 (1.78) Press Ring PR541-2 Wire Wrap PR541-2F (Flush Mount).025 SQUARE PR541-3 Round Post PR541-3F (Flush Mount).025 DIA 1.32 (33.53) 1.32 (33.53) 6 P3158 S STRAIGHT BODY 1 STANDARD SPRING FORCE 2 ALTERNATE SPRING FORCE* XX HEAD (TIP) STYLE G GOLD PLATED PLUNGER *Make to Order

9 TEST CENTERS P5160 Series.054 (1.37).040 (1.02) 2C (33.27).310 (7.87) Specifications Plunger Hardened BeCu Body Gold-plated phosphorous bronze Spring Music wire Ball Stainless steel Electrical Resistance <10mΩ Maximum Current amps Working Travel (4.24) Standard (-1): (71) 6.5 (184) Alternate (-2): (48) 3.5 (99) Alternate (-3): (71) 8.2 (232) 3C 1R STEEL PLUNGER.030 (0.76) R (0.46) Pogo Receptacle The P5160 Series is designed to be used with the PR54 Series receptacles below. The recommended mounting hole is.069 (1.75mm). The recommended drill is 1.75mm. Use ARIT54 tool for installation. PR54-O Crimp.180 (4.57) MIN.066 (1.68).300 (7.62).058 (1.47).048 (1.22) 3P.060 (1.52) (29.21).060 (1.52) 1Q.060 (1.52) PR54-OF (Flush Mount) PR54-1 Solder PR54-1F (Flush Mount) Solder Cup.070 (1.78) Press Ring 1V (30.23) PR54-2 Wire Wrap PR54-2F (Flush Mount).025 SQUARE PR54-3 Round Post PR54-3F (Flush Mount).025 DIA (40.26) 2W 1.56 (40.13) P5160 S STRAIGHT BODY 1 STANDARD SPRING FORCE 2 ALTERNATE SPRING FORCE* XX HEAD (TIP) STYLE G GOLD PLATED PLUNGER *Make to Order 7

10 .125 (3.18) TEST CENTERS P2665 Series.066 (1.68).080 (2.03) 1C 1R.090 (2.29).036R (0.91) (32.77).330 (8.38) Specifications Plunger Hardened BeCu Body Gold-plated phosphorous bronze Spring Stainless steel Ball Stainless steel Electrical Resistance <10mΩ Maximum Current amps Working Travel (4.24) 1V.080 (2.03) 120 Standard: (43) 3.0 (85) Alternate: (71) 5.8 (164) 1W.153 (3.89) Pogo Receptacle The P2665 Series is designed to be used with the PR80 Series receptacles below. The recommended mounting hole is.094/.096 (2.39/2.44mm). The recommended drill is a #41 or 2.4mm. Use tool T80-0 for installation. PR80-O Crimp.180 (4.57) MIN.093 (2.36).300 (7.62).058 (1.47).047 (1.19) 2W.060 (1.52) O.A.L (32.26) PR80-OF (Flush Mount) PR80-1 Solder PR80-1F (Flush Mount) Solder Cup 1.20 (30.48).090 (2.29).098 (2.49) Press Ring PR80-2 Wire Wrap PR80-2F (Flush Mount).025 SQUARE PR80-3 Round Post PR80-3F (Flush Mount).025 DIA 1.57 (39.88) 1.57 (39.88) 8 P2665 S STRAIGHT BODY 1 STANDARD SPRING FORCE 2 ALTERNATE SPRING FORCE* XX HEAD (TIP) STYLE G GOLD PLATED PLUNGER *Make to Order

11 .187 (4.75) TEST CENTERS P2757 Series.116 (2.95).098 (2.49) 1C.320 (8.13) (30.73) Specifications Plunger Hardened BeCu Body Gold-plated phosphorous bronze Spring Stainless steel Ball Stainless steel Electrical Resistance <10mΩ Maximum Current amps Working Travel (4.24) 2C O.A.L (28.96).120 (3.05) 34 Standard: (57) 4.0 (113) Alternate (Stainless steel): (99) 6.85 (194) 1R.070 (1.78).090R (2.29) Pogo Receptacle The P2757 Series is designed to be used with the S2757 Series receptacles below. The recommended mounting hole is.1365/ V.152 (3.86) 120 S2757-2ED.055 (1.40).133 (3.38).138 (3.51).118 (3.00).133 (3.38) S2757-2ETD.026 DIA (0.66) (26.75).025 (0.64) 1W.154(3.91) S2757-2EWWD.230 (5.84).025 SQ. (0.64) (32.59).065 (1.65) O.A.L (30.61).250 (6.35).510 (12.95) (39.70) 2W Receptacle with Probe.090 (2.29).065 (1.65) O.A.L (30.61).122 (3.10) 3W P2757 S STRAIGHT BODY 1 STANDARD SPRING FORCE 2 ALTERNATE SPRING FORCE* XX HEAD (TIP) STYLE G GOLD PLATED PLUNGER *Make to Order 9

12 Nonreplaceable Pogo Contacts The Pylon line of standard products include nonreplaceable Pogo Contacts. They differ from the replaceable contacts in that they do not require a socket. The nonreplaceable line is designed to be permanently mounted. Solder pots are incorporated for a reliable electrical connection. The construction is typically gold-plated brass bodies, combined with gold-plated springs and plungers. This ensures the user of excellent electrical contact. Available in body diameters from.030" to.187", nonreplaceable Pogo Contacts are another example of Pylon s quality and innovation and how it can work for you. 10

13 A-A-S/A-S Series.022 (0.56) x.050 (1.27) Deep Solder Pot.030 (0.76).021 (0.53) A-A-S- C.310 (7.87).030 (0.76) Travel A-A-S Series Specifications Plunger Gold-plated hardened BeCu Body Gold-plated phosphorous bronze Spring Gold-plated stainless steel Ball Gold-plated stainless steel Electrical Resistance <30mΩ Maximum Current amps Working Travel (0.51) A-A-S- R.030 (0.76) Standard: (14) 2.0 (57) The recommended hole is.0315 (#68 drill) for epoxy mounting..025 (0.64) x.045 (1.14) Deep.035 (0.89) Solder Pot.037 (0.94).040 (1.02).014 (0.36) A-S- C.030 (0.76).230 (5.84).010 (0.25).030 (0.76) Travel A-S Series Specifications Plunger Gold-plated hardened BeCu Body Gold-plated brass Spring Gold-plated stainless steel Ball Gold-plated stainless steel Electrical Resistance <30mΩ Maximum Current amps Working Travel (0.51) A-S- A-S- R V Gold Plated Brass Plunger 120 Standard: (20) 1.3 (37) The recommended hole is.0380 (#62 drill) for epoxy mounting. 11

14 C-S/E-S Series.026 (0.66).027 (0.69) x.080 (2.03) Deep.042 (1.07) Solder Pot.045 (1.14).049 (1.24) C-S- C.045 (1.14) C-S- R.395 (10.03).020 (0.51).045 (1.14) Travel C-S Series Specifications Plunger Gold-plated hardened BeCu Body Gold-plated brass Spring Gold-plated stainless steel Ball Gold-plated stainless steel Electrical Resistance <30mΩ Maximum Current amps Working Travel (0.76) Standard: (14) 3.4 (96) The recommended hole is.0465 (#56 drill) for epoxy mounting..045 (1.14).046 (1.17) x Deep.062 (1.57) Solder Pot.065 (1.65).070 (1.78) E-S- C.065 (1.65) E-S- E-S- F R.090 (2.29).495 (12.57).030 (0.76).065 (1.65) Travel E-S Series Specifications Plunger Gold-plated hardened BeCu Body Gold-plated brass Spring Gold-plated stainless steel Ball Gold-plated stainless steel Electrical Resistance <30mΩ Maximum Current amps Working Travel (1.09) E-S- V.115 (2.92).070 (1.78).050 (1.27) Standard: (29) 2.75 (78) The recommended hole is.0670 (#51 drill) for epoxy mounting. E-S- W.110 (2.80).045 (1.14) 12

15 F-S/G-S Series.043 (1.09) x.150 (3.81) Deep Solder Pot.082 (2.08).085 (2.16).092 (2.34).045 (1.14) F-S- C.066 (1.68).780 (19.81).030 (0.76) Travel F-S Series Specifications Plunger Gold-plated hardened BeCu Body Gold-plated brass Spring Gold-plated stainless steel Ball Gold-plated stainless steel Electrical Resistance <30mΩ Maximum Current amps Working Travel (1.68) F-S- F-S- R W Rhodium-plated brass plunger.090 (2.29) Standard: (57) 6.0 (170) The recommended hole is.0860 (#44 drill) for epoxy mounting..154 (3.91).054 (1.37).043 (1.09) x.150 (3.81) Deep Solder Pot.082 (2.08).085 (2.16).092 (2.34).061 (1.55) G-S- F.066 (1.68).780 (19.81).030 (0.76) Travel G-S Series Specifications Plunger Gold-plated hardened BeCu Body Gold-plated brass Spring Gold-plated stainless steel Ball Gold-plated stainless steel Electrical Resistance <30mΩ Maximum Current amps Working Travel (1.68) G-S- R Standard: (85) 6.0 (170) The recommended hole is.0860 (#44 drill) for epoxy mounting. 13

16 P2550/2532 Series * x.188 (4.78) Deep Solder Pot.125 (3.18).150 (3.81) P (7.99).065 (1.65).120 (3.05) (36.91).015 (0.38).375 (9.52).125 (3.18) P P (3.10).125 (3.18).375 (9.52) P2550-0: 3.0 oz. spring P : 6.7 oz. spring.154 (3.91) P2550 Series Specifications Plunger Gold-plated hardened BeCu Body Gold-plated brass Spring Stainless steel Ball Gold-plated stainless steel Electrical Resistance <30mΩ Maximum Current amps Working Travel (4.24).315 (7.99).065 (1.65) Standard: (34) 3.10 (88) The recommended hole is.1260 (3.2mm) for epoxy mounting..125 (3.18) P (8.12).070 (1.78).059 (1.50).062 (1.57) x.110 (2.79) Deep Solder Pot.088 (2.24).093 (2.36).110 (2.79) P (20.62).017 (0.43).139 (3.53) Travel P P2532 Series Specifications Plunger Gold-plated hardened BeCu Body Gold-plated brass Spring Stainless steel Ball Gold-plated stainless steel Electrical Resistance <30mΩ Maximum Current amps Working Travel (2.36) Standard: (28) 2.3 (65) The recommended hole is.0945 (2.4mm) for epoxy mounting. 14 *Consult factory for minimum order quantity

17 Low Ω/P2447/HC125A-TT Low resistance Pogo Contacts are designed for applications requiring minimum internal resistance and/or high current-carrying capacity. These objectives are achieved by making the Pogo plunger and terminal as a single unit. This construction method eliminates the resistance of the spring and body..052 (1.32) x.188 (4.78) Deep Terminal Moves with Plunger.156 (3.96).172 (4.37).187 (4.75).095 (2.41).040 (1.02).020 (0.51) (29.08).145 (3.68).445 (11.30) P2447 Specifications Plunger Nickel-plated hardened BeCu Body Brass Spring Stainless steel Terminal Nickel-plated brass Electrical Resistance <10mΩ Maximum Current amps Working Travel (5.08) Standard: (170) 14.0 (397) The recommended hole is.1570 (#22 drill) for epoxy mounting..052 (1.32).071 (1.80).092 (2.34).140 (3.56).144 (3.66).156 (3.96) (33.53).030 (0.76).270 (6.89) HC125A-TT (replaceable probe) Specifications Plunger Gold-plated hardened BeCu Body Gold-plated nickel silver Spring Silver-plated stainless steel Electrical Resistance <20mΩ Maximum Current amps Plunger Travel (Full) (6.35) The HC125A-TT is designed to be used with the SR125 receptacle. The recommended mounting hole is.141/.143 (3.58/3.63mm). The recommended drill is a 3.6mm. Use tool T125-0 for installation. Standard: (170) 16.0 (454) 15

18 P3325 Series/P4301-1F.061 (1.55).024 (0.61) x.062 (1.57) Deep Solder Pot Terminal Moves with Plunger.085 (2.16).092 (2.34) P (2.29).036 (0.91).075 (1.90).645 (16.38).030 (0.76) Travel P (1.27).150 (3.81) 120 P3325 Series Specifications Plunger Gold-plated hardened BeCu Body Brass Spring Music wire Electrical Resistance <10mΩ Maximum Current amps Working Travel (1.68) Standard: (142) 8.3 (235) The recommended hole is.0680 (#44 drill) for epoxy mounting. #6-32 Tap x.250 (6.35) Deep.187 (4.75) Diamond Knurl.225 (5.72).154 (3.91) (44.45) P4301-1F The Brute Specifications Plunger Gold-plated tellurium copper Body Gold-plated tellurium copper Spring Stainless steel Ball Stainless steel Electrical Resistance <5mΩ Maximum Current amps Working Travel (4.24) Standard: (454) 25.7 (729) The recommended hole is.1890 (#12 drill) for epoxy mounting..250 (6.35) Travel 16

19 Tools ARIT Receptacle Insertion Tools Model # ARIT54 ARIT54 T80-0 T125-0 Mounting Height T style tools Flush.125" Flush.220" Flush Flush Receptacle Series SR541 SR54 SR80 SR125 Adjustable Tool (ARIT) Instructions 1. Loosen set screws. 2. Rotate thimble to desired receptacle mounting height. 3. Lock both set screws. Maintenance Brushes Model # MB-1 MB-2 MB-3 MB-2 MB-1 Description Brass bristle brush (4-1/4" x 2-1/2") 4 row brass brush (3-1/4" x 1-1/8") Nylon brush (6-1/4") MB-3 Receptacle Installation (Press fit type only) The receptacle is inserted into the drilled hole and tapped into place using a plastic mallet and a receptacle insertion tool. Several taps (3-5) with the mallet is recommended to provide maximum receptacle retention. Epoxy is not required. The receptacle is held in place by the press ring, which collapses into the hole during insertion, forming a tight fit. While some insertion tools are designed to mount the receptacles flush with the probe plate, the ARIT series (Adjustable Tool) allows various mounting heights as required by the test fixture manufacturer. The press ring should be positioned for maximum retention in probe plates that are 3/8 inch thick or more. If the probe plate is too thin, the receptacle may fall through during insertion. In this case you can drill a smaller hole and use the press ring as a stop. However, you will need to secure receptacle with epoxy. Once the receptacle is installed, insert the probe until the top of the probe barrel is flush with the top of the receptacle. The probe is held in place with 4 retention detents. Specifications subject to change without notice. Drawings not to scale. Optional tip styles, spring pressures, and materials available, contact factory for more information. 17

20 Ostby Barton A Division of Everett Charles Technologies 487 Jefferson Boulevard Warwick, RI Tel: (401) Fax: (401) Everett Charles Technologies. Pogo is a registered trademark of ECT

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