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ZipLine™ Connector System
 

ZipLine™ Connector System

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To introduce FCI’s ZipLine™ connector system and its key features

To introduce FCI’s ZipLine™ connector system and its key features

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  • Welcome to this training module on ZipLine ™ Connector System.
  • This training module introduces FCI’s ZipLine connector system and its key features.
  • The ZipLine connector system uses the proven shield-less technology pioneered with FCI AirMax VS ® connectors to deliver low insertion loss and crosstalk at data rates up to 12.5 Gbps. By reducing the column pitch and increasing the pin count per column, ZipLine connectors are the first high-performance backplane connectors to achieve signal density of 84.6 differential pairs per linear inch of board edge.
  • Not only does the ZipLine Connector System achieve this significant milestone in linear signal density, but it does so in a smaller package. As the graphic shows, using ZipLine connectors in your design provides more space for components, more space for cooling air flow, and more space for signal routing.
  • Like FCI’s popular AirMax VS ® connector, the ZipLine connector allows for flexible pin assignments and eliminates the costly and heavy shields between columns of terminals. Since proximity to ground shields is not a requirement to achieve high performance, it is also possible to vary the column pitch to accommodate unique trace routing patterns. ZipLine connectors perform to Telcordia Central Office requirements and provide two points of contact at the mating interface for reliability. Compatibility with Hard Metric design practice allows the designer to utilize auxiliary components such as guides, power and even AirMax VS and Millipacs ® Hard Metric signal modules on the same board edge as ZipLine connectors. No PCB cutouts are necessary. Header options include two- or four-wall housings. The two wall shroud allows ZipLine modules to be stacked end-to-end with no breaks in the PCB hole pattern. The four-wall header provides additional protection for header contacts when a module is used alone, or at the end of a row of headers. ZipLine connectors are the highest density backplane connector with press-fit termination. A stainless steel organizer provides a strong ground structure around the outside of the right-angle connector module. This sturdy module can be pressed onto boards using simple “flat rock” tooling.
  • Current ZipLine connectors are designed to terminate to the same size plated-through holes as AirMax VS ® connectors .
  • FCI offers a variety of power and guide modules that complement the ZipLine connector system. Power options start with a 6-pair power IMLA that can be included as part of a ZipLine signal module. A power “Insert Molded Lead-Frame Assembly” or “IMLA” in this configuration handles 6 amps per contact with 6 contacts per IMLA. For higher-current applications or those that require sequential mating capability, Hard Metric power modules provide options for 20 to 40 amps maximum per contact or HCI ® power modules with capacity for up to 82 amps per contact. Some HCI modules also include an integral plastic guide blade. Other guidance systems employ either a metal blade guide or a keyed round pin guide. The round-pin system is capable of 8 keying positions and also offers an optional ESD discharge contact built into the guide receptacle.
  • Shown here is an example with two 6-pair power IMLAs integrated in a ZipLine connector module to provide an assembly that handles both signals and power. A single power IMLA can handle 36 amps, but the use of multiple power IMLAs in the same module requires de-rating.
  • Sequential mating of ground, power and signal contacts is often needed when daughter cards are plugged to a backplane. This chart shows the nominal mating pin wipe lengths for various ZipLine, AirMax VS, power, and guide modules that may be used together in an application.
  • FCI ZipLine signal connector modules include 6 pair connectors in both 12 and 16 column variations on 1.8 millimeter centers. In addition to traditional backplane configurations, some customers have asked for an orthogonal interface between opposite sides of a midplane. FCI has responded with a header that facilitates this type of interconnect. Note that the ZipLine right-angle receptacle module can be used in both backplane and orthogonal midplane applications.
  • A recent addition to the FCI ZipLine connector product family is a right-angle header. This header enables coplanar mating of boards, which can be useful for extender cards, low profile assemblies, and in direct-attach, rear-plug-in card applications.
  • The standard ZipLine 6 pair, 12 IMLA backplane connector consists of a housing loaded with header contact IMLAs. Both standard and orthogonal headers have identical mating interfaces. The only difference between the headers is the configuration of the press-fit tails that terminate to the printed circuit board. The housing controls the separation of the IMLA columns.
  • This page shows ZipLine orthogonal midplane connectors appear in a typical application. In its densest form, the ZipLine connector provides 72 orthogonal pairs per midplane crossover. The headers are pressed into shared via holes on a minimum 3.5mm thick midplane.
  • Similar to what was presented earlier for backplane connectors, you can see that ZipLine TM orthogonal connectors provide the high density, with one of the small footprints. ZipLine orthogonal connectors provide more room for components, traces, and air flow.
  • Here shows a representation of the signal pattern on an orthogonal midplane. FCI’s data shows that under worst case asynchronous conditions, near end and far end cross talk values are very low.
  • This page shows two items of interest. First, it highlights the different tail patterns for standard backplane and orthogonal midplane header configurations. It also demonstrates that IMLAs can be selectively loaded into the housing, in these examples spacing adjacent columns on 3.6 millimeter centers. Wider column spacing may be desirable in designs where trace routing and PCB layer count are concerns, and density is not.
  • ZipLine connectors had zero errors when tested to the IEEE802.3ap standard. FCI ZipLine connectors are fully compatible with the fastest silicon available today.
  • Another advantage of the ZipLine connector system is that the intra-pair skew is practically zero, further enhancing high speed performance.
  • Trace routing for ZipLine connectors on 1.8 millimeter column pitch is achievable with 8 mil spaces and traces with one pair per printed circuit board layer. The drill size is the same as that used with FCI’s proven AirMax VS ® connector system.
  • When IMLAs are populated in every other position, you can achieve 3 differential pairs per layer with 6 mil spaces and traces. ZipLine connector electrical performance is not impacted, though density is obviously decreased.
  • This chart shows part numbers for FCI ZipLine connectors that are currently in mass production. Contact FCI for additional part numbers if required.
  • Thank you for taking the time to view this presentation on “ ZipLine ™ Connector System” . If you would like to learn more or go on to purchase some of these devices, you may either click on the part list link, or simply call our sales hotline. For more technical information you may either visit the FCI site, or if you would prefer to speak to someone live, please call our hotline number, or even use our ‘live chat’ online facility. You may visit Element 14 e-community to post your questions.

ZipLine™ Connector System ZipLine™ Connector System Presentation Transcript

  • ZipLine ™ Connector System
    • Source: FCI
  • Introduction
    • Purpose
      • To introduce FCI’s ZipLine ™ connector system and its key features
    • Outline
      • ZipLine connector system overview
      • ZipLine connector system configuration
      • ZipLine Backplane connector system
      • ZipLine Orthogonal connector system
    • Content
      • 22 pages
  • ZipLine TM Connector System Overview 5 pair, 2.0mm pitch 12.5 3.125 37.5 50.8 63.5 Signal density (pairs/in) ZipLine TM 3 pair, 2.0mm pitch 4 pair, 2.0mm pitch 6.25 84.6 6 pair, 1.8mm pitch Signal speed (Gbps) High Speed with More Signal Density
  • X,Y, Z Density increasing signal density extra space for signal routing on the backplane and/or airflow for cooling extra space for daughter card components 1” number of high speed differential pairs per inch of card width
  • ZipLine ™ Connectors Mechanical Overview
    • Highest density connector with press-fit termination
    • Flexible pin assignments - no ground shields between columns
    • Flexible column pitch (1.8mm & 3.6mm are tooled)
    • Hard Metric design practice
      • 12.5mm from Backplane to edge of Daughter Card
    • 2 wall and 4 wall header options
    • 2 points of contact (200 cycle Telcordia CO performance)
    • Flatrock application tooling for R/A connectors
    • Stainless steel organizer is grounded to top outside ground pins in every other column
    • Organizer design allows for integrated guide modules
  • ZipLine ™ Connectors Mechanical Overview
    • Press-fit tail dimensions:
      • Standard AirMax VS ® press-fit tails:
        • 0.60mm or 0.0225” drill
        • 0.45 - 0.55mm finish diameter
        • 1.60mm tail length
    • Minimum card pitch:
      • 25.0mm (narrow body header housing)
      • 27.0mm (wide body header housing)
  • ZipLine TM Connector Modules
    • ZipLine TM 6 pair power modules
      • 6 position power; 48V max; 6A max per contact; no advance mate pins (same wipe as standard signal)
    • Hard Metric power modules
      • 2, 3, 4, or 6 position; 150V max; 40A max per contact; advance mate options
    • HCI ® power modules
      • 2 or 3 position; 300V max; 82A max per contact; separation walls; advance mate and integrated guide options
    • Hard Metric guide modules
      • 8 keying positions; ESD option
    Similar guide modules can also be combined with a signal module
  • ZipLine TM 6-pair Power IMLAs
    • Current carrying capacity per preliminary product testing (30 deg C max T-rise)
      • Single IMLA: 6A per position, 36A per column
      • 2 adjacent IMLAs: 4.5A per position, 27A per column
      • 12 adjacent IMLAs: 2.25A per position, 13.5A per column
  • ZipLine TM Connectors Mating Sequence using HM Accessories
  • ZipLine ™ Connector System Configurations Same R/A receptacle for orthogonal and backplane applications
    • Standard backplane applications
      • 6 pair, 12 column, 1.8mm pitch, 72 pairs
      • 6 pair, 16 column, 1.8mm pitch, 96 pairs
    • Orthogonal midplane applications
      • 6 pair, 12 column, 1.8mm pitch, 72 pairs
  • ZipLine ™ Connector System Configurations
    • Coplanar applications
      • 6 pair, 12 column, 1.8mm pitch, 72 pairs
    12.5mm
  • ZipLine ™ Backplane Connector System
    • 6 pair, 12 IMLA assembly with 1.8mm column pitch
    • Same mating interface as 72 pair orthogonal connector
    • Same header housing as for orthogonal; only header IMLAs are different
  • ZipLine ™ 72 Pair Orthogonal Connector
    • 6 pair, 12 IMLA assembly with 1.8mm column pitch
    • 1.2mm pair offset column to column
    • Shared via solution (3.5mm min midplane thickness)
    • 72 orthogonal pairs per midplane crossover
  • X,Y, Z Density for Orthogonal Connectors increasing orthogonal pair count extra space permits larger holes for airflow through midplane extra space for daughter card components number of high speed differential pairs per connector
  • ZipLine ™ Orthogonal Midplane Footprint SI Simulation
    • Worst case asynchronous XTALK
    • All adjacent aggressors
    • @50ps (10-90%)
      • NEXT: 0.12% MAX
      • FEXT: 0.04% MAX
    0.0 % 0.03 % 0.03 % 0.03 % 0.03 % 0.0 % 0.0 % 0.0 % 0.0 % 0.01 % 0.01 % 0.01 % 0.01 % 0.0 % 0.0 % 0.0 % NEXT FEXT 0.12 % 0.04 % Tx Rx
  • ZipLine ™ 3.6mm Pitch Configurations orthogonal backplane Same receptacle will mate to either header Standard 1.8mm pitch housings with every other column loaded
  • ZipLine ™ Connectors 10Gbps BER Testing per IEEE802.3ap
    • 4 Broadcom BCM8072 dual-channel 10 Gbps transceivers
    • IEEE802.3ap reference backplane w/8 one-meter channels
    • 1 victim channel + 7 aggressor channels
    • Nelco 4000-12SI material on daughter cards and backplane
    • bit error rate (BER) was better than 5e-16
    • 10 Gbps on each channel
    • 40 Gbps aggregate data rate
  • ZipLine ™ BP Connector SI Simulation Intra-pair skew: 3ps max for all pairs (“zero” skew) Pair 7 Pair 8 Pair 9 Pair 10 Pair 11 Pair 12 Pair 13 Pair 14 Pair 15 Pair 16 Pair 17 Pair 18
  • ZipLine ™ Connector Trace Routing
    • 1.8mm pitch
    • 0.6mm drill (standard AirMax VS ® press-fit)
    • 8-8-8 mil routing possible
    • 1 pair per layer
  • ZipLine ™ Connector Trace Routing
    • 3.6mm pitch
    • 0.6mm drill (standard AirMax VS ® press-fit)
    • 6-6-6 mil routing possible
    • 3 pairs per layer
  • ZipLine™ Configurations & Part Numbers
  • Additional Resource
    • For ordering ZipLine connector, please click the part list or
    • Call our sales hotline
    • For more product information go to
      • http:// www.fci.com/ zipline
    • Visit Element 14 to post your question
      • www.element-14.com
    • For additional inquires contact our technical service hotline or even use our “Live Technical Chat” online facility