help with 100 pin plug

[richard296]

No kidding. It's part of the galanti amp you's assisted me with. Pics enclosed. The plug and socket has bad connections inside so someone has bridged with wires from top pin to bottom. Dismantled tried cleaning with spray etc but every time you move it another wire breaks off. My plan is to use circuit board with extended header pins as pic and crimp the wires into plugs both sides of board. The only problem i have are the fittings are so small. Any suggestions on anything a bit larger. many thanks richie

[camallison]

Two and a half IDC connectors? Then etch a double-sided board with fingers to plug on to. My ten pennyworth.

Colin

[ed731pdh]

Some designs just should never see the light of day, and this is one of them. I agree with Colin, IDC it.

[camallison]

I have used a 60-way and a 40-way of these successfully in the past:

http://www.te.com/catalog/bin/TE.Connect?C=23459&M=PPROP&P=&BML=10576,17580&LG=1&PG=1&IDS=11461,11462,11463,11467,11471,11458,11459,11469,11470,11537,11539,11536,11538,11541,11543,11544,11540,11542,11464,11465&N=20

Colin

[richard296]

Thank you all for your suggestions. The 60 + 40 plug would be ideal. I couldn't find the plugs and sockets without the ribbons. The original plug is numbered in rows of 5 through to 100. I would have liked to keep a similar format for repairs identification in future. The pcb board and pins,plugs etc i have are dupont which i think are just to small. I am sure you all will come up with some suitable solution. please get your thinking caps on. Thank you in advance richie

[pwdrive]

100 way connectors are available from Farnell, if you say that the wires keep dropping off then you will probably have the same problem with a new connector when trying to plug and unplug it, are the wires single strand or multi strand?

Most old connectors can be cleaned and tightened up.

Would it be possible to extend the wires and hard wire them ie: get rid of the connector?

Lawrence.

[richard296]

lawrence. They are multi strand wires. There are 5 fine nuts and bolts keeping both halves of plug together. I have checked inside all terminals look very clean. I have also cleaned them with elec spray. There are only 6 or so wires defective i may be able to bridge with wires across. With the wires being so close it is difficult to find where they go and solder in situe especialy the centre ones. My plan was to start again working from one end with a new idea/plug or whatever. Now that i've had feedback from yourselves. I think i will try to repair wires to existing plug. When i said the wires are falling of it's because i have to flip the plug upside down then back again to solder. Bear in mind there are 200 wires in total. Many thanks for all your feedback. richie

[Nick]

Personally, I'd replace that with some DIN 41612 aka IEC/EN 60603-2 (Eurocard) connectors.

I have loads of spares if you want FOC - 0.1" pitch and commonly configured in 64 (type "B") or 96 (type "C") pin variants - are you certain all 100 are used?

[richard296]

Nick thank you for your response and offer. You say 0.1 pitch. Unless i'm mistaken these are smaller than what i already have dupont 2.5 pitch. Am i wrong. thank you richie

[camallison]

Nick thank you for your response and offer. You say 0.1 pitch. Unless i'm mistaken these are smaller than what i already have dupont 2.5 pitch. Am i wrong. thank you richie

0.1 inch pitch = 2.5 mm.

Colin