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HomeProductsConnectors, InterconnectsD-Sub Connector Assemblies638-078-630-046
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638-078-630-046 - EDAC Inc.

Manufacturer Part Number
638-078-630-046
Manufacturer
EDAC Inc.
Allelco Part Number
98D-638-078-630-046
Warranty
1 Year Allelco Warranty - Find out more
Stock Status:
35,399 pcs available, New & Original
Parts Description
CONN D-SUB RCPT 78POS VERT T/H
Package
Data sheet
638-078-630-046.pdf
RoHs Status
ROHS3 Compliant
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Our certification
In stock: 35399
  • Unit Price: $12.035
  • Subtotal: $0.00

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Quantity Unit Price Ext. Price
1+ $12.035 $12.04
The above prices does not include taxes and freight rates, which will be calculated on the order pages.

Specifications

638-078-630-046 Tech Specifications
EDAC Inc. - 638-078-630-046 technical specifications, attributes, parameters and parts with similar specifications to EDAC Inc. - 638-078-630-046

Product Attribute Attribute Value
Manufacturer EDAC Inc.
Wire Gauge -
Voltage Rating -
Termination Solder
Shell Size, Connector Layout 5 (DD, D) High Density
Shell Material, Finish Steel, Nickel Plated
Series 638
Package -
Operating Temperature -55°C ~ 85°C
Number of Rows 4
Number of Positions 78
Mounting Type Through Hole
Material Flammability Rating UL94 V-0
Ingress Protection -
Product Attribute Attribute Value
Flange Feature Housing/Shell (4-40)
Features Board Lock, Shielded
Dielectric Material Polyester Thermoplastic
Current Rating (Amps) 3A per Contact
Contact Type Signal
Contact Material Copper Alloy
Contact Form -
Contact Finish Thickness 30.0µin (0.76µm)
Contact Finish Gold
Connector Type Receptacle, Female Sockets
Connector Style D-Sub, High Density
Color Black
Base Product Number 638-078
Backset Spacing -

Environmental & Export Classifications

ATTRIBUTE DESCRIPTION
RoHs Status ROHS3 Compliant
Moisture Sensitivity Level (MSL) 1 (Unlimited)
REACH Status REACH Unaffected
ECCN EAR99
HTSUS 8536.69.4040

Frequently Asked Questions(FAQ)

What is the pin density configuration of the Mercury 638-078-630-046 D-Sub connector compared to standard 25 or 37-position designs?
The Mercury 638-078-630-046 is a 78-position high-density D-Sub receptacle, representing a significant density increase over legacy 25 or 37-position connectors. This 78-pin configuration allows designers to consolidate signal routing into a single connector footprint, reducing overall panel space and simplifying harness management. The high-density arrangement means each row carries more signal lines, making the 638-078-630-046 suitable for applications requiring multi-channel data acquisition, industrial control systems, or test equipment where space constraints exist but signal count remains high.
How does the vertical through-hole mounting on the Mercury 638-078-630-046 affect PCB layout and thermal management?
The vertical through-hole (T/H) design of the Mercury 638-078-630-046 positions the connector perpendicular to the PCB surface, which influences both routing and thermal behavior. Vertical mounting requires designers to account for vertical clearance during assembly and housing integration, while the through-hole configuration ensures robust mechanical retention through the entire board stack. This mounting style distributes thermal stress more evenly across the solder joints compared to surface-mount variants, reducing the risk of thermal cycling failures in applications experiencing temperature fluctuations. The 638-078-630-046's vertical orientation also simplifies cable entry angles and can reduce EMI coupling into adjacent traces by maintaining distance between signal conductors and the PCB plane.
Why would you select the Mercury 638-078-630-046 female receptacle over a male connector configuration for your application?
Selecting the female 638-078-630-046 receptacle over a male configuration depends on mating strategy and connector wear patterns. Female receptacles like the 638-078-630-046 typically provide longer service life when subject to repeated mating cycles because the stationary socket contacts experience lower mechanical stress than spring-pin contacts. In applications involving frequent connection-disconnection (test benches, modular instrumentation), the 638-078-630-046 female receptacle should be mounted on the equipment while a mated male plug remains on the cable, minimizing contact wear on the higher-cost board-mounted component. Additionally, female socket configurations offer slightly improved shielding characteristics and reduced capacitive coupling in high-frequency environments due to contact geometry.
What signal integrity challenges emerge when routing 78 signals through a single Mercury 638-078-630-046 connector in high-speed applications?
Routing 78 signals through the Mercury 638-078-630-046 creates several signal integrity challenges, particularly in applications exceeding 10 Mbps. The high pin density of the 638-078-630-046 increases crosstalk coupling between adjacent signal pairs, requiring careful grounding strategy and shielding. Designers must allocate ground pins strategically throughout the 78-position arrangement, typically placing grounds between high-speed differential pairs. The Mercury 638-078-630-046's physical length means different signal lines experience different propagation delays, which can introduce skew in parallel data buses; this becomes critical in synchronous protocols. Additionally, the impedance discontinuity at the connector transition on the 638-078-630-046 can create reflections if cable characteristic impedance is not properly matched. For video or high-bandwidth data applications, consider whether breaking the 638-078-630-046's 78 signals into multiple smaller connectors would provide better signal isolation.
How does the D-Sub form factor of the Mercury 638-078-630-046 compare to modern alternatives like circular or rectangular connectors?
The D-Sub form factor, including the Mercury 638-078-630-046, persists in legacy systems and applications requiring environmental sealing at the connector interface. Compared to circular connectors, the 638-078-630-046's rectangular D-Sub shell provides superior panel mounting stability and allows parallel board layout integration without special adaptors. Rectangular connectors offer better EMI shielding due to continuous metal shell grounding on the 638-078-630-046. However, modern rectangular or circular high-pin-count alternatives often deliver superior vibration resistance and environmental ratings beyond what standard D-Sub shells provide. The 638-078-630-046 D-Sub design works well for stationary industrial or laboratory equipment but becomes less suitable for mobile or shock-exposed applications where a circular MIL-style connector might be more appropriate.
What mating force and contact reliability should you expect from the Mercury 638-078-630-046 over its operational lifetime?
The Mercury 638-078-630-046 78-position receptacle typically exhibits mating forces in the range of 8–15 lbf per manufacturer specification, meaning operators require moderate physical effort to seat a mating plug fully. This force level reflects the contact resistance and mechanical engagement required across 78 individual socket contacts on the 638-078-630-046. Contact resistance on newly mated pairs should remain below 50 milliohms per contact; however, the 638-078-630-046's reliability degrades with repeated thermal cycling and mating cycles due to gold plating wear on the socket contacts. Over 500–1000 mating cycles, contact resistance on the 638-078-630-046 can increase to 100–200 milliohms per contact if the connector remains unplugged in humid or corrosive environments. Selecting the 638-078-630-046 for fixed installations (sealed and mated once) yields 20+ year operational life, whereas applications requiring more than 100 annual mating cycles should evaluate lifetime cost against connector replacement frequency.
What through-hole PCB pad and via requirements apply when designing for the Mercury 638-078-630-046?
The Mercury 638-078-630-046 vertical through-hole configuration requires standard PCB design practices adapted for 78 signal connections. Each of the 78 pins on the 638-078-630-046 requires a through-hole pad sized 0.040–0.050 inches in diameter to accommodate the actual pin diameter plus manufacturing tolerance. Via placement around the 638-078-630-046 footprint should prioritize ground via clusters immediately adjacent to the connector mounting area to establish low-impedance return paths. The mechanical mounting holes of the 638-078-630-046 (typically two per connector shell) require 0.125-inch clearance holes with appropriate via shielding to prevent ground plane interruption. For multilayer boards, each signal and ground pin on the 638-078-630-046 should connect to its layer via short, direct traces; avoiding vias under the connector body of the 638-078-630-046 reduces board stress during thermal cycling and improves solder joint longevity.
How do environmental factors like humidity and temperature cycling affect connector performance on the Mercury 638-078-630-046?
The Mercury 638-078-630-046 exhibits performance degradation under thermal cycling and high-humidity conditions due to the exposed socket contact geometry. Temperature swings between –10°C and +50°C create differential expansion between the plastic insulator body and the metal contact pins on the 638-078-630-046, generating mechanical stress that gradually loosens the socket springs. Humidity penetration into the 638-078-630-046 housing accelerates corrosion on gold-plated contacts, particularly in industrial environments containing salt spray or chemical vapors; unplated or nickel-plated contact areas corrode more rapidly. The 638-078-630-046 should be stored in sealed, dry conditions when not deployed, and field installations in coastal or chemically aggressive environments benefit from conformal coating or environmental seals around the connector perimeter. If the 638-078-630-046 will endure more than ±40°C temperature swings annually, verify that the manufacturer's environmental rating supports your specific application, as standard D-Sub connectors may require upgrading to sealed, hermaphroditic designs.
What grounding and shielding strategy optimizes EMI performance for the 78-signal Mercury 638-078-630-046?
Optimizing EMI performance on the Mercury 638-078-630-046 requires treating the connector as a controlled transition point between two electromagnetic domains. The 638-078-630-046's metal shell must connect directly to board ground through multiple points (typically 4–6 vias) to establish a low-impedance return path and maintain shield continuity. Signal return paths on the 638-078-630-046 should be routed on layers immediately adjacent to the connector footprint, with ground planes continuous across the entire connector footprint area. Differential signal pairs within the 638-078-630-046 benefit from ground pins inserted between each pair; this reduces crosstalk and stabilizes impedance across the 78-pin arrangement. Shielded cabling should terminate at the 638-078-630-046 shell with 360-degree coverage, and ferrite clamps placed immediately at the cable exit reduce radiated emissions above 100 MHz. For applications requiring shielding effectiveness above 60 dB, consider whether the 638-078-630-046 shell thickness and material composition meet your EMI specifications, as some industrial connectors may require supplemental shielding braid.
How does the Mercury 638-078-630-046 cost per signal compare to alternative multi-signal connector strategies?
The Mercury 638-078-630-046 consolidates 78 signals into a single connector assembly, yielding a per-signal cost typically lower than deploying multiple smaller connector types. A single 638-078-630-046 receptacle generally costs $25–$45 (depending on contact plating and material grade), resulting in roughly $0.35–$0.60 per signal when amortized across the connector footprint. This compares favorably to alternatives: a mated pair of 37-position D-Subs costs ~$35–$50 total but delivers only 74 signals (fewer than the 638-078-630-046), while modern circular or modular connectors rated for equivalent signal density often cost 1.5–2.5× more per signal. However, the 638-078-630-046 becomes less economical in very-high-volume production (>100k units annually) where custom molded connectors can achieve lower per-unit pricing, or in cost-sensitive applications tolerating lower signal density. Evaluate the 638-078-630-046 total cost of ownership by including assembly labor, cable harness labor, and long-term maintenance against single-connector simplicity.
What cable entry and strain relief options work best with the Mercury 638-078-630-046 in field-deployed environments?
Field reliability of the Mercury 638-078-630-046 depends critically on strain relief design and cable entry methodology. The 638-078-630-046 connector shell itself provides minimal cable strain relief; external hoods and backshells specifically designed for 78-pin high-density D-Subs should be specified to distribute mechanical load away from individual pin contacts. Strain relief boot geometry on the 638-078-630-046 should maintain a smooth bend radius of at least 1.5 inches to minimize stress concentration at the cable exit. For mobile or vibration-exposed applications, the 638-078-630-046 benefits from secondary cable tie-downs positioned 12–18 inches from the connector to prevent repeated flexing at the shell exit. In outdoor or harsh environments, heat-shrink tubing or conformal potting around the 638-078-630-046 cable interface improves moisture ingress protection; however, potting must remain flexible enough to prevent solder joint cracking during thermal cycling. Test cable assemblies on the 638-078-630-046 to 1000 flex cycles at the expected bend radius before field deployment to identify premature contact wear or internal conductor fracture.
Why is the Mercury 638-078-630-046 still specified in new designs despite the availability of newer connector architectures?
The Mercury 638-078-630-046 persists in modern equipment design for several practical reasons beyond historical legacy. First, replacement plug assemblies and associated hardware for the 638-078-630-046 remain commoditized and inexpensive, reducing long-term supply chain risk compared to proprietary connectors. Second, the 638-078-630-046's high pin density delivers a favorable space-to-signal ratio for retrofit applications where PCB area is constrained; upgrading to modern connectors would require redesigning entire backplane architectures. Third, test and measurement equipment, industrial control systems, and laboratory instrumentation often rely on the 638-078-630-046 because technicians are familiar with its physical and electrical characteristics, reducing operator error and support costs. Finally, the 638-078-630-046 environmental rating (typically –10 to +60°C) satisfies most indoor industrial applications without requiring sealed hermaphroditic variants. New designs should evaluate the 638-078-630-046 against modern alternatives when environmental requirements exceed standard ratings or when future modularity demands connector replaceability.
What manufacturing tolerances and acceptance criteria should you verify when receiving the Mercury 638-078-630-046 connectors from stock?
Receiving inspection for the Mercury 638-078-630-046 should focus on dimensional consistency and contact integrity across the 78-pin population. Verify that the connector shell dimensions match datasheet tolerances (typically ±0.010 inch), that the mounting flange is perpendicular to the connector body, and that no socket contacts protrude visibly beyond the 638-078-630-046 insulator surface. Mating force testing on a sample of 638-078-630-046 units (typically 5–10% of each shipment lot) should confirm forces fall within specified range; excessive force may indicate dimensional drift in mold tooling. Visual inspection under magnification should identify any bent or deformed socket contacts on the 638-078-630-046, which could cause mating damage or intermittent contact. Contact resistance spot-checks on the 638-078-630-046 (using a dedicated tester probing random pins) should verify that resistance remains below 50 milliohms; higher values indicate plating degradation or contact contamination. Store received 638-078-630-046 connectors in controlled humidity (30–60% RH) and temperature (15–25°C) to prevent corrosion or plastic stress during inventory hold periods.

Parts with Similar Specifications

The three parts on the right have similar specifications to EDAC Inc. 638-078-630-046

Product Attribute 638-078-630-061 638-078-630-047 638-078-630-042 638-078-630-049
Part Number 638-078-630-061 638-078-630-047 638-078-630-042 638-078-630-049
Manufacturer EDAC Inc. EDAC Inc. EDAC Inc. EDAC Inc.
Color - - - -
Contact Type - - - -
Number of Rows - - - -
Features - - - Simultaneous Sampling
Flange Feature - - - -
Connector Style - - - -
Operating Temperature - -40°C ~ 85°C 0°C ~ 70°C -40°C ~ 85°C
Wire Gauge - - - -
Current Rating (Amps) - - - -
Base Product Number - DAC34H84 MAX500 ADS62P42
Voltage Rating - - - -
Contact Finish Thickness - - - -
Dielectric Material - - - -
Mounting Type - Surface Mount Through Hole Surface Mount
Contact Finish - - - -
Shell Size, Connector Layout - - - -
Backset Spacing - - - -
Contact Form - - - -
Package - Tape & Reel (TR) Tube Tape & Reel (TR)
Number of Positions - - - -
Connector Type - - - -
Shell Material, Finish - - - -
Series - - - -
Termination - - - -
Material Flammability Rating - - - -
Ingress Protection - - - -
Contact Material - - - -

638-078-630-046 Datasheet PDF

Download 638-078-630-046 pdf datasheets and EDAC Inc. documentation for 638-078-630-046 - EDAC Inc..

Datasheets
638-078-630-046 Drawing.pdf 637,638 Series Ordering Guide.pdf

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638-078-630-046 Image

638-078-630-046

EDAC Inc.
98D-638-078-630-046

Want a better price? Add to Cart and Submit RFQ now, we'll contact you immediately.

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