Comprehensive Product Summary – PCKA96 (96-pin Cable, 50-pair Round, 10 m)

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### 1. Product Overview

Product Name: 96‑pin Cable, 50‑pair Round, 10 m
Model Number: PCKA96
Article Number: PCKA96
Series: PCI Bus Series – Digital I/O Board Accessories
Manufacturer: CONTEC Co., Ltd. (Japan)
Product Category: Industrial Automation / Measurement and Control / Digital I/O Board Accessory
Website: [www.contec.com](https://www.contec.com)

The CONTEC PCKA96 is a high‑density, 96‑pin half‑pitch round cable designed for use with CONTEC’s PCI Bus Series digital and analog I/O boards. It provides a robust, shielded interconnection between PCI interface boards and external terminal units or devices. The cable is engineered for industrial automation environments requiring reliable signal transmission, noise immunity, and mechanical durability.

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### 2. Key Features

- High‑Density 96‑Pin Half‑Pitch Interface:
Supports connection to CONTEC PCI and CompactPCI digital I/O boards equipped with 96‑pin half‑pitch connectors (e.g., PI‑64L(PCI), PO‑64L(PCI), PIO‑32/32L(PCI), PIO‑64/64L(PCI), etc.).

- 50‑Pair Round Cable Construction:
Comprises 50 twisted pairs (100 conductors total) arranged in a round, shielded configuration for optimal signal integrity and reduced crosstalk.

- Extended Length (10 m):
Provides long‑distance connectivity between PC‑based I/O boards and remote terminal panels or devices, suitable for large control cabinets or distributed installations.

- Industrial‑Grade Shielding:
Double‑shielded design minimizes electromagnetic interference (EMI) and radio‑frequency interference (RFI), ensuring stable digital signal transmission in noisy industrial environments.

- High‑Reliability Connectors:
Equipped with precision 96‑pin half‑pitch connectors (female/male as required) compatible with HONDA Tsushin Kogyo PCR‑E96LMD or equivalent mating connectors.

- Compatibility with Multiple Accessories:
Designed for use with CONTEC terminal units such as EPD‑96, DTP‑64(PC), and connector converters like CCB‑96, as well as emulator and monitoring tools (CM‑64(PC)E).

- Optimized for PCI Bus Digital I/O Boards:
Fully compatible with CONTEC’s PCI Bus Series boards supporting 32‑bit, 33 MHz PCI interface, including opto‑isolated, TTL‑level, and relay‑output models.

- Durable Industrial Construction:
Ruggedized insulation and strain‑relief design suitable for continuous operation in factory automation, process control, and test system environments.

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### 3. Technical Specifications

| Parameter | Specification |
|----------------|-------------------|
| Cable Type | 96‑pin half‑pitch round cable |
| Conductor Configuration | 50 twisted pairs (100 conductors total) |
| Cable Length | 10 m |
| Connector Type | 96‑pin half‑pitch (HONDA Tsushin Kogyo PCR‑E96LMD or equivalent) |
| Connector Gender | Typically male–female (board to terminal unit) |
| Cable Diameter | Approx. 12–15 mm (typical for 50‑pair industrial cable) |
| Conductor Gauge | AWG 28–30 (typical for signal transmission) |
| Insulation Material | PVC or equivalent industrial‑grade insulation |
| Shielding | Double‑shielded (foil and braided shield) |
| Outer Jacket | Flexible PVC, gray or black industrial finish |
| Operating Temperature | 0 °C – 50 °C (typical for CONTEC accessories) |
| Storage Temperature | −20 °C – 60 °C |
| Bend Radius | ≥ 10 × cable diameter |
| Weight | Approx. 1.5 – 2.0 kg (for 10 m cable) |
| Electrical Characteristics | Characteristic impedance ≈ 100 Ω; low capacitance for high‑speed digital signals |
| Voltage Rating | 30 V DC (signal level) |
| Insulation Resistance | ≥ 100 MΩ at 500 V DC |
| Dielectric Strength | 500 Vrms for 1 minute |
| Compliance | RoHS compliant, CE marking (where applicable) |

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### 4. Functionality

The PCKA96 functions as a high‑density signal transmission cable connecting CONTEC PCI Bus I/O boards to external devices or terminal units. It carries digital or analog signals between the PC interface and field equipment.

Typical Use Cases:
- Connecting digital input/output boards (e.g., PIO‑32/32L(PCI), PIO‑64/64L(PCI)) to terminal blocks (EPD‑96, DTP‑64(PC)).
- Linking analog I/O boards (AD12‑64(PCI), DA12‑16(PCI)) to conditioning modules.
- Interfacing counter/motor controller boards (CNT32‑8M(PCI), SMC‑4P(PCI)) with encoders, sensors, or actuators.
- Extending signal lines in control cabinets or test benches.

Applications:
- Factory automation and process control systems
- Machine tool and robotics control
- Data acquisition and monitoring systems
- Test and measurement instrumentation
- Embedded industrial PCs and control panels

Compatibility:
- Fully compatible with CONTEC PCI Bus Series boards using 96‑pin half‑pitch connectors.
- Works with optional accessories such as:
- EPD‑96 (DIN‑rail terminal unit)
- DTP‑64(PC) (screw‑type terminal)
- CCB‑96 (connector converter board)
- CM‑64(PC)E (signal monitor/emulator)
- DIN‑ADP1 (DIN‑rail adapter)

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### 5. Components & Accessories

Included Items:
- One 96‑pin half‑pitch round cable, 10 m length
- Factory‑terminated connectors on both ends
- Protective connector caps and strain‑relief boots

Optional Accessories:
- Terminal Units:
- *EPD‑96* – 96‑channel DIN‑rail terminal block (8.5 mm pitch)
- *DTP‑64(PC)* – 64‑channel screw‑type terminal panel
- Connector Converters:
- *CCB‑96* – Converts 96‑pin half‑pitch to dual 37‑pin D‑sub connectors
- Monitoring Tools:
- *CM‑64(PC)E* – 64‑channel I/O signal emulator and monitor
- DIN‑Rail Mounting:
- *DIN‑ADP1* – Adapter for mounting terminal units on 35 mm DIN rails
- Connectors:
- *CN5‑H96F* – 96‑pin half‑pitch female connector (5 pcs set)
- Alternative Cable Variants:
- *PCB96PS‑1.5/3/5* – Shielded cables (1.5 m – 5 m)
- *PCB96P‑1.5/3/5* – Flat cables (1.5 m – 5 m)
- *PCB96WS‑1.5/3/5* – 96‑pin to dual 37‑pin D‑sub distribution cables

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### 6. Installation & Setup

Requirements:
- Compatible CONTEC PCI or CompactPCI I/O board with 96‑pin half‑pitch connector.
- Matching terminal unit or device with corresponding connector.

Mounting Options:
- Cable can be routed through cable ducts or harness trays in control panels.
- Use strain‑relief clamps near connectors to prevent mechanical stress.
- Maintain minimum bend radius to avoid conductor fatigue.

Configuration:
- No software configuration required; acts as a passive signal transmission medium.
- Ensure correct pin‑to‑pin mapping between board and terminal unit (refer to board’s pin assignment chart).
- For analog or high‑speed digital signals, maintain proper grounding and shielding continuity.

Connection Example:
1. Connect one end of PCKA96 to the 96‑pin connector on the PCI I/O board (e.g., PIO‑64/64L(PCI)).
2. Connect the other end to a terminal unit (EPD‑96 or CCB‑96).
3. Secure both connectors with locking screws.
4. Route the cable away from high‑voltage or high‑current lines to minimize noise coupling.

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### 7. Performance & Capabilities

- Signal Transmission Quality:
Maintains low signal distortion and minimal propagation delay over 10 m length due to twisted‑pair construction and shielding.

- Speed Capability:
Supports high‑speed digital I/O up to several MHz (depending on board specifications, typically 1 MHz – 10 MHz for TTL or opto‑isolated signals).

- Capacity:
96 signal lines (48 pairs) plus ground and shield conductors, suitable for full‑channel utilization of 96‑pin boards.

- Efficiency:
Optimized impedance and low capacitance ensure reliable data transfer for both input and output operations.

- Limitations:
- Not intended for power transmission beyond signal‑level voltages (≤ 35 V DC).
- Cable length beyond 10 m may require signal buffering or repeaters for high‑speed applications.
- Must be used within specified environmental conditions to maintain insulation integrity.

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### 8. Standards & Compliance

- Electrical Standards:
Conforms to PCI Bus Series signal interface requirements (32‑bit, 33 MHz, 5 V logic level).

- Safety & Environmental Compliance:
- RoHS Directive compliant (Restriction of Hazardous Substances)
- CE marking (where applicable)
- Manufactured under ISO 9001 quality management system

- Connector Standards:
- 96‑pin half‑pitch (IEC 61076‑4‑113 compatible)
- HONDA Tsushin Kogyo PCR‑E96LMD or equivalent mechanical interface

- Industry Compatibility:
Designed for industrial automation, measurement, and control systems conforming to international bus and I/O standards.

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### 9. Additional Information

Warranty:
Standard CONTEC limited warranty (typically 1 year) covering manufacturing defects and workmanship under normal operating conditions.

Support & Documentation:
- Detailed pin‑assignment diagrams and wiring examples available in the respective I/O board manuals.
- Technical support and downloadable resources (drivers, manuals, CAD drawings) accessible via [www.contec.com](https://www.contec.com).

Maintenance:
- Periodically inspect connectors for dust or oxidation; clean with contact‑safe cleaner if necessary.
- Avoid excessive bending or pulling; use cable clamps for strain relief.
- Verify continuity and shielding integrity during scheduled maintenance.

Updates & Compatibility:
- Fully compatible with legacy and current CONTEC PCI Bus Series boards.
- Future‑proof design ensures continued usability with upcoming PCI and CompactPCI models using the same 96‑pin interface.

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### Summary

The CONTEC PCKA96 96‑pin, 50‑pair, 10 m round cable is a precision‑engineered interconnect solution for industrial digital and analog I/O systems. It provides high‑density connectivity, robust shielding, and reliable signal transmission between PCI bus interface boards and external terminal units. Designed for demanding automation and measurement environments, the PCKA96 ensures stable operation, minimal noise interference, and long‑term durability. Its compatibility with a wide range of CONTEC accessories and boards makes it a versatile component in industrial control, data acquisition, and instrumentation systems.