There is a growing demand for power, signal and data to be made available just about everywhere we look – even in the most extreme types of environments. This means that the cables providing connectivity to these technological components have to work reliably under tough conditions – on automated factory floors, inside heavy machinery, exposed to outdoor elements or even underwater. One of the most common points for potential damage in any electrical system is any place where these cables get plugged in – the connectors.

So what’s the difference between a normal connector and a harsh connector?

Harsh connectors are expertly designed for extreme environments where technology is being pushed to new frontiers.

Some of the main elements that rugged electrical connectors will protect against include:

• Water – this includes rain, water vapour, and possible water submersion.
• Dust – industrial and outdoor environments often contain a lot of dust or dirt, which can be harmful to electrical systems.
• Extreme temperatures – very low or high temperatures can be detrimental to technology.
• Explosive environments – ATEX zones are work areas that could be potentially explosive because of the presence of dangerous substances in the form of combustible dust, gas, vapour or mist.
• Rough handling – some connectors need to be mated and unmated multiple times in a day, often hurriedly, which increases the risk of wear and tear on the connector. Connectors being dropped or dragged along hard surfaces can also cause damage to the components inside the connector and affect the integrity of power, signal or data connections being passed through the cable.
• Pressure – power, data and fibre optics are needed in aircraft, in space and even at the bottom of the ocean, where pressures can reach up to 9,000 pounds per square inch.
• Salinity – the high salt content of water and air in coastal and marine environments can cause corrosion and calcareous growth. The correct material selection is therefore vital to ensure the maximum lifecycle of technology components used in coastal and marine environments.

Key features of a harsh environment connector:
• IP rating – depending on the application, harsh connectors should have Ingress Protection (IP) Ratings of IP67 (protection from dust and immersion between 15cm – 1m), IP68 (protection from dust and long-term immersion up to a specified depth) or IP69K (protection from dust, close-range high pressure and high temperature spray downs). IP69K is ideal for applications in the food processing and medical industries, where equipment must be regularly sanitised.
• Locking/coupling mechanisms – a robust coupling mechanism is a must for harsh connectors. There are many different types of connector couplings, including ring, twist locking, threaded, bayonet, push-pull and quick disconnect couplings, all with different attributes for various types of applications.
• Housing and insulation – the type of material the connector is made of is an equally important consideration. For applications where the connector is likely to be exposed to extremes of temperature and plenty of moisture and dust, a corrosion-resistant metal housing may be the most appropriate option. For other uses requiring lightweight and flexible connectors, high-temperature resistant plastic composites may be more attractive. Overmoulded cable versions are also sometimes available as an option where it is not a requirement for the unit to be re-terminated.
• Seals & grommets – rubbery seals can be used inside the coupling for keeping the connection tightly in place and watertight.

The shape of the connector, thread pattern or mating mechanism and positioning of pins also play an important role in the creation of a truly rugged and reliable connector. Circular connectors allow for better ease of engagement and disengagement as well as capacity for a wider variety of contacts and voltages. Circular connectors are also easier to seal and less likely to wear or break, and an intelligent ‘scoop proof’ design can avoid damage to the pins if the connector is mis-mated.

Bulgin’s popular Buccaneer range is an excellent example of IP66, IP67, IP68 and IP69K rated environmentally sealed circular connectors. These secure, rugged and highly reliable connectors can be used in harsh or hostile environments and offer a wide choice of options from 2 to 32 poles with screw, solder or crimp terminations as well as USB, SMB & RJ45 options for data to solve any type of design requirement.

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* Ultra-compact design
* Suitable for very high EMI disturbances
* Various mounting options
* V-Lock cord retaining option
* Fuseholder meets latest IEC standard

Today’s electronic equipment is designed to deliver high performance in a compact size. Often this causes problems affecting the equipment itself or other nearby devices due to the inherent electro-magnetic interferences being generated in and between the different systems. To meet these EMC challenges, high performance power entry modules must also keep pace, and such is the case with the new DD14 series from SCHURTER. The DD14 series packs remarkable functionality into a new generation of compact power entry modules.

The new DD14 combines an IEC C14 appliance inlet with 2-pole switch and 2-pole fuseholder. EMC performance is further enhanced with a depth-saving 2-stage filter. Shielding is optimized by screwing the metal casing of the filter to the panel, using its horizontal or vertical flange. A snap-in filter version eliminates the flange, consuming even less panel space.

The DD14 integrates the EMC filter directly in line with the power input. The two-stage filter design suppresses interference voltages more effectively over a much broader frequency spectrum than single-stage filters, thereby having a positive effect on electro-magnetic compatibility. Standard and low-leakage medical filter options are available for use in commercial or facilities ICT equipment according to IEC 60950 and medical equipment according to IEC 60601-1. The series meets the new fuseholder requirements outlined in IEC 60127-6 for enhanced fire safety and is also suitable for use in home appliances according to IEC 60335-1. It is compatible with V-Lock retaining cordsets.

The DD14 is rated for current levels up to 10 A / 250 VAC according to IEC and 8 A 125/250 VAC according to UL / CSA. It is ENEC and cURus approved.

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The power entry module series 6200, 6202 and 6205 are now equipped as standard with the V-Lock cord retention feature and are made of new material, whereby the components meet the increased glow wire tests according to IEC 60127-6 Edition 2 and IEC 60335-1 for appliances in unattended use.

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Completely Submersible TeeTube TH381 Connectors; 80A Rotary Isolator Switch; Debox 100% Tool-Free Junction Boxes

Hylec is well-known for its extensive ranges of junction boxes, terminal blocks, door enclosures, weatherproof connectors and HVAC components, and among these is the new 80A Rotary Isolator switch, the latest addition to the ROTARY ISOLATOR range of AC and DC switches for industrial and commercial buildings. IP67-rated and able to withstand water up to a depth of 1 metre, ROTARY ISOLATOR switches enable fast shut down in emergencies and ensure the circuit is completely de-energised for routine service and maintenance. With plenty of internal space for ease of installation, this range offers best-value/performance on the market.

Another new product that has taken the trade by storm since its introduction in April is the TH381 TeePlug, a completely submersible waterproof micro-connector for underwater and harsh environment installations. IP68/IP69K-rated and only 14mm in diameter, the TeePlug TH381 Series provides complete protection against high pressure water jets too. Its push-pull design installs up to 80% faster than competitive waterproof connectors. The TH381 Series suits outdoor lighting applications, such as architectural lighting, underwater lighting, road sign and billboard illumination and connection of exterior and interior Class 2 electrical devices.

The Debox range of in-line junction boxes, including the 100% tool less Debox SL can be assembled in a few seconds. It is supplied complete with a 16A, UL and VDE-approved, 4-pole screw-less push wire terminal block, DeboxSL joins flat or round profile cable and includes everything to save electricians on-site installation time and reduce costs. No tools are required: after inserting the cables and closing the included cable clamps, the lid is simply snapped shut and held with the supplied locking clip. This innovative cable junction box from Hylec-APL is IP20 protected, flame retardant to UL94V-0, and suits internal applications, including ring main lighting, LED lighting and power.

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Schurter improves upon a classic product: the new 4797-5 series IEC outlets are available with integrated Light Pipes. An intelligent, space and cost-saving solution for PDUs used in data centers and other multi-distributed power applications.

- Integrated Light Pipes for Status Indication
- Cord retention

The human need for information continues to expand at record pace, while continual advancements in information and communications technology (ICT), strive to keep pace with this demand. New data centers continually appear in the most unconventional of places to support this growing demand. These data centers are under constant pressure to improve upon efficiency and reliability under growing regulatory requirements to reduce energy use and cost. Meanwhile, the demand for reliable transmission with increased speed must keep pace. At the base of this modern day economic demand and supply phenomena is an intelligent, reliable power supply and – at the base of that – a simple connector. Schurter is pleased to introduce its IEC outlets with integrated Light Pipes, which bring a simple yet improved solution to intelligent power distribution

Freely Configurable Status Indication
Today, PDUs often use LEDs mounted in between outlets to display a current status. The high packing density of servers in modern data centers demands the same of power distribution units. With Schurter's appliance outlet, the integrated Light Pipes provide space and assembly cost savings over conventional strip designs. Service technicians are able to clearly see which systems are working properly, or respond to required maintenance adjustments. The triggering of the LEDs is freely configurable, wherein each state can be clearly and independently represented. An outlet could, for example, signal an outage with a red LED, or a critical power consumption pattern with a yellow LED.

Optionally the Schurter 4797-5 is available with up to four Light Pipes.

Cord Retention
In order to prevent against unintentional removal of a power cord, the new sockets offer a pull-out safety device. Depending on the arrangement of the sockets in the bar – horizontally or vertically – the Schurter V-Lock or other cord retention systems with side latches can be used. Both systems are usable with the 4797-5 outlets.

The snap-in bracket is designed for front panel mount and can fit a panel thickness 1.5 mm. Optionally variants from 1.0 to 3.0 mm are also available.

Technical Data / Approvals
- Ratings IEC/CCC 10 A / 250 VAC; 50 Hz
- Ratings UL/CSA 15 A / 250 VAC; 60 Hz
- Dielectric Strength > 1.5 kVAC between L-N    (1 min/50 Hz)
................................... > 3 kVAC between L/N-PE  (1 min/50 Hz)
- Allowable Operating Temperature: -25 °C to 70 °C (Pin Temperature)
- IP Protection from front: IP 20 acc. IEC 60529
- Suitable for appliances with the protection class I acc. IEC 61140
- Snap in mount for panel thickness 1.0, 1.2, 1.5, 1.7, 2.0, 2.5 or 3.0 mm
- PCB Terminal 2.8 x 0.8 mm

Applications
With its unprecedented functionality and compact design, the new appliance outlet 4797-5 is optimal for intelligent appliances with multiple outlets, such as intelligent PDUs and UPSs used in data centers.

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Schurter is launching its series 6610-5, the logical next step from the successful 6610 series; a new level of functionality is added to the industry’s original outlet popularly known for the highest level of efficiency during assembly.

- Integrated light pipes for status indication
- IDC Terminals
- V-Lock cord retention

The new 10 A-appliance outlet, series 6610-5, offers integrated guides for light pipes. It features up to two light pipes, intended to channel light from LEDs placed on a printed circuit board to the outlet surface. Technicians are able to clearly see which systems are working properly, or respond to required maintenance adjustments. The controls of the LEDs are freely configurable, wherein each state can be represented clearly and independently. To avoid damage and to make the wiring easier, the light pipes

can be inserted after the installation and need to be ordered separately of the sockets in the PDU.

The use of IDC connectors is particularly efficient. Multiple sockets can be wired quickly in a single step. This highly efficient way of wiring saves considerable time and thus labor costs. The phase contact is available with an optional PCB, quick connect or solder terminal for an independent line supply and status indication. To ensure an even better optical feedback, SCHURTER provides the individual outlets in black, white and grey.

The 6610-5 series is available in two arrangement versions, so called "along" and "cross". Depending on the application and type of PDU, mounting several sockets vertically (cross) or horizontally (along) one behind the other can be achieved. The IDC terminals are then oriented accordingly for insulation displacement of the wires.

The new 6610-5 series offers a pull-out safety feature to prevent against unintentional removal of the power cord. Depending on the arrangement of the outlets in the strip – along or cross – the Schurter V-Lock or cord retention systems with side latches can be used. The snap-in mounting of the 6610-5 is designed for plate thicknesses from 0.8 to 3.0 mm. Additional versions to be launched in the near future will include 16 A appliance outlets.

Technical Data / Approvals
- Ratings IEC/CCC 10 A / 250 VAC; 50 Hz
- Ratings UL/CSA 15 A / 250 VAC; 60 Hz
- Dielectric Strength > 1.5 kVAC between L-N > 3 kVAC between L/N-PE (1 min/50 Hz)
- Allowable Operating Temperature. -25 °C to 70 °C (Pin Temperature)
- IP Protection: from front IP 20 acc. IEC 60529
- Insulation Cover: Suitable for appliances with protection class I acc. IEC 61140
- Terminal: IDC -Terminal
- Panel Thickness: Snap in from 0.8 mm to 3 mm
- Material housing: Thermoplastic, black, white and grey, Frianyl B3 V0

Applications
With its unprecedented functionality and compact design, the new appliance outlet 6610-5 is optimal for intelligent appliances with multiple outlets, such as intelligent PDUs and UPSs used in data centers.

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The New and Inexpensive 2.5 A Appliance Inlet of the Type 2570 in Diverse Variants

The appliance inlet series of the type 2570 by SCHURTER provides diverse mounting variants and terminal options. Because of its cost effective design and the wide range of approval certificates for Europe, America and Asia, is the C8 inlet best suited for both industrial and consumer appliances.

The appliance connector for snap-in mounting is available with solder-, quick connect- or PCB-terminals. The PCB-terminals in combination with the sandwich mount are specially for the application on printed circuit boards. This way the board can be fully equipped and tested before being mounted. The mounting is done by introducing the connector into the back wall, and placing the appliance housing into the groove on the inlet.

Thanks to the use of rolled contact pins, the variants with solder or PCB terminals are very inexpensive and therefore suitable for consumer goods. Nevertheless do they comply with all the security requirements and are approved by all the relevant international standards.

Technical Data / Approvals
*  Ratings IEC/CCC 2.5 A / 250 VAC; 50 Hz
*  Ratings UL/CSA 2.5 A / 250 VAC; 60 Hz
7 A / 125 VAC; 60 Hz
*  Operating Temperature from -25 °C to 70 °C
*  Variants for Sandwich- or Snap-in Mounting
*  Solder-, Quick Connect- or PCB- Terminals

Application
With the complete approvals for Europe, America and China, as well as the low sales price, the 2570 Series can be sold to all industries. The Variants are applicable in medical-, audio- and industrial equipment.

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IP68/IP69 rated; 10A – 400V AC/DC; 80% quicker to install; 14mm diameter

Hylec-APL, the specialist supplier of electrical components and enclosures, announces the launch of the new TeePlug® TH381 plug and socket electrical micro connector designed for underwater use and harsh environment installations.  Offering the highest levels of reliability, TeePlug TH381 Series connectors provide complete protection against the effects of permanent submersion in water to ensure electrical connection, even when subjected to high pressure water jets.  The IP68/IP69K rated TeeTubeTH381 models also prevent dust and dirt ingress.  Measuring only 14mm in diameter, the TeeTubeTH381 Series suits outdoor lighting applications, such as architectural lighting, street lighting, underwater lighting, illumination of road signs and billboards and the connection of interior and exterior Class 2 electrical devices.

TeePlug TH381 connectors feature a push-pull design that installs up to 80% faster than competitive waterproof connectors, saving valuable time on-site and reducing cost.   Intuitive and functional in use, TeePlug TH381 connectors incorporate a special coupling system that confirms correct alignment and mating with an audible click and also prevents accidental disconnection, even against opposing forces of 25kg (8Kg according to EN61535).  Models with an additional optional safety system are available to further protect against disconnection by requiring the use of a tool such as a flat-blade screwdriver for uncoupling.   TeePlug TH381’s IP68 water resistance rating is guaranteed even when subjected to bending forces of up to 5Kg, and they are resistant to high pressure water jets up to 100Br, 16l/min at a water temperature of 80degC.   Vibration and external mechanical stresses are no problem either, as cable traction is prevented up to a force of 8Kg.

Electrical specification is 2-poles, 10A – 400V AC/DC.  Wire section is 0.25mm² to 1.5mm² without ferrules.  TeePlug TH381 Series plugs and sockets are available in two variants, cable to cable and panel-mount, and in two sizes to suit cable diameters between 5.8mm and 6.9mm and 7.0mm – 8.0mm. Cable reduction grommets are available for smaller cables, as are additional accessories, including sealing caps, a dedicated spanner for quick, safe installation, a bigger cable gland for larger cables and a rear nut for panel-mounted installations.

Building on the heritage of the proven TeePlug range, the new TeePlug Series TH381 is the optimum electrical connector for all submerged and challenging installations.

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Wieland Electric Inc., a leading global manufacturer of innovative electrical interconnect technology, has expanded its portfolio of revos rectangular connectors with the new revos IT Series split housing data cable feed-through connectors, which enable up to four pre-terminated data cables to be safely routed through a control cabinet or enclosure wall.

The revos IT Series data cable feed-through connectors accommodate cables with diameters spanning 4mm to 9mm, and are rated for IP65 environmental protection against dust and water ingress. In addition, the connector’s design incorporates a strain-relief feature to further enhance the robustness of the connection.

“More networked and automated machines on factory floors mean more specialized, pre-terminated cables, all of which need to be safely and conveniently routed through control cabinet or enclosure walls,” said Martin Lalonde, application engineer at Wieland Electric. “The revos IT Series’ split housing is ideally suited for passing preassembled cables - like encoder, data, and other unique cables - while maintaining the quality and signal integrity of the OEM cabling, and providing the convenience and robustness of industrial rectangular connectors.”

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The range of TeeTube connectors from Hylec provide a completely water-tight seal to IP68 at up to 5 bar.  In addition to being exceptionally hardwearing and robust, TeeTubes have a unique space-saving design.

The terminal block with secure sealing forms part of the external housing and can be directly screwed to the connector’s entry points, so no secondary housing is required.   The range is very comprehensive and includes straight through, T splitter and Y splitter models for 2 and 3 cable entry in a variety of sizes. There are also dual terminal versions available for easy fitting and looping of conductors (2+2 and 3+3 pole).

Standard Series TTK20 TeeTubes have a diameter of 26.5mm for cables of between 5mm and 13 mm and suit 32A max current.  For really tight spaces, there are Micro TeeTubes which are a mere 23mm in diameter, while larger cables between 8mm and 17mm diameter can be accommodated in the slightly larger 32mm diameter TTK25 Series.

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