• Q. What is a Connector? Why it is used in industries?

    A: It is a component which mechanically connects conductors and provides an electrical connection that is easily disconnectable.

    A typical manufacturing plant has thousands of electric connections on both fixed equipment and moving machines. When those connections wear out or fail, it brings production machines to a dead stop - because hardwiring new replacement cable can take hours. One way to minimize such downtime is to fit multi-conductor power and signal cables with quick connectors at both ends, so that cables can be replaced in just minutes. It also necessary to protects the connected portion from external particles.

    Benefit:  Minimize installation time; Minimize installation, operation, and maintenance expenses.

  • Q. What parameters define a connector?

    A: Dozens of connector varieties and thousands of individual connectors exist, but five key parameters help narrow the options:

    1. Number of contacts:

                it may seem obvious that the number of contacts in the connector should match or exceed the number in the cable - but one common mistake is to miscount by nt counting ground, while connectors do not.

    2. Wire Gauge(AWG) or  (conductor size).

                Cable's wire gauge (conductor size) must be within the allowed range of the connector contacts. In general, screw contacts accommodate a broader range of wire gauges than comparable crimped contacts.

    3. Cable outside diameter (OD):

                This dimension is often overlooked during specification. A poor seal results if the cable OD is too small relative to the connector, whereas an oversized cable OD may prevent it from fitting into the connectors.

    4. + 5. Maximum voltage and current:

                Perhaps the most important specification to ensure a safe design a connector must be rated to handle the voltage and current of an application.

    Other parameters must be taken into consideration for difficult operating  environments or unusual electrical requirements - as when, for example, a connector sports the correct number of contacts, wire gauge, and OD but an insufficient current or voltage rating.

  • Q. What are the parts of a connectors?

    A: A connector consists of

    - Gland ( SKINTOP )

    - Hood

    - Female insert and contacts

    - Male inserts and contacts

    - Base

  • Q. How is a connector(EPIC®) built out of different components?

    A: The construction of a rectangular connector can be selected specifically for a customer‘s requirement. EPIC® industrial connectors from Contact are made up of various components (housings and contact inserts). The various components of the heavy duty rectangular connector are purchased individually and made up on a modular principle. A wide range of housing sizes and many options of inserts and contacts make it possible to design the ideal connector for each application.

    The following individual components have to be purchased in order to produce the complete rectangular connector:

    1. Cable Gland: The Cable Gland provides a seal between the cable and the connector housing. It may also be used to offer additional functions like strain relief and braid continuity for EMC protection.
    2. Hood: The connector housing for the cable entry.
    3. Male insert: Types of contact termination
                                                                            Cage clamp
    3.1 only Crimp: contacts have to be ordered separately
    4. Female insert: Types of contact termination
                                                                            Cage clamp
    4.1 only Crimp: contacts have to be ordered separately
    5. Base:
                  Panel mount: Cable entry though cut out in panel
                  Surface mount: Cable entry through a gland into the side of the connector base
                  Cable Coupler: for cable to cable connection

    For circular connectors the principle is the same, but there may be the possibility that certain components are already put together. e.g. housing + cable gland. In this case less single components have to be ordered

    EPIC® connectors can easily be configured with the connector selector

  • Q. How do we configure a connector?

    A: Follow below steps

    1. Refer above Q & A.

    2. Note all the parameters according to application requirement.

    3. Pls connect to the below link and do the configuration.

    4. Apply all the parameters step by step to arrive the connector set.

  • Q. What is the meaning of cycles of mechanical operation of connectors(EPIC®)?

    A: Cycles of mechanical operation are tested according to European standard DIN EN 60512. The complete test program consists of many single tests. The most important tests out of the standard are

    Visual examination: No damage shall occur which could impair normal use and the change of contact resistance shall be no more than 50% of the reference value at first mating or <= 5MOhm. The higher value is permissible.

    Very of the change of contact resistance is the limiting factor, which means that the resistance is more than 5mOhm or 50% than reference value. The connector is after given mating cycles mostly alright but does not apply with values given in the standard. Finally decides the application if the connector has to be replaced.

  • Q. In what kind of applications are connectors necessary for? When are connectors used?

    A: Typically, connectors are required for cabling on highly dynamic applications - to 1000 V, 125 A, and 280 contacts where required.

    Elsewhere, connectors are used on machinery that must withstand extreme environments - with protection to IP 65, 67, 68 and NEMA 4, 4X, or 12.

    - When equipment consists of interchangeable modules (quick disconnect)

    - When equipment must be portable (quick disconnect)

    - When machines are very large and must be broken down for shipment and re-assembled at customer location (assembly speed and accuracy)

  • Q. Can I use a standard crimping tool for crimping an EPIC® connector?

    A: Crimps are a very good connection between the wire leads and the crimping contact. They are mechanical robust, have a low resistance, require less space and they have long term stability. This only works, if the crimp was skillfully gastight. This can only be sure with Lapp approved crimping tools. For this purpose it’s important to use the correct cross section, the right contact, the use of approved tools and the right crimping dies. Extensive testing by LAPP ensures a proper function over a long period to ensure. Therefore it’s only allowed to use approved tools.

  • Q. Why connectors have no CE marking?

    A: The low voltage directive, basically “electrical equipment” for voltages between 50V and 1000V AC or 75V and 1500V DC. For such equipment, CE marking is required. Connectors are “basic components” within the meaning of the low voltage directive and therefore excluded from the scope of the directive. As basic components are expressly connectors (fastener, connector) mentioned in section 9 in the footnote 11th.

    A further aspect is the safety. This is to be assessed only after installation or assembly. EPIC® connectors are sold in pieces. Only during the assembly by the user, the safety is established.

    This is the official statement from the ZVEI (Zentralverband Elektrotechnik- und Elektronikindustrie e.V.), (Electrical and Electronic Manufactures Association)

    "DIRECTIVE 2006/95/EG of the European Parliament and the council of 12 December 2006 on the approximation of the laws of the member states relating to electrical equipment for use within certain voltage limits”.

  • Q. Should design engineers use connectors?

    A: No - unless downtime must be reduced. Power and signal disruptions have many mechanical and electrical causes, from forklift  accidents to over-current conditions. In installations where critical electrical connections abound, some will eventually get damaged. Connectors add a small premium to the initial cost of cabling. but can pay for themselves by eliminating even a few minutes of inevitable downtime on a busy production line.

    Benefit:  Minimize installation time; Minimize installation, operation, and maintenance expenses.

    Aslo refer above Q & A.

  • Q: Should design engineers consider connector derating due to hot temperatures?

    A: Extreme installations require considerations of the five general parameters(FAQ 76), Plus other criteria. In hot applications, for example, designers must account for the fact that connectors are gradually derated with increasing temperatures.