Flexibility is one of the key buzzwords when it comes to modern machine and system concepts. This means that production machines must be as easy as possible to convert or adjust to individual workpieces. For high availability, it is also important to be able to replace or repair system components quickly - this applies to components such as sensors or drives as well as complete units, including feeding or handling systems. Using plug-in connectors for wiring opens up completely new possibilities when setting up previously hard-wired system components and connecting drives or power supplies.

Figure 2: The EMC gland turns the standard metal housing into an EMC housing: the wall bushing makes installation easier and protects the contact insert when plugged in - ensuring continuous shielding.

© Phoenix Contact

Basically, all housings have a mounting side and a cable side. Grommet enclosures are used for the cable side. The seal between the enclosure and the cable is provided by a gland, which is screwed into the corresponding thread of the enclosure in the metal enclosures. This screw connection is already integrated in the plastic enclosures of the series. When the nut is tightened, the internal cone is pressed against the cable sheath enclosed by the seal. This creates a reliable seal and strain relief - for cables with diameters from 4 to 17 mm.

On the device side, surface-mounted housings are ideal for wall feed-throughs on the control cabinet or terminal box. Base enclosures for mounting on the machine frame are also part of the D7 range. The flat screw-on housings allow cables to be routed parallel to the rack or frame. Feed-through enclosures are also being used more and more frequently in automation and system technology. In the case of the D7 series, the housings are mounted at right angles to the mounting surface, which considerably simplifies installation(Fig. 2). This allows plug connectors to be arranged tightly and cost-effectively. The surface-mounted and base-mounted housings can be attached to the device, the switch cabinet or the terminal box using the usual two screws. If high mechanical loads are to be expected, four screws are used for fastening. Universal flanges even allow both. Appropriate coupling housings also simplify the extension of cables - for example, for system expansions. This means that a connector solution with an IP67 degree of protection is available for almost every application - the connectors are dust-tight, keep water out and thus protect the electrical connection.

The cable-plug contact connection

Figure 3: Examples of square contact inserts for signals and power - the seal is always mounted on the pin contact carrier.

© Phoenix Contact

The technical requirements for the contact inserts are just as varied as those for the housings themselves: How many contacts are needed? What voltages and currents does the respective application work with? What cross-section do the conductors have? Like the contact inserts already available in other Heavycon series, the new D7 contact inserts are made of polycarbonate - a material that has become widely accepted for industrial connectors. Numerous properties - such as high rigidity and strength as well as good insulation - predestine this material for use in almost all industrial applications, including railroad technology.

Contact inserts with up to 12 power contacts at 250 V and 10 A are inserted into the housings. The Q12 high-pole connector - Q means square here - is standardized in the ISO 23570 standard. It is used, for example, in compact motors or as a signal connector. Where square connectors are required, the 5-pole Q5 connector is available - with rated voltages of 230/400 V and rated currents of up to 24 A per contact. Contact inserts are also used for high currents. The 2-pole HC-Q2 plug connector can be used for voltages up to 400 V and currents up to 40 A. With the Q3, an additional power contact is available with the same technical properties.

To prevent mismating, the contact inserts for the housings can be equipped with plastic coding - at least four coding positions are possible. This applies to the contact inserts from the Heavycon Q series with 2, 3, 4, 7 and 12 poles as well as to all contact inserts from the Heavycon A3 and A4 series. These contact inserts are used in both metal and plastic housings. The Q4 has a special feature: the 4-pole contact inserts for 830 V / 40 A are coded in such a way that they can only be used in plastic housings.

Authors:
Hartmut Schwettmann is Head of Product Marketing in the Industrial Field Connectivity division at Phoenix Contact;
Thomas Wolting works in Product Marketing Industrial Field Connectivity at Phoenix Contact as Senior Product Manager.