Xuron Kevlar Scissors Hold and Cut Slippery Fibers
April 2010—A precision scissors that is especially designed for cutting Kevlar® in fiber optic cables is available from Xuron Corp. The shears are ergonomically correct for production and field service applications.

The Xuron® Model 9180 Kevlar Shear features one serrated edge to prevent the fibers from sliding and another highly sharpened edge that makes a clean, even, and uniform cut. Ideally suited for prepping fiber optic cables, this ergonomic scissors has cushioned rubber grips that comfortably fit into any hand, and a return spring that opens the cutting head wide after each cut.

Designed for production use, the Xuron Model 9180 Kevlar Shear can be used by left- or right-handed workers with varying hand sizes. There are no awkward finger loops to inhibit gripping, and they can be used for cutting other cable insulations or de-gating parts, as well as Kevlar.

The Xuron Model 9180 Kevlar Shear list price is $23.75.

Visit Xuron online.

Alpha Wire Series XM Flexible Control Cable
March 2010—Alpha wire has introduced a Series XM flexible control cable that provides continuous-duty flexing in a robust PVC-jacketed cable. A new PVC formulation enables continuous flexing in strenuous applications, such as high-speed pick-and-place robotic systems, automated material handling equipment, conveyors, and transfer shuttles.

Available in conductor sizes from 18 AWG to 8 AWG and up to 65 conductors, oil- and sunlight-resistant XM cables have a dynamic temperature range from -5°C to 90°C. They are approved to a wide range of standards that includes UL Types TC-ER, MTW, WTTC, and CSA AWM I/II A/B FT4. Furthermore, Series XM meets NFPA 79 standards for industrial machinery applications. The cables are available unshielded or with a braid shield for environments with potential EMI/RFI interference. Conductors are available in red, blue, or black to match industry-standard color coding for AC and DC circuits.

Visit Alpha Wire online.

Tyco Electronics Launches PSA, Thermal Transfer Printable Labels for Wire and Cable Identification
April 2010—Tyco Electronics introduces EET G4 woven nylon, Pressure-Sensitive Adhesive (PSA) acrylic labels for thermal transfer printers. The labels are suitable for wire, harness, and cable identification labeling, as well as applications with irregular contours or that have low surface energy.

The industrial, instrumentation, consumer electronics, commercial, and building markets will benefit from these labels, as they are available in multiple sizes to fit a wide range of wire, harness, and cable dimensions. For wire and cable applications, the labels can be applied in a “flag” or “wrap-around” format. Additionally, the EET G4 labels easily conform to the flexible nature of flat-ribbon cables without causing peeling or delamination.

The product line has passed the Mark Permanence test (MIL-STD-202; method 215) and Eraser Rub test (MIL-M-81531), indicating that the labels have exceptional resistance to abrasion and alcohol-based solvents, such as isopropyl alcohol, when printed using the recommended thermal transfer ink ribbon.

Visit Tyco Electronics online.

Tyco Electronics Expandable, Braided Polyester Sleeves
March 2010—Tyco Electronics’ Raychem Versaflex polyester sleeves for mechanical protection of wire and cables are now available in North America. The sleeves are competitively priced and offer extreme flexibility and strength through a braided design that allows for easy expansion and contraction of the sleeves while retaining tension.

The RoHS-compliant product line easily conforms to irregularly shaped products or substrates without the need to heat shrink. The sleeves do not retain heat or moisture and offer resistance to abrasions. Specific applications include cable bundling and protection of wire harnesses and hoses in the industrial, commercial, and rail industries.

Product offering includes flame-retardant and non-flame retardant versions, which are both available in multiple sizes. The flame-retardant version meets UL VW-1 flammability requirements.

Visit Tyco Electronics online.

Molex TM-4000 Universal Crimp Press Terminates Large Lug Products
March 2010—Molex’s heavy-duty TM-4000™ Universal Crimp Press provides up to 31 kN (7000lbf) for bench-top crimping large lug products of up to 4 AWG. The TM-4000 Universal Crimp Press is an inexpensive, electrically controlled, direct-drive press designed for mid-volume, semi-automatic bench-top operations such as those found in the automotive, industrial, and commercial markets. Capable of production rates of up to 2,400 terminations per hour, the TM-4000 offers contract manufacturers, assembly houses, and design engineers an effective and affordable method of applying a wide range of side- and rear-feed terminals to heavy-gauge wires.

To help reduce tooling costs and provide production flexibility, the TM-4000 accepts most industry standard applicators, including air-feed applicators that process terminals mounted on Mylar tape, as well as FineAdjust™ and Mini-Mac™ applicators with side and rear feeds.

The TM-4000 Universal Crimp Press meets the strict OSHA (Occupational Safety and Health Administration) safety and noise requirements and is CE approved, according to the essential health and safety requirements of the Machinery Directive, Low Voltage Directive, and EMC Directive, which reduces the risk of injury. Two attached safety interlock switches prevent the press from cycling if the guard is open or when it is being hand-cycled.

Visit Molex online.

Samtec Offers Family of Rugged Tiger IDC Cable Assemblies
April 2010—Samtec’s rugged, multi-finger Tiger IDC contact system is designed for applications requiring high reliability and/or high mating cycles, with optimized normal insertion and withdrawal forces. Samtec offers three rugged “off the shelf” Tiger IDC twisted pair and flat cable systems, as well as custom IDC design capabilities for virtually any application.

Two 30 AWG Flat Cable Tiger IDC assemblies are available in a choice of pitches with reverse wiring, breakout, and daisy chain options. The .050-inch (1.27mm) pitch (FFSD Series) and low profile 2mm (.0787-inch) pitch (TCSD Series) systems mate with an extensive assortment of Samtec’s standard .050-inch (1.27mm) and 2mm (.0787-inch) pitch terminal strips.

The 32 AWG Twisted Pair IDC Cable Assembly (FFTP Series) is on .050-inch (1.27mm) pitch and provides up to 2½ times the performance of traditional IDC flat cable. The system mates with a choice of standard Samtec .050-inch  (1.27mm) micro, shrouded, and ejector headers.

All three Tiger IDC Cable assemblies offer a variety of rugged options, including strain relief and polarization. They are available in single- or double-ended with socket or terminal strip end options.

Pricing begins at 10¢ per line at production quantities.

Visit Samtec online.

ODU Disposable Cable Systems
January 2010—Today, disposable medical cable systems can be more cost-effective than sterilization. ODU’s new MINI-MED Disposable System offers an affordable disposable option that is sized for installation in confined spaces. The price for the connector, cable, and assembly starts at 1.28 € ($1.75) per piece.

ODU MINI-MED features:

• Space-saving size

• 2 to 6 contact positions

• Protection class IP 68 when inserted

• Blind mating

• Assembled with PVC or highly-flexible silicone cable

• Cable lengths: 0.5m, 1.0m, 1.5m, 2.0m, 3.0m, and 5.0m

• Can be sterilized in EtO

• Free of DEHP

• Disinfection by wiping

• 0.9 percent NaCI-resistant

• Plug, receptacle, and in-line receptacle are available

For more information, visit www.disposable-connector.com/en.html.

Tyco Electronics Relieves Cable Congestion
January 2010—Tyco Electronics has launched a new Madison Cable brand Cat 5E miniature trunk cable designed for the telecommunication and data communication industries. The product, available in shielded or unshielded configurations, eliminates cable congestion and offers a more flexible, easy-to-route interconnection for high data-rate Ethernet and xDSL applications.

A central feature of the product is its reduced diameter for improved routing within, or between, cabinets and frames for central offices or telecommunication closets. Additional benefits include reduced weight, improved cabinet/frame airflow, and easier handling and routing.

The multi-pair cables can be customized for specific applications and include a variety of pair-counts and AWG sizes. Non-halogen and outdoor-rated configurations and customizable shielding are also offered.

The product meets industry standards (TIA/EIA 568, ISO 11801), safety ratings (UL/CSA), and ADSL/VDSL2 and GbE (Category 5E) requirements, and fits a wide selection of industry standard connectors.

Specific applications include: Cat 5E, DSLAM, Gigabit Ethernet routers/concentrators, ADSL/VDSL Frames, xDSL cross-connects, trunk splice, and FTTN Pedestal.

For more information on the Cat 5E miniature trunk cable, contact Marc Dupuis at Tyco Electronics/Madison Cable at 1.508.926.4145 or visit http://www.tycoelectronics.com/help. The product flyer (literature number 1773456-1) can be requested through this system.

Lemo’s Aluminum Connector Series Designed for High-Rel Military and Harsh Environments
February 2010—Lemo introduces its new precision-engineered connector series designed for military and other harsh environment applications that require robust performance in a lightweight, compact size. The Lemo M Series Connector family has been uniquely designed for applications that require a durable, yet reduced weight and compact solution. This new connector design is for the designer that requires a MIL-38999 type of connector in a much smaller and lightweight package that meets the vibration, RFI, water ingress, and corrosion specifications.

A third-party testing house validated (EIA 364 and MIL-STD 810) the M Series for lightening strike, vibration, and other critical environmental, EMI shielding, and flammability attributes critical to aerospace and military environments. “The results were superb and validated our confidence in the family, which offers compelling advantages above and beyond our competitors,” said Tim Hassett, managing director of LEMO USA. “Other exciting news is that we now have a unique position in the market due to our most recent partnership with Avnet, who we have chosen as our preferred distributor. With Avnet’s expertise in the military, aerospace, energy, and industrial markets, in addition to their design-in win successes, we see a future in customer satisfaction and long-term growth.”

For more information, visit www.LEMO.com.

ITT Ensures 100% HMI Shielding with 19-way Pogo Pin Connector and Cable Assembly
January 2010—ITT Interconnect Solutions has developed a 19-way commercial Pogo pin connector and cable assembly that meet the stringent electrical and mechanical specifications of demanding environments. Rated to IP55 specifications, the 19-way connector and cable assembly are ideal for use in medical test and diagnostic imaging equipment, aircraft electronics, instrumentation, and industrial equipment.

“The 19-way Pogo pin connector features our proprietary Pogo pin technology, which achieves low contact resistance under 10mA and guarantees reliable and robust performance and a lifespan of more than 5,000 mating cycles,” said Keith Teichmann, director of marketing for ITT Interconnect Solutions. “The commercial Pogo cable assembly also provides exceptional EMI shielding, with 100 percent effectiveness throughout the entire assembly.”

The harsh environment, 19-way commercial Pogo pin connector features stainless steel shells, snap-on breakaway coupling, and an interfacial seal. The connector’s mating system is both tactile and audible, with an ergonomic grip for easier handling. The cable assembly includes bulkhead, front mount, receptacle, plug with RJ45, and in-line plug options.

Depending on cable and length, typical pricing for the 19-way Pogo pin connector and cable assembly ranges from $100 to $200, open-ended assembly. Lead time is from 10 to 12 weeks.

For more information, visit www.ittcannon.com.

Phoenix Contact Robust Systems Cabling Solution for SIMATIC® S7-300
January 2010—Phoenix Contact expands its VARIOFACE Professional (VIP) systems cabling line with a robust overmolded front adapter/cable system for the Siemens SIMATIC® S7-300. The unique characteristic of this cabling system is the polymer overmolding surrounding each end of the cable. A completely encapsulated plug-in adapter connects to the Simatic S7-300 I/O card, providing a secure connection. On the other end, the standard ribbon cable connector that mates with a corresponding interface module is also overmolded. Together, the overmolded ends provide maximum strain relief and optimal protection.

The single-piece construction makes installation easy and efficient. To transmit signals from the S7-300 to the field, just plug in both ends of the cable. With only two points of connection, there are fewer points of possible failure, and a more secure signal transmission is achieved. Additionally, the single-piece construction requires fewer parts to order and maintain.

The overmolded front adapter/cable system for Siemens SIMATIC S7-300 is compatible with Phoenix Contact’s existing VIP interface modules. The VIP line includes two versions of the Siemens SIMATIC S7-300 cabling system for 32-channel I/O cards, and a separate solution for 16-channel I/O cards.

For more information, visit www.phoenixcontact.com.

Siemon 10+Gb/s SFP+ Passive Copper Cabling Products for High Performance Data Centers
February 2010—Siemon’s new high-performance 10+Gb/s SFP+ passive copper cable assemblies were developed as a cost-effective and lower-power alternative to optical cables for short reach links in high-speed interconnect applications, such as high-performance computing (HPC), enterprise networking, and network storage systems. The low-latency assemblies support data transfer rates up to 10+ Gb/s per lane, exceeding the stringent electrical SFF-8431 and mechanical SFF_8432 standards specifications.

Siemon’s hot pluggable SFP+ cable assemblies are fully shielded with robust die cast housings and enhanced spring fingers to minimize EMI leakage. The internal PCB assembly is factory terminated to twin-axial shielded cable and provides superior signal integrity to support 10+Gb/s high frequency data rates. The assemblies are impedance matched to ensure interoperability with SFP+ host port and minimize insertion loss.

The new 10+Gb/s SFP+ products support a wide array of data protocols/interfaces, including 8Gb/s FibreChannel HCA, 10Gb/s FibreChannel SAN, 10Gb/s FibreChannel over Ethernet, 10Gb/s Ethernet single lane, 10Gb/s InfiniBand QDR single lane and various 10Gb/s Unified Architecture network links, as well as other 10Gb/s Switch and Host Controller Adapter card and high performance links.

“These same cables support serial single-lane applications, such as RapidIO, RocketIO, and other value-added IO interface links,” said Ed Cady, business development manager for Siemon.

Product options include varied EEPROM programming, wire gauges, and assembly lengths for specific applications.

For more information, visit www.siemon.com.

Delphi’s Wired for Green
December 2009—As fuel prices soar, many vehicle manufacturers are reducing vehicle weight in order to enhance fuel economy. And if that weight reduction can be accomplished using material that is also recyclable and will have a minimal impact on the environment, it’s a value-added bonus.

Delphi Corp.’s innovative Halogen-Free Ultra-Thin-Wall Cable was named a finalist in the Environmental category of the 39th Annual Society of Plastics Engineers Automotive Innovation Awards in November 2009. The innovative wiring insulation material received high marks for cable size/weight reduction and recyclability. And it’s even more robust than conventional insulation.

“The main function of the insulation is to insulate the conductors, such as copper or aluminum, from other conductive materials that could carry current,” said Doug Gruber, product business unit director, Delphi Electrical/Electronic Architecture Distribution Systems North America, Delphi Packard Electrical/Electronic Architecture. “Resistance to cuts and abrasion are key insulation characteristics. Delphi has taken it one step further in developing a product that can minimize a vehicle’s impact on the environment—both in terms of fuel economy gains and end-of-life recyclability.”

But how much of a difference can it really make? Consider these factors. 

• Size and weight: Today’s vehicles contain as much as 100 pounds (45.3 kilograms) of wiring. It may come as a surprise that insulation represents roughly 25 percent of that total. So simply reducing the amount of insulation required can pay big dividends. Delphi Halogen-Free Ultra Thin-Wall insulation measures just 0.2mm thick, compared to about 0.4mm for conventional thin-wall cable. That difference—equivalent to about two sheets of paper—accounts for a mass reduction of up to 27 percent and a volume reduction of up to 47 percent in a typical wiring harness. That can translate to a reduction of roughly five pounds (2.2 kilograms) when the entire harness is taken into account.

“That means an automaker can fit more features into the same space, or reduce the weight of wire needed to maintain an existing level of features, which can help lower vehicle weight and improve its fuel economy,” said Gruber.

• Recyclability: Delphi Halogen-Free Ultra Thin-Wall Cable is manufactured using a modified polyphenylene ether alloy recyclable coating. Traditional methods call for polyvinyl chloride (PVC) insulation in wiring used in a vehicle body or interior, or a cross-linked polyethylene (XLPE) insulation. Both have different impacts when it comes to the environment.

“PVC contains halogens, which are effective, but can make the insulation itself difficult to dispose of at end of life, as the halogens can escape and produce byproduct compounds if the cable is incinerated,” said Gruber. “XLPE is halogen-free, but is not highly recyclable. Using a polyphenylene ether alloy takes care of both halogen-free and recyclability issues, yet remains cost-effective and robust.

• Robustness: Delphi Halogen-Free Ultra Thin-Wall Cable is actually more durable than conventional thicker wiring. It is heat resistant in continuous temperatures up to 221°F (105°C). It also features high flame retardance, meeting the requirements of ISO (International Organization for Standardization) Class A and B. And it offers excellent pinch resistance (nearly double that of traditional cable), as well as outstanding abrasion resistance. In fact, it exceeds SAE (Society of Automotive Engineers) and ISO abrasion testing standards.

Alternative Solutions
The inherent advantages of Halogen-Free Ultra Thin-Wall Cable enable variations that can further enhance a vehicle platform’s environmental—and cost—performance, including:

Halogen-Free .13 mm2 Cable: The strength and stiffness of Delphi’s Halogen-Free Ultra Thin-Wall Cable insulation and small crimp terminals allow for the use of a smaller gauge size—up to half the size of conventional thin-wall cable—without sacrificing performance or requiring automated assembly. And that means reduced copper content, which, in addition to the obvious weight reduction, also reduces cost, as copper costs have increased 370 percent since 2003.

Halogen-Free Aluminum Cable: Delphi is also developing aluminum core cables as a cost-effective alternative to copper, which costs nearly three times as much as aluminum. Halogen-Free Aluminum Cable offers a 48-percent mass reduction compared to copper wire, enhancing the weight reduction potential when integrated with Halogen-Free Ultra Thin-Wall Cable insulation.

To learn more about Delphi Halogen-Free Ultra Thin-Wall Cable, click here.

ITT Interconnect Solutions’ APD 1-way Connector Ensures Safety in Hybrid and Electric Vehicles
December 2009—ITT Interconnect Solutions has expanded its line of APD Series circular connectors with the new APD 1-way finger-protection device. The robust, reliable connector ensures maximum user safety and provides IP69K-sealing to withstand elements in harsh environments, making it ideal for the transportation and automotive industries.

“As the need to move away from fossil fuels to alternative energy sources grows, there is an increased focus on hybrid and electrical vehicles. Safe connectors suitable for use in high-voltage and maximum power applications are required, and the APD 1-way connector effectively meets those needs,” said Keith Teichmann, director of marketing for ITT Interconnect Solutions.

The APD 1-way finger-protective connector is easy to use and features a plastic cap that protects the user’s fingers. The connector receptacles mate with standard APD 1-way plugs and incorporate ITT ICS’ proven APD contact, crimp, and coupling nut system. Pin contacts are available with standard crimp and additional screw or bolt terminations. The connectors suit cable cross-sections from 16mm² to 50mm².

Voltage rating for the APD 1-way connectors is to 400VDC in mated condition, and the connectors are capable of handling voltages to 630VDC, based on normative regulations (the connector must not be mated or unmated under load). Current rating is to 245 amps at 25°C.

Please consult ITT for pricing for the APD 1-way connector. Lead time is eight weeks. 

For more information, visit www.ittcannon.com.