IPD and Illumination

Unit:3 Power Carrying Devices

3.2 Connectors and Termination

Electrical circuits are composed of a multitude of components, including wires and cables.
Electrical connectors are used to join these to form a continuous path for electrical current to
flow. Connectors have male-ends (plugs) and female-ends (jacks) which connect to each other
forming either a permanent connection or, more often, a temporary connection that can be
assembled and removed with special tools.

Composition​:
Most connectors have two main parts – the housing, and terminals.

a​) ​Housing – The housing is the case used to contain the terminals. It ensures stability of the
connections and protects the electrical contacts from short-circuiting and environmental
hazards. Connector housings are normally made of molded plastic, but other insulating
materials like ceramics are also used.

b) ​Terminals – Terminals are the pins in a connector which provide electrical conduction to
make the connections secure. They are almost always composed of a metal, but some of them
use other conductive materials (carbon, silicon, etc.).

Features / Properties

1.Keyed Connectors – These are designed to connect only when they are in the proper
orientation. This prevents accidental damage to the pins and prevents users from inserting them
in the wrong sockets.
2.Locked Connectors – A locking mechanism ensures the connectors are held in place,
preventing connections from breaking accidentally, or from shifting when the connector is
bumped or jolted.

3.Hermetically Sealed Connectors – Some applications require an electrical connection which

might be submerged in water. These connectors are purpose built to be fully functioning under
water and withstand pressure up to certain depths.

4.Water Resistant Connectors – While they usually can’t withstand being submerged, these
connectors provide protection for the electrical connections against water damage from
splashes or occasional dampness.

5.Moisture/Oil Resistant Connectors ​– These are designed to protect the electrical

connections from damage caused by oil or moisture.

6.EMI or RFI Filtering – Additional features built into the housing top protect the connectors
from electromagnetic interference (EMI) or radio frequency interference (RFI), which can affect
circuits carrying electrical signals.

7.ESD Shielded Connectors – Electrostatic discharge can damage wiring and components.
ESD shielded connectors provide additional protection against this.

Specifications

To select the right electrical connectors that will get the job done and minimize risks, there are a
few factors which should be considered, depending on the application, type of connectors and
the strength of the electrical current the circuit will carry.
Performance Parameters
Performance parameters need to be selected based on the conditions in which the electrical
connector is going to operate-

a) Current –​ The current rating describes

the rate of electricity flow (current) a connector is designed to accommodate. This is measured
in amperes (A or amps). The Current rating on a connector will usually be in the range of 1A to
50A, though smaller and larger ones are available for special applications.

b) Voltage – ​The voltage rating

describes the range and type of voltage the connector is designed to carry. This is measured in
volts (V) for the voltage and Alternating Current (AC) or Direct Current (DC). Typically, the
ratings can be 50V, 125V, 250V, and 600V, but others are available too.

c) Operating Temperature –​ The

operating temperature range describes the range, recommended temperature and
minimum/maximum safe operating temperature for the electrical connector.

Physical Parameters
Physical parameters should be selected carefully, since they describe how the electrical
connector is designed, the connections it can be used for and much more:

a) Contact Pitch –​ This is the distance

from the centers of adjacent pins or the terminals in a connector. It is usually measured in
millimeters (mm). Larger contact pitches mean fewer connections or pins per area, which
reduces electrical arcing and thereby, interference. However, it does increase the overall size of
the connector.

b) Number of Contacts –​ Apart from the

type of contact pitch, the number of contacts or individual conductive elements present in
electrical connectors also vary.

c) Material – ​While the connector

casings are usually made of plastic, the materials used for the connectors are usually a
combination of metal and plastic for insulation, though just about any conductive material can be
used. The properties of the materials affect the performance, like conductivity, strength,
resilience and formability. Some commonly used ones include:

i) Brass – Zinc content can vary from 5-40%; cheapest metal to purchase by weight; springy;
strong; high conductance, used in KK terminals

ii) Phosphor Bronze – Good strength; tough; high conductibility and fatigue resistance; flexible
and elastic, used in electrical contact springs
iii) Beryllium Copper – Best alloy for spring terminals; cheaper than phosphor bronze, used for
high-performance applications

iv) High Copper Alloy – Strong modified copper; good electrical and thermal properties; retains
its form at high temperatures, mainly used in automotive applications

Types of Electrical Connectors

There are many types of electrical connectors, which can be categorized by level, function, and
type of termination:

Automotive Electrical Connectors

Automotive electrical connectors are designed to be used specifically in vehicles.

Heavy Duty Rectangular Connectors

Heavy duty rectangular connectors are designed to accommodate large electrical loads and
direct signals under a multitude of operating conditions. They are normally used in industrial
applications where the delivery of high power is required. For this reason special terminations
such as solder cup, wire wrap, and other heavy duty terminals, are used to secure the safe
delivery of power.

Panel Interface Connectors

Panel interface connectors (PICs) are devices installed in the outside of a panel that houses a
PLC, a computer, or other devices. The PIC allows the user to interface the PLC or the
computer without opening the panel door avoiding potential safety hazards. Power receptacles
and communication ports can be placed in a number of combinations to produce various
customizable products.

Plug and Socket – A female socket with one or more pins connects into a male socket or plug.
This provides easy, allowing connections to be made without tools. A pinout diagram can be
helpful for multi-pin connectors.

Rack and Panel – These connectors are usually used to connect stationary equipment with
removable electronic parts, especially when space or reliability of the connection are important
factors. Connection types include rack to panel, cable to cable, and cable to panel. They are
often used in printers, modems, home stereo systems and telecommunications.

Types of cable termination and Methods

The electrical cable termination is the physical and electrical connection of a cable-end that
connects to another cable, or to the terminal of the equipment.

Electrical terminations provide the required electrical connection as well as the mechanical
support, and physical protection of the cable.

There are different types of terminations based on the function, type of cable and construction
materials.

1. Crimp connection,
2. soldered connection,
3. compression termination,
4. wire-wrapping connection,
5. direct connection,
6. loop or eye connection.

The following procedures generally address the proper methods and tools required to terminate
copper cable.

1. Determine method and length of sheath removal. You can perform sheath removal three
ways:

a) Ringing tool: The ringing tool contains a razor blade, set to a depth that allows you to slit the
sheath deep enough to separate the sheath, but not nick the inner pairs. To properly use this
tool, insert about 13 mm to 19 mm (0.5 in to 0.75 in) of the cable into the tool. Turn the tool and
then remove the severed sheath with electrician snips.
b) Electrician's snips: Using the electrician's snips, carefully cut into the sheathing to a depth
that exposes the rip-cord. Using the rip-cord, pull down the sheathing until you're ready to
remove the proper length of sheath. Then remove the severed sheath with the snips.

c​) ​Slitter tool: You should carefully insert the slitter tool between the cable sheath and the
pairs. Slide the tool carefully down the sheathing until you've prepared the proper amount of
sheathing for removal. Then, remove the severed sheath using snips.

2. Using a proper sheath removal tool in accordance with ANSI/TIA/EIA-568-A standards and
the termination equipment manufacturer's specifications.

Terminating Techniques
a) ​Screw Terminal

There are a variety of methods used to terminate conductors. One of the most common types is
the screw terminal. Regardless of the type of terminal used it is important that the joint between
the conductor and the terminal is electrically and mechanically sound,

In other words the terminal screw should be sufficiently tight. The conductor insulation should be
removed far enough to allow the conductor enter the terminal. The conductor should be
insulated right up to the metal of the terminal. Stranded conductors should be twisted to form a
solid mass. The cable sheath should be removed a distance of at least 20 mm. This must be
done to prevent surface leakage current, allow more flexibility at the termination and also to
identify the core colour.

b) Screw Head and Nut and Washer Terminals

When terminating conductors under screw-heads or nuts, it is best to form the conductor into an
eye, using round nose pliers. The eye should be slightly larger than the screw diameter, but
smaller than the outside diameter of the screwhead, nut or washer.

The eye should be placed in such a way that rotation of the screw head or nut tends to close the
joint in the eye. If the eye is put the opposite way round, the motion of the screw or nut will tend
to untwist the eye, and will probably result in poor contact.

c) Cable Shoes terminal

Cable lugs and connectors are key components for the highest safety requirements. In order to
guarantee the safest connections, even with simple connections.
Splicing techniques and methods
3.3 Bus-Way Construction and Standards

Busway as defined by the National Electrical Manufacturers Association (NEMA) is a

prefabricated electrical distribution system consisting of bus bars in a protective enclosure,
including straight lengths, fittings, devices and accessories. Busway transports electricity and
connects to electrical gear such as switchgear, panelboards and transformers.

Busway is an excellent alternative to cable and conduit in commercial and industrial applications
because it’s not as complex to configure, less expensive to install and easier to replace,
especially in applications where load locations are likely to change.

Busway components include:

1. ​Bus bars, or conductors, conduct electricity; they are made from aluminum or copper and
vary in size
2. ​Housing,​ an aluminum or steel enclosure to contain the busbars
3. ​Insulating system made of a combination of air, epoxy and mylar; it separates the
conductors from each other to prevent electrical faults
4. ​Fittings such as elbows, offsets and tees help to properly route busway from one electrical
connection or termination
Busbar Way, a prefabricated trunk consisting of Copper / Aluminium busbars and suitable
insulating medium. The size of the trunking system will be bigger for air insulated system
compared to Sandwich type insulated Trunking system.

Construction and installation of Busbar Trunking (BBT) system included:

Comply with the General Conditions, Supplementary Conditions and the requirements of
concerned divisions / sections of the Electrical Specification. In addition read and conform to all
Electrical Sections of these specifications.

Provide all labour, materials, products, equipment and services to supply and install the
bus-way (busbar trunking) as indicated on the drawings and specified in these specifications.

REFERENCE STANDARDS FOR ELECTRICAL BUSBAR TRUNKING SYSTEM

All electrical installations shall be carried out in accordance with the best International
Standards and Codes of Practice specifically with the current issue of the IEE Regulations (BS
7671) and the requirements of the supply authority.

The entire installation shall be carried out and tested in accordance with the relevant National
and International Standards and requirements of local authority.

The design, manufacture, testing and performance of the busbar trunking system shall be in
accordance with the latest edition of BSEN60439 – 1 & 2 (IEC 439 – 1 & 2) standard, BS5486-2
and AS 3439.2.
Types and size of Bus Way required for this project shall be in satisfactory service under similar
conditions for not less than 5 years.

Provide verification certificates prior to manufacturer for MEP Consultants review.

The Bus-Way manufacturer shall be certified to the highest Quality Management System
Standard, namely ISO 9001 and ISO 14001 for Environmental Management Systems.

All bus-way shall include a CE MARK on its labels in accordance with the low voltage directive
number 73/23/EEC

Types of Bus way

A. Non-segregated busway​ has copper

phase bars located in one enclosure separated by air and epoxy insulation. Environmental
ratings include indoor, outdoor and dust tight. Housing or enclosure material can vary from
aluminum, steel or stainless steel. Capable of providing both medium and low voltage solutions,
non-segregated phase bus duct is well suited for harsh environments.

Common market segments: electrical utilities, petrochemical sites and heavy industry.
Non-segregated phase bus duct is used in applications up to 38 kV and 6000 A.

​ . Sandwich-style busway has phase bars stacked together inside a non-ventilated

B
aluminum or steel enclosure. This busway can be indoor, sprinkler proof or outdoor rated and
can be used for delivering power between gear using feeder pieces. Additionally, tap-off
locations can be provided on the busway itself. This style is called plug-in busway and is
typically used to power equipment below the busway. Capable of providing high ampacity with
equally high short-circuit withstand ratings, sandwich-style busway is a cost-efficient solution in
multiple markets
Common market segments: commercial construction, general and heavy industry and data
centers. Sandwich-style busway is used in applications up to 600 V and up to 5000 A.

C. Track busway is a continuous plug-in design where plugs can be installed or removed
nearly anywhere along the busway. These plugs can have cord drops or fixed receptacles
allowing for power distribution to equipment below the busway. Capable of providing low voltage
and ampacity solutions with simple onsite reconfigurations, track busway is common in data
center markets but is also very effective in laboratories and warehouse applications.

Common market segments: data centers, machine shops and labs. Track busway is rated for
indoor use and is available up to 225 A and 600 V.

D. Air-insulated busway has either copper or aluminum phase bars held in place with
polymer supports contained in an aluminum enclosure. The plastic clips keep the conductors
equally spaced and isolated, providing the air insulation. This busway is indoor rated and is
available in plug-in pieces and feeder designs. Capable of providing medium ampacity and low
voltage solutions with robust safety ratings.

Common market segments: data centers, machine shops and labs. Air-insulated busway is
rated for indoor use and is available up to 600 A and 600 V.