Discover our systems

Restrained Connector System

The restrained system is designed for those operating environments where frequent connections and disconnections are required. A unique feature of the racking mechanism within CONNEC’s restrained system is the ability to disengage phase conductors whilst the racking system remains engaged.

Contiguous phase earths – power cable construction maintained “end to end”

Multi-channel, single mode fibre optics within the connector system

Impedance matching of connectors to power cables

Increased range of cable size fitment

Improved plug to receptacle engagement to increase conductor contact area, reduce surface wear, and so minimise operating temperatures

Universal 6-pin configuration (3 power, 3 auxiliaries)

Optimised spares inventory by standardising components across all products

Testing to ex-certification as the “gold standard” in electrical connector safety

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Bolted Connector System

(1 kV to 11 kV, up to 500 A)

In addition to the technological features that are standard across all products, CONNEC’s bolted system includes a “life-of-plug” coupler as a beneficial replacement for individual phase insulators that are prone to damage and replacement during actual use.

Contiguous phase earths – power cable construction maintained “end to end”

Multi-channel, single mode fibre optics within the connector system

Impedance matching of connectors to power cables

Increased range of cable size fitment

Improved plug to receptacle engagement to increase conductor contact area, reduce surface wear, and so minimise operating temperatures

Universal 6-pin configuration (3 power, 3 auxiliaries)

Optimised spares inventory by standardising components across all products

Testing to ex-certification as the “gold standard” in electrical connector safety

Ability to remotely test for live/dead before disengaging connections

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Products Under Development

CONNEC has two current major product developments, the first being a 25 kV version of the bolted system, the second being the incorporation of multi-channel single-mode fibre optic cores into the connector system so as to bring a composite “plug and play” smart, medium-voltage cabling solution to the market.

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Future Product Potential

The combination of CONNEC’s intellectual property, proprietary polymers, and product development “know how” will enable further product development, including: A 35 kV bolted coupler system, The incorporation of aluminium phase conductors, A lower current 1 kV restrained system. In addition, CONNEC’s proprietary polymers with their unique combination of electrical and mechanical properties, are useable in a wide range of other products.

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FAQ

See below frequently asked questions by our customers.

Can I install and use CONNEC products in explosive atmospheres?

Yes, Connec has a range of products up to 11 kV that are certified to both ANZEx and IECEx and are specifically designed for use in potentially explosive atmospheres such as underground coal mines. Non-Ex versions of the same products are also available for use in non-explosive atmospheres and utilise aluminium.

Are there different current ratings available?

CONNEC equipment has a common Ex current rating of 425 A across all products in both the bolted and restrained products. Higher current ratings in the order of 500 A can be provided for Non-Ex applications based on an understanding of electrical system loads and the associated operating environment. At the current time, CONNEC does not provide an 800 A connector system, having preferred to improve the design of the connector system rather than over-specify the current rating in order to compensate for potential flaws inherent within the connector.

Is CONNEC equipment compatible with other connector systems?

No. CONNEC (polymer) connector systems are Type-B, whereas other traditional (metallic) connector systems are Type-A. As a temporary solution to allow CONNEC (Type-B) equipment to be connected to traditional (Type-A) equipment, jumper cables have been provided for use, which are typically short cable sections pre-installed with a CONNEC (Type-B) connector on one end, and a traditional (Type-A) connector on the other. However CONNEC does not endorse combining its Type-B connectors with Type-A connectors as the introduction of a weak link in to the system where phase earths are corrupted, results in many other system advantages being compromised as a direct consequence.

Where are the Flame Paths located?

All CONNEC flame paths are located ‘internally’ (i.e. insulating tubes) as opposed to ‘externally’ (i.e. face flange). This design feature increases electrical safety via a decreased ignition risk, as well as improved system durability given that unlike Type-A connectors, minor damage to the face of a CONNEC connector during handling does not compromise the flame path.

How do you connect two bolted plugs together - do you use Phase Connector Pins (aka Duck Eggs)?

CONNEC have designed a single piece “coupler” to connect two bolted plugs together, thereby avoiding typical issues associated with the use of traditional phase connector pins (aka “Duck Eggs”). The CONNEC plug coupler is ‘keyed’ to ease alignment, lower insertion forces and prevent the inadvertent transposition of phases when making connections. It also provides independent (segregated) earth continuity for each phase and an overall screen to maintain cable geometry across the connector, this being specifically designed for VSD applications and is unique to CONNEC’s (Type-B) connector system.

Can you supply complete OEM Cable Assemblies?

Yes, CONNEC can provide OEM cable assemblies as an additional service if required. We do this via our network of cable shop partners to provide the necessary cable supply, fitting and testing. Our cable shop partners are AS3800 accredited and located in key geographic locations to improve logistics and reduce transport time/cost.

What sort of Warranty is offered?

CONNEC currently offer two types of warranty: Standard Warranty (12 months) for product purchases with no services; and Extended Warranty (48 months) for product purchases where services (e.g. Cable Assemblies) are also incorporated.

Can I purchase spare parts to repair equipment?

Yes, CONNEC offer a range of spares kits and individual spare parts specific to each product in each range (i.e. bolted and restrained).

Do you offer customised (bespoke) solutions?

Yes, CONNEC can design/prototype/manufacture items specific to a customer’s needs, either on a commercial basis for individual customers, or self-funded based on the size/scale/repeatability of the application. We always encourage active feedback from our customers and partners to both help solve industry problems and to continuously improve our products and services to suit.

Is the polymer body as strong as the metal bodies?

The polymer compounds used in CONNEC products are proprietary to CONNEC and have undergone and passed the same rigorous testing as for all other traditional metal body equivalents in order to pass ANZEx and IECEx certification requirements.

What is the voltage range of CONNEC products?

CONNEC products are currently designed for 1.1 kV, 3.3 kV, 6.6 kV and 11 kV operating voltages.

Are CONNEC products suitable for use in VSD applications?

Yes, both CONNEC bolted and restrained product ranges are specifically designed with independent (segregated) earth tubes to readily accommodate VSD applications without the need for system modifications, this including the most recent variant of our 3.3 kV restrained system that has been designed with the use of VSD’s for longwall AFC’s in mind.

Does the 11 kV Plug require filling with Encapsulant?

The phase tubes containing the phase conductor terminations are the only components that require filling with encapsulant. By design, CONNEC’s 11 kV plug body does not require filling with encapsulant, effectively reducing weight and the time/cost when fitting and/or maintaining cables, with the added benefit of making our 11 kV plug bodies re-usable due to this feature (less wastage). At an operating voltage of 25 kV, it will be necessary to utilise encapsulant in order to adequately mitigate partial discharge and/or corona effects.

Can you connect earth straps between plug connections?

Yes, there are threaded sections on the edges of the plug faces where earth straps may be connected.

What is the typical fit-off time to terminate a plug?

Fit-off times vary depending on the cable type and whether a steel-wired armour (SWA) gland is required. Based on our experience to-date, CONNEC Plugs can be fitted-off in as little as 1.5 hours and up to a maximum of 4 hours according to the type of plug and cable involved.

Does the claim of reduced SKU mean that parts are common between the products and/or ranges?

Yes, CONNEC products have been designed to use as many of the same parts (e.g. thimbles, cores, etc.) as possible so as to reduce the amount of spares inventory required.

Is the cable seal and cable retention separate?

Unlike Type-A connectors, Connec’s products incorporate independent cable retention and cable seal mechanisms, the collet assembly and cable gland being specifically designed as separate components so as to substantially reduce the potential for compromised ingress protection (IP) sealing, and/or internal connection integrity (thimbles).

What materials are used for the Ex and Non-Ex types?

As standard, Ex type uses manganese bronze, whereas Non-Ex type uses aluminium.

What size is the maximum cable size (CSA) you can use?

Bolted plugs can accommodate inductors up to 400mm2 and restrained plugs up to 240mm2.

Can your equipment be supplied pre-fitted with cable tails?

Yes, CONNEC can provide cable tails fitted to our products as a value-added service to save time and ease of installation if required.

Can I test that isolation has been successful using non-contact methods?

Unlike metallic Type-A connector systems, CONNEC’s bolted system with it polymer-based body allows testing for live/dead at the connector prior to compromising flamepaths as part of plug/coupler disengagement.

Do you offer training on your products?

Yes, CONNEC can provide remote or on-site training on all our equipment, along with supporting documentation including drawings and detailed instruction manuals. It is also an OEM responsibility under ISO9001 accreditation to only approve cable shops to work on our products that are deemed by CONNEC to be adequately trained and competent.

Can you provide lockable end covers for use during electrical isolation?

Yes, CONNEC has developed lockable end covers with this very purpose in mind, which supplement our standard end covers that are primarily used to protect the electrical connection surfaces when exposed following disengagement.

Are your plugs and couplers easier to connect in operational use than current Type-A products?

Over and above the significant weight reductions of our products, the engagement system has been substantially re-designed to improve ease of connection, including the incorporation of mechanical engagement devices on all our products.

Are your products smaller in size than Type-A equivalents?

As a result of incorporating contiguous phase earths into all of our connector systems, the diameter of our products is generally greater than Type-A equivalents. However as a result of making significant use of lighter polymer materials, our products are generally lighter than Type-A equivalents and are therefore easier to handle with a lower risk of injuries being sustained.

Do your products allow improved/faster cable fault detection and cable replacement in operations?

As a result of phase earths not being compromised at connection points, cable constriction is maintained “end to end” which allows cable faults to be located more efficiently than when using Type-A equivalent systems.

Are discounts offered for volume purchases?

Yes, CONNEC is prepared to negotiate on pricing for increased volumes as part of reaching mutually beneficial commercial deals with end-users.

Is CONNEC’s fibre-optic connector system a world’s first?

Whilst other connector systems offer a fibre-optic option, based on published information they are either based on multi-mode fibre and/or expanded beam (EB) connectors, or are located outside the connector system where they are far more prone to damage than inside the coupler. To the best of our knowledge, CONNEC’s fibre-optic connector system that incorporates single-mode fibre and physical contact connectors is a world’s first in medium-voltage multiple use connectors and has been designed to facilitate the high bandwidth, long transmission distance data comms that is becoming a critical part of current and future industrial systems.

Can CONNEC’s products be supplied with and without fibre-optic functionality?

Yes, the inclusion of fibre-optic functionality through CONNEC’s connectors is a customer option and is not a mandatory inclusion.

Can aluminium conductors be used with CONNEC’s products?

CONNEC’s current suite of products are solely approved for use with copper conductors. However CONNEC is aware that aluminium conductors are becoming more attractive in medium-voltage applications due to the ever-increasing demand for copper in other applications – e.g. windings for electric motors etc. As such, in line with its commitment to develop bespoke products based on customer needs, aluminium conductors will be incorporated into our product range as and when it is demanded of by one or more customers.

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