Specifications and Certifications
Things to know about Toughcon
The Toughcon circular connector system was developed by Schlicker GmbH and has been produced and assembled in our factory in Radevormwald for 15 years. We are ISO 9001 certified. Our products are RU, CE and RoHS certified.
With our engineering and flexible production, we make the impossible possible and create customised solutions that are convincing in terms of ease of assembly, cost-effectiveness and operational safety.
The circular connectors have the following specifications:
| Key | Value |
|---|---|
| Housing Sizes | 11, 17 , 23 |
| Number of contacts (up to) | 4, 9, 14, 24, 37, depending on housing sizes |
| Coding options (only TM Metall series) | 2, 3 or 5, depending on housing sizes (additional codings with use of coding pins) |
| Material metal housing TM | Zinc diecast |
| Material contact carrierTM/TT | Glass-Fibre reinforced PPO |
| Material metal housing TM TT | Glass-Fibre reinforced PPO |
| Temperature range | -30°C bis +105°C |
| IP Code | TT plastic IP44 standard / IP65 with sealing (accessories) / TM metall always IP65 |
| Flammability | self-extinguishing UL 94V-1 |
| Insulation resistance | ≥ 500 MΩ |
| Rated voltage | 250V in standard configuration, upgrades possible |
| Test voltage | 2,5kV in standard configuration, upgrades possible |
| Overvoltage category | II according to DIN EN 60664-1:2007 |
Comparison TT93 (standard contact) and TT53 (compact, highly capacity)
| Contact Family | TT93 | TT53 |
|---|---|---|
| Acceptable current load at at +68°F in free air | ≤ 13A | 10A bis 40 A, depending on version |
| Material | Brass, stainless steel (others on request) | Copper alloy |
| Connection cross section | 0,05 - 4 mm2 / AWG 30-12 | 0,75 - 10 mm2 / AWG 20-08 |
| Max. insulator diameter | 3,2 mm2 - 4 mm2 / 0.0126 to 0.157 inch | - |
| Surface | Tin or gold | Gold |
| Connection cycles min. | 500 gilded, 100 tin-plated | 200 to 500, depending on version |
| Pluggability | only insertable without current | only insertable without current |
| Contact resistance | ≤ 5 m Ω | ≤ 1 m Ω |
| nsertion/withdrawal force | ≤ 4,5N | ≤ 5N |
Test Procedures
| Test | Procedure | Requirements |
|---|---|---|
| Firm contact position | An axial load is exerted on the contact in order to press it to the socket or plug rear side. | At least 45 N per contact and at least 66 N on average for all the contacts |
| Tension strain | According to MIL-STD 1344A procedure 3001.1 | No electrical breakdown or flashover below1500 volt |
| Vibration resistance | According to MIL-STD 202F procedure 204D, test conditions B contacts at 100 mA test current connected in series during the test | No detaching of parts, maximum permissible test current interruption of ten microseconds |
| Shock resistance | according to MIL-STD 202F procedure 213A test condition A maximum value 50 G contacts at 100 mA test current connected in series during the test | No damage. No test current interruption longer than 10 microseconds permissible |
| Temperature change | The plugged connection is subjected to five temperature cycles between -55°C und +105°C / -67°F and +221°F | No damage. The specification is fulfilled. |
| Thermal load | The plugged connection is subjected to 200 hours at 105°C / 221 °F. | No damage. The specification is fulfilled. |
| Corrosion | Salt spray test according to MIL-STD 202 procedure 101, test condition B | No damage. The specification is fulfilled. |
| Insulation resistance | According to MIL-STD 1344, procedure 3003. The resistance is measured between neighbouring contacts. | Minimum of 5000 MΩ at ambient temperature |
| Weathering resistance | Spray water is used appropriate to IP65 rating | No moisture ingress is determined. The specification is fulfilled. |
Properties of Toughcon (Overview)
Important features of Toughcon circular connectors:
- Available in panel/chassis (wall sockets) and ‘free-hanging’ (cable sockets) versions
- Available in plastic and metal versions -> cost and weight reduction for those applications where the metal version is not required
- Coded position between the top part and insert allows the existing contacting requirements to be plugged in using key polarisation
- Special thread with clear latching point ensures anti-vibration locking
- The wide range of different crimping contacts allows the use of stamped, bent and precision-turned contacts with maximum currents of up to 40A (for special solutions with TT53 contacts), The large selection of possible contacts allows the use of stamped, bent and precision-turned contacts with maximum currents of up to 40A (for special solutions with TT53 contacts) per individual contact
- Contacts are available with gold or tin plating
- Both pin and socket are available for a large selection of wires from AWG 5 (TT53 special solutions) to AWG30 (TT93)
- Protection class: Standard IP44 or IP65, depending on version, IP67 with additional components in the metal version (when mated)
- Based on military standards:
- Dielectric strength: MIL-STD 1344A procedure 3001. 1
- Impact resistance: MIL-STD 202F procedure 213A, test condition A. Maximum value 50G (contacts connected in series with 100mA test current.)
- Corrosion: MIL-STD 202 procedure 101, test condition B
- Insulation resistance: MIL-STD. 1344 procedure 3003
- Glass fibre reinforced thermoplastics with flammability rating according to UL category 94V-1 are used for the inserts and plastic connectors.
- Standard crimping tools available for stamped and turned contacts
- International market acceptance for many years
You can find all the information and many examples in our current Toughcon catalog.