Heavy Duty Power Cables, Battery Cables & Meter Tails

For over a decade Connect-2 Technology has been providing numerous customers with high quality heavy duty power cables, battery cables and meter tails. Utilising quality terminals and tooling from manufacturers such as Amp (Tyco), Cembre, JST and Takbro to produce a range of assemblies suitable for standard high power requirements through to specific uses in demanding environs where resistance to corrosion and extreme vibration is required.

Our extensive range of heavy duty tooling provides us with the ability to terminate single wires from 0.5mm2 to 120mm2 in both solid and stranded variants. Specific features of the Amp heavy duty terminal options, of which we stock in-depth, are as follows: -

SOLISTRAND Range:

The Amp SOLISTRAND range of terminals and splices are specifically designed to terminate both solid and stranded wires as well as irregular shaped conductors and combinations of these. The use of ‘matched’ Amp tooling ensures a uniform quality of the joint providing highly consistent performance, optimum electrical properties and a long service even in the most punishing of environments.

Corrosion and vibration resistance together with the tensile strength of Solistrand terminals and splices ensures that they are well within the limits of commercial and military specifications.

The Solistrand range includes; Ring and Fork/Spade Terminals, Parallel and Butt Splices.

Features:

• Accept solid, stranded and irregular shaped copper wires and combinations of more than one type without loss of performance.


• Constructed from fine grade high conductivity copper per ASTM B-152 and tin plated.


• Meet or exceed the requirements of MIL-T-7928, Type I, Class 1 and 2.


• Brazed barrel seam for uniform metal strength around the entire barrel area.


• Dimpled or serrated inner barrel surface for optimum tensile strength and electrical contact area after crimping.


• The “W” crimp creates optimum terminations of high reliability and providing long service even in the most punishing environments.


• Corrosion (including salt spray and most chemical fumes) and vibration resistant.


• Temperature rating 170° C.


• Approvals: CAA, MOD, CSA, UL and BS4G178
  

AMPOWER III Range:

The Ampower III range has been designed to accept a broad range of stranded wire from 10mm2 to 300mm2. Both terminals and splices are ideally suited for secondary power distribution in buildings and power plants. Compression crimping forms the terminal barrel and stranded wire into a strong, almost homogeneous unit, producing excellent conductivity with low temperature rise and outstanding resistance to oxidation and corrosion.

Features:

• Wire sizes 10mm2 to 300mm2 both rigid stranded (Class 2) and flexible (Class 5) wire types.


• Tube type terminal made from highly conductive electrolytic copper with a bright tin finish offers outstanding resistance to oxidation and corrosion.


• Accepts IEC 228 and IEC 719 designated cables.


• Wire size and stud holes clearly marked in metric.


• Chamfer design and inspection hole ensure ease of handling.


• Performance based on UL 486A, BS 4579-1, IEC 77.

If our services are relevant to your needs please contact us via the details on our web site (see info panel on the right above) or by email to myself – Geoff. Nossiter.

Molex KK® Series Wire-to-Board Connectors

The Molex KK system is an industry established "building block" connector system used to produce a huge variety of “wire-to-board” interconnection assemblies. Connect-2 Technology has been providing customers with cost efficient solutions using the KK range for more than a decade. Utilising auto tooling, ‘in-depth’ stocking and years of experience we can provide exactly to your requirements for applications requiring 2.50mm (.09"), 2.54(.100"), 3.96 (.156") and 5.08mm (.200") centres.

The KK range provides a friction lock system together with a polarizing wall and/or location pegs to ensure correct assembly. This range has become an ‘industry standard’ due to its reliability and versatility.

Since 1995 Connect-2 Technology has manufactured many thousands of assemblies incorporating the KK connector range (in numerous combinations to many different customers), as such we hold large stocks of housings within our standard stock range together with tin plated, gold plated and phosphor bronze reeled terminals to enable fast turnaround and an exact match to your specific requirements.

Features:

• Available on 2.50mm (.098"), 2.54mm (.100"), 3.96mm (.156") and 5.08mm (.200") centre spacing.
• Polarization via insert-able keys and pegs, polarizing ribs or polarizing wall headers.
• Locking ramp for improved mated retention with locking headers.
• Many circuit sizes.
• Accepts KK gas tight crimp terminals.
• Mates with headers or pins in the board.
• Available with Tin, Gold, Select Gold or Phosphor Bronze plating.
• Connect-2 Technology holds considerable stock.
• Auto tooled to provide high reliability crimp termination.

Electrical:

• Voltage: 250V.
• Current: Phosphor Bronze: 4.0A max. Brass: 2.5A max.
• Dielectric Withstanding Voltage: 1500V AC.
• Insulation Resistance: 50K (High Pressure Version 500K) Megohms min.

Physical:

• Housing: Nylon UL 94V-2 or UL94V-0.
• Operating Temperature: 0 to +75°C.

If our services are relevant to your needs please contact us via the details on our web site (see info panel on the right above) or by email to myself – Geoff. Nossiter.

New Connect-2 Technology Website

We are pleased to announce that our new Connect-2 Technology website is now ‘live’ with in-depth details on all aspects of our manufacturing services, providing current and prospective customers with a complete range of information on our capabilities.

Features and information on:

• Connection Solutions
• Customer Testimonials
• Equipment Profile
• Group Companies
• Industries Served Profile
• News
• Product Development
• Production Partners
• Products and Services
• Projects Undertaken
• Quality and Customer Care
  

Why not take a quick look now here

'Off-Grid' Solar Bus Stop Illumination

A leading UK developer of solar powered LED lighting systems, appointed Connect-2 Technology as the sole UK sub-contract manufacturer for an innovative solar bus stop illumination system, which was undertaken by our ‘special projects division’.

This included involvement from the design and development stage into the conversion for the manufacturing process. For such a hi-tech high profile product, great care was taken to provide a highly efficient, responsive and bespoke manufacturing solution. Ensuring that the product maintains its high reliability throughout its lifetime was a key consideration requiring great care throughout the production process.

The completed unit is a single ‘self contained’ device that incorporates;

* Solar panel; 10W monocrystalline silicon.
* Battery packs; 4 x 2.3 AmpH.
* Controller; programmable with energy management.
* Casing; high impact ABS moulded, sealed, waterproof and incorporating bright white LEDs.

If you are a product based electronics company looking to outsource your manufacturing process, either in part or in whole, Connect-2 Technology can provide a customised solution to suite your specific needs.

We can demonstrate a long established record in converting both existing ‘in-house’ as well as ‘start-up’ projects with a number of highly successful clients. So if you feel our services are relevant to your needs please contact us via the details on our web site (see info panel on the right above) or by email to myself – Geoff. Nossiter.

Sira Certified

Connect-2 Technology has been Sira certified, for the manufacture of Luminaires, Lamps, Accessories and Transformers for use in potentially explosive atmospheres in compliance with Directive 94/9/EC, since June 2006.







Explosion protection concepts under which we have been assessed: -

d - Flameproof
e - Increased Safety
m - Encapsulation
D - Dust Ingress Protection

The ATEX Directive
The ATEX Directive, derived from the French “ATmospheres EXplosibles” and formerly known as 94/9/EC, contains the ESR (Essential Safety Requirements) to which electrical equipment and protective systems used within potentially explosive atmospheres must conform.

The new ATEX directive currently in place within the European Union was made mandatory on 1st July 2003. Primarily intended for manufacturers of hazardous area equipment for use in the presence of flammable gases, vapours fumes or dusts, the new directive requires a quality management system to be implemented. Procedures for the design, manufacture and verification of products are to be approved by a notified body (i.e. Sira, Baseefa 2000, CESI, Demko, Kema) and all equipment conforming to the new directive will feature Ex and CE marking.

Expansion of Skills.
Connect-2 Technology gained this certification as part of our obligations under a contract supply agreement with our manufacturing partner. Which, further demonstrates our commitment to develop the skills and abilities of our “special projects division” as well as the company’s enthusiasm for expanding the broad range of solutions we provide our customers.

Product development

A major function of our technical engineering department is to convert customer drawings for the manufacturing process; developing work instructions, bills-of-materials, internal drawings, etc., to enable a smooth and accurate transition to a manufactured product. As part of this initial process we also add value where design for manufacture is required.

As a subcontract-manufacturing organisation it is vital that we fully understand our customers’ requirements which is why, when an assembly is being manufactured for the first time, it is meticulously checked and evaluated to ensure accuracy and compliance with all relevant component standards. Our engineers are trained to be ‘proactive’ and if they believe that an enhanced or more cost effective solution is available, then they will offer it to the customer.

When required Connect-2 Technology can also provide help and support from the outset of the design process, through to the pre-production stage, by jointly developing solutions and providing samples to ensure that projects are realised in a speedy and effective manner. Customer feedback is documented and filed as part of the requirements of our ISO 9001:2000 accreditation.

If our services are relevant to your needs please contact us via the details on our web site (see info panel on the right above) or by email to myself – Geoff. Nossiter.

Long-term reliable electrical connections

Many of our customers require considerable numbers of straightforward single lengths of wire processed with a wide variety of end-preparation options, ranging from insulated and un-insulated crimped terminals to precision tin-dipped ends and/or simple strip-length preparation.

An important factor in providing long-term reliable electrical connections is to ensure that all wiring is manufactured to the terminal manufacturers recommended specifications and tolerances. This will include precision cutting and stripping of the wire and crimp termination being made using only the correct tooling and strict conformance with the terminal manufacturers recommended tool settings. It is surprising how many times we still receive customer samples (either manufactured by customers themselves or second parties) with incorrectly applied crimp connections that may look OK visually but would not go anywhere close to the recommended pull-off force.

The quality practices and disciplines within Connect-2 Technology ensure customers always receive product manufactured to comply with specific recommended pull-off forces, ensuring long-term reliable connections.

We utilise a wide range of high-speed wire processing and termination equipment to enable fast and efficient production of medium/large quantities of terminated and/or prepared single wires quickly and accurately. Our tooling bank covers a vast range of both insulated and un-insulated terminals from AMP, Cembre, Elcon, Harting, JST, Molex, Takbro, etc.

We supply customers across many industry sectors including: - Aerospace and Defence, Communications & Data, Consumer Electronics, Industrial Control, Instrumentation, Power & Energy, Rail and Transportation. Typically, single wire ranges are from 0.03mm2 to 10mm2 (32AWG – 8AWG) for automated processing and up to 120mm2 with hydraulic cutting and termination.

Box & Panel Building Services

One of the objectives of our recent manufacturing area refurbishment was to increase our flexible workspace areas to accommodate a strong growth in electrical/electronic box and panel building contracts. We are currently producing mechanical box builds for a number of new projects including power control units for diesel generator sets, battery charge point units and wired panel sets for baggage handling systems.

We have continually developed our capabilities and the skill set of our technicians and assemblers to ensure we meet or exceed the growing requirements of our customers. Responding to our customers needs has always been one of our priorities with many taking advantage of our expansion in subcontract services which now include everything from a simple wire assembly to a fully built control box incorporating PCB’s, DIN-Rail Assemblies, Components and Wiring.

If you have a similar requirement or would like a quick quote for standard assemblies and harnesses please send your drawings/specifications by email here or fax/post to the contact details found here.

Manufacturing Area Refurbishment Completed

All manufacturing area refurbishment work was completed on schedule and a big word of THANKS! is due to all of the Connect-2 Technology staff that worked tirelessly throughout the week of 28th May to help achieve our objectives.

We now have additional work areas and manufacturing facilities providing a significant increase in production and routing flexibility. Greater efficiency in production cell utilisation and increased speed in ‘change-round’ times has provided us with a faster workflow and maximised the use of our multi-skilled staff.

Operational flexibility is a major tool, which enhances our ability to increase the number and diversity of production cell types to match the growing requirements of our customers and enable future expansion across a broad range of assembly services.

Major Refurbishment of Manufacturing Area

Due to continued expansion of our UK manufacturing operations it has become necessary to undertake major alterations, including building work, to one of our main production areas. This work will provide us with increased production facilities enabling a further capacity increase to our range of services.


Unfortunately, to accommodate this work we have no option but to close our manufacturing unit for 1 week. In order to minimise any disruption we have arranged for this closure to take place over the week of the Spring Bank Holiday: -

w/c Monday 28th May.

We will reopen the facility on: -

Monday 4th June.

Any orders already received (as of the date of this letter) for despatch during the week of the closure will be despatched on 25th May 2007. Please ensure that orders placed for despatch late May avoid w/c Monday 28th May and if placed prior to 30th April have a due date of 25th May.

We thank all customers for your cooperation in advance and assure you of our best attention at all times.