Enclosures, Cables and Connectors

Enclosures ● Needs to withstand hostile environments-rain, snow, saltwater blowing debris. ● Needs a full hinge and a positive latching system. ● Nema type 4 or 4X ● Materials available: ● ABS plasic ● Polycarbonate ● Fiberglass ● Stainless Steel ● Aluminum

ABS Plastic: Advantages and Disadvantages ● Light ● Easily modified by machine shop ● Nonconductive ● Brittle ● Not UV resistant – needs paint ● No Hinged Units

Polycarbonate: Advantages and Disadvantages ● Light ● Easily modified by machine shop ● Fairly durable ● More UV resistant than ABS plastic ● Nonconductive ● Black or clear color ● Still needs to be painted for UV resistance ● No Hinged Units

Fiberglass: Advantages and Disadvantages ● Lightest ● Easily modified by machine shop ● More durable than Polycarbonate ● Mostly UV resistant ● Nonconductive ● Best R factor ● Most inexpensive ● Pain to machine (dust) ● Will break down over long time (years) if not painted

Stainless Steel: Advantages and Disadvantages ● Most durable of all materials (will last forever) ● Pain to machine (hard material) ● Most heavy ● Conducts heat/cold/electricity ● Most expensive

Aluminum: Advantages and Disadvantages ● Very durable (will last forever) ● Easy to machine ● Expensive ● Heavy ● Conducts heat/cold/electricity ● Needs coating ● 2 nd most expensive

Sizes and Costs ● MaterialSizeWeight Price ● SS16 x 14 x ● 16 x 12 x ● Fiberglass16 x 14 x ● 15.5 x 12 x ● Al16 x 14 x ● 16 x 12 x ● 20 x 16 x

Cables ● Hostile environments – water, snow, cold, heat, mud, saltwater, rodents, farm machinery ● No. of traces? ● Standard lengths? ● Jacket choices: PVC, teflon, polyurethane ● Inner insulation choices: PVC, teflon, polyethylene

Cable Costs ● 22 AWG 4 twisted pairs, PU jacket, PE insulation – 1000 $1.46/ft $1.19/ft ● 22AWG 5 conductors, tpe jacket and insulation, $2.78/ft ● 22 AWG 4 twisted pairs, PVC jacket, shielded, 500 $1.22/ft

Connectors ● Weather resistant ● Small in size ● No of pins? ● Multiple insertions/extractions ● Easily installed on cables ● Cost

Connectors ● AMP CPC series 1 connectors ● Bulgin 900 series “Buccaneer” ● Bulgin STD Buccaneer ● Bulgin 400 series Buccaneer ● Conxall ● Amphenol mil-spec connector

AMP CPC Connectors ● Have existing inventory, crimpers, experience ● Inexpensive ● Fairly easy to install ● No spec for waterproofing ● Large – 27 mm dia for 9 pin connector

Bulgin 900 Series Buccaneer ● Waterproof specs ● Low temp specs to - 40 deg C ● 7 contacts available ● Large – 7 pin connector has 50 mm dia. ● No more than 7 contacts ● Expensive – aprox. $29.00 ea on avg. ● No existing tooling or experience

Bulgin STD Buccaneer Connector ● Waterproof specs ● Saltwater resistant ● -40 deg C low temp spec ● Inexpensive – 9 pin connector $9.00 on avg ● USB and ethernet connectors in same size ● Large – 9 pin connector 38 mm dia ● No existing tooling or experience

Bulgin 400 series Buccaneer ● Waterproof specs ● Low temp specs to - 40 deg C ● Small – only 19 mm dia for 12 pin connector ● Inexpensive – only $4.00 each on avg ● No existing tooling or experience

ConXall Multi-Con Connectors ● Waterproof specs ● Low temp specs to - 55 deg C ● Saltwater resistant ● Smaller than exisiting AMP CPC connectors 22 mm dia 9 pin conn ● Min 300 mate/unmate cycles ● Inexpensive – aprox. $7.00 ea on avg ● No existing tooling or experience

Amphenol mil spec Connectors ● Waterproof specs ● Cold temp specs ● Varied configurations and sizes available ● Have exisiting experience ● Metal shells instead of plastic ● Large – 32 mm dia for 7 pin connector ● Expensive – upwards of $40.00 ea min.