Hawke ATEX INLINE Connector, ControlEx Termination Hook up Procedure 자료


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오늘 이 시간에는 Hawke ATEX INLINE Connector, ControlEx 시리즈의 Termination Hook up Procedure 관련 자료를 소개합니다. 





ControlEx Termination Procedure



1. Hawke International does not recommend the use of their ControlEx Connectors in applications where rigid PVC/SWA/PVC power cabling (typically to BS 6346 standards) is used in portable / semi-portable applications.

2. Barrier type glands must be fitted to flexible power and loose filled control cabling entering the connectors to maintain the Exd protection concept and to reduce the potential for core movements within the cable being transferred to the connector’s internal components. Where connectors are terminated to topside umbilical cables, or portable connectors, a barrier type cable gland should always be used.

3. Hawke Ex Connector products are designed to be used in multi-voltage applications in circuits up to 660V AC/DC. It is
possible that on certain installations, there may be a mix of applications utilising different voltages on the Connector
products. In these instances, the installer / circuit designer must ensure that the plugs and sockets, or their associated
cabling, is clearly marked with the correct circuit voltage and current rating to ensure that the equipment being supplied is
matched correctly with the supply voltage. The variable insert positions which are a feature of the Connectors may also be
used to provide additional means of safety in these applications.


ControlEx Hook Up Procedure


1. Remove the CP/CR connector assembly, electrical insert and cable gland
(sold separately) from their packaging.

2. Terminate the cable into the cable gland in accordance with the manufacturer’s Instructions. Ensure a minimum tail length of 130mm.



3. Unscrew the rear engaging nut from the connector shell, removing the rear shell and keyway tube.



4. Slide the rear engaging nut over the rear shell as shown and screw the rear shell onto the entry thread of the cable gland ensuring there is a sealing washer between the gland and rear shell. A small amount of Loctite 638
or equivalent can be added to the cable gland thread at this stage to further help prevent loosening of the cable gland in portable applications.


Where a thread adaptor is being used, ensure a suitable IP seal is fitted between the cable gland and thread adaptor, and thread adaptor & running coupler. If the thread adaptor has an integral O-Ring, please ensure this makes full contact with the cable gland and running coupler to maintain the IP
protection. Check to ensure the captive O-Ring seal on the rear shell is in place and is undamaged


If the tab washer is being used, ensure this is fitted in the orientation shown. Use the flats on the rear shell to further tighten.





5. Cut the conductors to the length shown in the table below.



Note: Maximum tolerance is to allow for twisted cables and placement of cores within connector shell. If core spacing relative to insert numbering does not require excess core, use minimum cut lengths.


6. Strip back the insulation from the conductor’s as shown





7. Proceed to step 8 if internal earthing is not required.


NOTE: If internal earthing is not being used, the internal earth crimp must not be fitted and the grub screw in the rear shell must be removed


If earthing is required slide the internal crimp (supplied with CP/CR inserts) over the earth conductor and crimp using suitable tool. The stud can then be fitted into the rear shell and fastened using the grub screw shown. The stud on the earth crimp should not protrude from the outer diameter of the rear shell. Adjust if necessary.



8. a) Solder inserts – black (1.5 – 35mm²). Tin the conductors and fill the solder cups on the back of the inserts with solder as required Solder conductors in place and remove any solder spikes/excess from the solder cup. It is advised that heat shrink should be fitted over the connection at this point

b) Solder inserts – white (1.5 – 4mm2). As above, however, inserts should be soldered outside of the insert body and not fully assembled. If the contacts are to be solder terminated to the conductors, this must be done prior to insertion
through the rear contact retainer. It is advised that heat shrink should be fitted over the connection at this point Then follow (c ii & iii).

c) Crimp Inserts (1.5 – 4mm²) – white.


i) Crimp the conductors into the contacts using Weidmuller CTX CM 1.6/2.5 crimp tool HCT1, or Astro Crimp Tool HCT2. For 0.75 to 1.5mm² conductors use the 1.5 die. For 1.6 to 4mm² use the 2.5 die. It is advised that heat shrink should be fitted over the connection at this point

ii) Feed the contacts through the required numbered hole on the rear contact retainer and slide the insertion tool over the contacts up to the groove (one end for pin and one for socket). Clip the groove on the contact into position in the rear contact retainer with the tool.




iii) Align the main pip on the rear contact retainer with the key on the front contact retainer and slide over the contacts into position. Ensure the 2 smaller pips are also in line



d) Crimp Inserts (6 – 35mm²) – black. Undo the grub screws on the crimp barrels and slide them off the back of the contacts. Slide the conductors into the back of the barrel. Orientate the barrel so that the grub screws are pointing
outwards and crimp with a suitable crimp tool.

Push the barrels back onto the rear of the contacts and tighten grub screw into the groove on the contact. Back off grub screw half a turn on crimp barrels of 10mm² or larger to allow them to slide up and down the contact slightly






9. Clip spacer tube over conductors. Bend conductors slightly so that there is no or minimal gap between the insert/spacer tube and rear shell. On crimp insert of 10mm² or larger, slide the crimp barrels up and down the contacts to achieve this and then lock them in place by tightening the grub screw’s on the crimp barrels.

The insert has 3 pips, shown below, which should be located as shown. The main centre keyway should align with the centre of the spacer tube




NOTE: If being used on offshore topside applications where extreme temperature fluctuations or extreme levels of humidity may be present, it is advisable to use Dow Corning 4 Electrical Insulating Compound within the spacer tube to help prevent any possible humidity build-up. See point 15 below



10. Looking from the front of the connector shell, align the key on the insert to the required key inside the connector and slide the whole assembly into the shell. The EX16 connector has 3 keyways, and all other connectors have 5 possible keyways





11. Fully screw the rear engaging nut onto the thread on the connector shell, do not rotate the connector shell during this process. Tighten grub screw in rear engaging nut. There should be a gap visible of no more than 1mm between running coupler and shell





12. If the tab washer is being used, fix the tab using the button head screw to the rear engaging nut. Bend the tabs over the
flats of the cable gland.

13. If being used, terminate the external earth to the ring terminal crimp provided with the insert. Remove the button head
screw and spring washer from the rear engaging nut. Attach the crimp to the rear engaging nut as shown above

14. The connector is now ready for use. Please refer to the ‘Hook Up’ procedure.

15. If additional protection is required due to extreme atmospheric conditions, before inserting the assembled connector insert and spacer tube into the connector shell (step 10 above) Dow Corning 4 Electrical Insulating Compound can be used to fill the spacer tube. It is recommended that the running coupler be filled, along with the inner face of the insert to ensure no humidity can affect the contacts



ControlEx MK IV Connector Hook Up Procedure


Before commencing hook up, a visual inspection should be carried out on the cable / gland / connector assembly. The assembly should be checked to ensure that all of the assembly components are tight. If the assembly components have loosened during transportation / cable installation, they should be retightened in accordance with the relevant assembly instruction sheets without twisting the cable in the cable gland / connector assembly.


Areas to be checked:





NB: These areas should also be checked as part of a routine maintenance programme.


1) Turn off the power to the connectors.
2) Ensure the connectors are both set to the same keying position number and are of the same insert type.





3) Engage the CP connector with the BR / CR connector and align the key on the CP connector to the keyway on the BR / CR connector.



engaging nut clockwise onto the BR/CR shell. If the engaging nut will not screw on more than half a
turn, then the connectors are set to different keying positions.



5) Tighten the grub screw on the engaging nut.


6) If the optional locking pin is being used, this should be fitted at this stage, once the connectors are fully mated.



7) To disconnect, turn off the power, slacken the tightened grub screw, turn the engaging nut anticlockwise and remove the connector. If power is to be put through the connectors whilst de-mated, then a flameproof cap (available separately) must be fitted.





Technical Data

ControlEx MKIV Spec.pdf

ControlEx Spec.pdf

ControlEx MKIV Hookup Procedure 20131105.pdf

ControlEx MKIV Hookup Procedure 20131218.pdf

ControlEx Hook up procedure 20091202.pdf

ControlEx Inline connector termination 20091202.pdf

0.Ex Connectors Master Catalogue 20130819.pdf







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Hawke Exd Connector, MK IV ControlEx 기술사양


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오늘 이 시간에는 호크 방폭커넥터 제품군 가운데, Contrl 관련 애플리케이션에 적합한 Hawke MK IV ControlEx 시리즈를 살펴보도록 하겠습니다.





Range For Harsh and Hazardous Locations

Hazardous Area Connector

MK IV ControlEx

IECEx/ATEX Certificate 


Note: Inline connector receptacle (CR) also available





The 4th generation ControlEx has been designed as a result of over 20 years of plug-and-socket experience. Manufactured in Stainless steel, the connectors provide unrivalled durability in hostile environments.


Both ATEX/IECEX, GOST & NEC certified, the connectors are Exd rated with an Ingress Protection rating of IP66 / IP67 and have industry leading DTS01 deluge protection.





The wide range of insert variables can handle up to 60 cores.


Other improvements include an all-new padlock facility, allowing the connectors to be securely locked to prevent accidental un-plugging of equipment and improved secure cap fixings.


The 4th generation ControlEx maintains many of the original features which made its predecessor extremely popular, including a variable keying system to prevent accidental cross-mating, modular gold-plated field crimpable inserts for ease of wiring and a fully inspectable flameproof barrier providing direct inspection of the flameproof seal.






Tamb: -40°C to +60°C.

II2 GD Exd IIC Gb, Extb IIIC T95Db.

IP66, 67

DTS01 deluge protected.

Certificate No's Baseefa12ATEX0014X & IECEx BAS 12.0006X.


ControlEx Features


(1) Easy Fieldwireable
Pin and socket inserts are numbered front and back to assist wiring and avoid
termination errors. Crimp and solder inserts available.



(2) Internal Keyway Spacer

Eases accessibility for termination as tube fitted after termination complete,
along with allowing easy installation into the required keyed position (See (4))



(3) Locking Pin
Optional locking pin provides the facility for mated connectors to be permanently
locked, via the use of a padlock, ensuring they cannot be separated under load. (Padlock not supplied)





(4) Keying Position
The unique visual 5 position insert keying system (3 on Ex16) along with the integral machined keyways prevent contact damage and ensures safe use by eliminating the possibility of misconnection of adjacent circuits.




(5) Running Coupler
Allows the connector to be installed onto a pre-assembled cable gland. Connector is rear loading and includes locking engaging nut.




(6) Acme Thread at Mating Interface
Unique ACME thread offers a smooth and quick fully mating action.




(7) Fully Inspectable Flameproof Barrier
Provides direct inspection of the flameproof seal and offers users the peace of mind that the connector is safe for installation.




(8) Anti-Rotation Device
Connector plugs and receptacles come complete with anti-rotation ring, which
when fitted between the connector and gland, helps to eliminate the possibility of the gland loosening, locking this in position.






Technical Data


ControlEx MKIV Spec.pdf

ControlEx MKIV Hookup Procedure 01.pdf

ControlEx MKIV Hookup Procedure 02.pdf

0.Ex Connectors Master Catalogue 20130819.pdf






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