Product News

Reliable, Efficient Charging Solutions for EVs in Any Environment

Amphenol Industrial Operations has introduced the ER Series SAE J1772 AC charging cable and inlet, an advanced solution designed for electric vehicles (EVs), hybrid-electric vehicles, and other e-mobility applications. This new connector series is compliant with SAE J1772 standards for AC Level 1 and Level 2 charging systems, addressing the rapidly growing demand for reliable and efficient charging solutions in both personal and commercial markets.

As the global electric vehicle market continues to expand, the need for versatile charging infrastructure becomes more critical. The ER Series is designed to accommodate a wide range of applications, from residential charging setups to commercial electric vehicle supply equipment (EVSE) installations. The cable can handle up to 250V AC and support current ratings up to 80 amps, making it suitable for a variety of charging speeds, whether for slow, overnight charging or faster, high-capacity charging stations. This adaptability ensures that the ER Series can meet the needs of electric buses, trucks, delivery vehicles, and personal EVs alike.

Ease of use is a key design feature of the ER Series. The connector is built with an ergonomic handle, making it easy to plug in and remove. The system’s low insertion/withdrawal force, rated at less than 75 Newtons, ensures smooth operation, reducing wear and tear on the connector and the vehicle’s inlet. This is particularly important for everyday users, who need a charging system that is both intuitive and durable. Additionally, the ER Series is rated for over 10,000 mating cycles, guaranteeing long-term reliability even with frequent use. The connector’s performance is further enhanced by Amphenol’s proprietary contact and plating technologies, which minimize temperature rise and reduce contact resistance. These technologies help ensure safer charging while extending the lifespan of the system.

One of the most significant benefits of the ER Series is its rugged and environmentally resistant design. The connector is rated IP67, meaning it is dustproof and waterproof, offering reliable performance even in challenging conditions. The ER Series is also protected by a Type 3S rating, which makes it resistant to ice buildup and capable of functioning in subzero temperatures. This durability makes the ER Series a dependable choice for users in regions with harsh winters or extreme weather conditions. With an operating temperature range of -30°C to +50°C, the connector is designed to function reliably across a broad range of environments, while its components can withstand even more extreme temperatures during storage and transport.

The ER Series supports two different charging modes, adding to its versatility. Mode 2 charging is a portable solution, allowing users to charge their vehicles from a standard household socket or an industrial CEE socket with the appropriate cable. This option is convenient for individual users who need flexibility in where they charge their vehicles. Mode 3, on the other hand, is designed for use with dedicated charging stations or home-mounted wall boxes. This mode offers controlled charging, where the vehicle communicates with the charger to determine the appropriate current before voltage is supplied. This not only ensures a safe and efficient charging process but also provides greater peace of mind for users.

Built to endure tough environments, the ER Series can withstand up to 96 hours of salt spray exposure, making it especially well-suited for industrial and heavy-duty applications. In locations where equipment is exposed to corrosive conditions, such as coastal areas or areas with high pollution, the connector’s durable design helps prevent damage, extending its operational life. The system is engineered to protect both the connector and the vehicle's inlet from premature wear, ensuring a long-lasting, reliable connection even in demanding environments.

Amphenol Industrial Operations has long been recognized for its leadership in high-performance interconnect systems, and the ER Series SAE J1772 solidifies that reputation. By offering a cost-effective, dependable solution for EV charging, Amphenol is meeting the needs of a rapidly expanding market. The ER Series combines ease of use, durability, and high performance, positioning it as a key advancement in EV charging technology. Whether for individual consumers or large-scale commercial operations, the ER Series delivers a solution that meets the demands of today’s EV market.

Amphenol APC Series Expansion: Advanced Connectivity for Industrial Applications

Amphenol Industrial Operations has long been a trusted leader in providing rugged and reliable connectivity solutions. With the expansion of the APC (Amphenol Plastic Connector) Series, Amphenol continues its commitment to meet the demanding needs of various industries by offering advanced plastic connectors that combine durability, versatility, and cost-effectiveness. The APC Series is poised to serve an even wider range of applications in industrial machinery, factory automation, HVAC systems, medical devices, and more.

Overview of the APC Series

The APC Series, a product line that includes standard, mini, and power versions, is designed to deliver high-performance connectivity for signal and power transmission in challenging environments. These connectors are built with a lightweight plastic shell that offers inherent corrosion resistance and robust mechanical performance, making them ideal for both indoor and outdoor applications.

The APC Series connectors come with a triple-start ACME thread for fast coupling, stamped and formed contacts, and a self-locking mechanism. This design ensures not only ease of use but also durability in ruggedized environments, offering up to 500 mating cycles and an IP67 rating when mated. Furthermore, the connectors are UL and CSA certified, providing customers with confidence in their safety and compliance with international standards.

Key Features

1. Lightweight and Corrosion Resistant: The connectors feature a plastic shell, which reduces the overall weight of the system while ensuring corrosion resistance, making them suitable for harsh environments.
2. Power, Signal, and Hybrid Options: The APC Series offers a range of configurations that include power-only, signal-only, and hybrid power-signal connectors, providing flexibility for different applications. Current ratings range from 7.5A to 70A, depending on the connector size and contact arrangement.
3. Fast Coupling System: With a triple-start ACME thread on the APC standard and a two-way bayonet system in the mini variant, the connectors ensure fast and secure coupling, reducing installation time and maintenance efforts.
4. Environmental Protection: The APC connectors are designed to withstand tough environmental conditions, with IP67-rated sealing to protect against dust and moisture. The connectors also feature UV resistance, thanks to their UL94 V-0 flammability-rated plastic shell, making them suitable for outdoor use.
5. Stamped and Formed Contacts: The connectors are equipped with stamped and formed copper alloy contacts, which are available with tin, silver, or gold plating for enhanced electrical performance and corrosion resistance.

Market Applications

The APC Series has been widely adopted across multiple industries, thanks to its versatility and robust design. Some of the key application areas include:

• Industrial Machinery: The rugged design of the APC connectors makes them ideal for use in heavy-duty industrial machinery, where they can withstand vibration, shock, and extreme temperatures​.
• Factory Automation: In automated production environments, the APC connectors provide reliable signal and power transmission, ensuring continuous operation of robotics, control systems, and other automation equipment.
• Medical Equipment: The lightweight and corrosion-resistant properties of the connectors make them suitable for medical devices that require high levels of cleanliness and durability.
• HVAC Systems: The ability to withstand extreme temperatures (-40°C to +105°C) and environmental sealing make the APC Series a perfect fit for HVAC systems, providing long-term reliability in temperature control equipment.

Enhanced Electrical and Mechanical Performance

The APC Series is engineered for performance in both electrical and mechanical aspects. The connectors offer a rated voltage of up to 600V and a dielectric withstanding voltage of up to 2500V. The insulation resistance is 500MΩ, ensuring safe and reliable operation in high-voltage applications. The connectors are designed to withstand vibrations of 10-2000 Hz and mechanical shocks of 50G, making them highly suitable for high-impact environments such as transportation and material handling.

Expanded Product Range

The expansion of the APC Series includes both the standard and mini variants, with additional options in shell sizes, contact arrangements, and mounting styles. This allows engineers to choose the most appropriate solution for their specific requirements. Whether it’s the compact APC Mini for space-constrained installations or the high-power APC connectors for heavy-duty applications, the expanded range offers unparalleled flexibility.

The APC Mini Series, in particular, is designed for signal applications in compact devices, featuring a two-way bayonet coupling for quick mating. It is ideal for medical instrumentation, communication equipment, and smaller industrial systems. On the other hand, the APC Power Series is designed for applications requiring high current, with the ability to handle up to 70A at 1000V, making it perfect for power distribution and energy storage systems​.

Conclusion

Amphenol’s APC Series represents a significant advancement in industrial connector technology. With the expansion of this product line, Amphenol continues to provide solutions that are not only rugged and reliable but also versatile and cost-effective. The APC Series is perfectly suited to meet the growing demands of industries such as industrial automation, medical equipment, HVAC, and more. For those seeking a connector that delivers top-tier performance in harsh environments, the APC Series offers a comprehensive and scalable solution​.

Amphenol Industrial Expands Amphe-PRB Connector Series for Emerging Markets

Amphenol Industrial, a leader in high-reliability power and signal connectors, has announced the expansion of its Amphe-PRB series. Specifically designed to meet the growing demands of industries such as energy storage, industrial automation, and alternative energy, the Amphe-PRB series offers a balance of affordability and Amphenol’s trusted reliability. This expansion is a significant move toward providing cost-effective and rugged connectivity solutions tailored to the changing needs of modern industries.

The Amphe-PRB series is Amphenol’s answer to the increasing demands for affordable, high-performance connectors in emerging markets. As industries like energy storage, renewable energy, and automation continue to grow, they operate under strict cost constraints while still requiring robust solutions. Traditional metallic circular connectors, though durable and reliable, often do not meet these economic requirements. The Amphe-PRB series provides an innovative alternative.

This new addition to Amphenol’s product line features a lightweight thermoplastic design, making it both durable and cost-effective. The thermoplastic shell is UL F1-rated for outdoor use, offering excellent resistance to ultraviolet light, water exposure, and immersion. These features make it ideal for use in challenging environments where ruggedness and reliability are paramount. Designed to bridge the gap between performance and cost, the Amphe-PRB offers an affordable solution without compromising on the quality that defines Amphenol products.

The Amphe-PRB series boasts several key features. One of its most notable characteristics is the quick positive coupling enabled by its reverse bayonet design. This feature allows for a secure connection that reduces installation time, making it easier for users in high-vibration environments to ensure a solid, stable connection. Additionally, the Amphe-PRB connectors are rated to withstand shocks and vibrations up to 15g, which is critical for applications where consistent connectivity is essential, such as in industrial automation and heavy equipment.

The series also has an ingress protection rating of IP67, ensuring that the connectors are fully protected from dust and can withstand immersion in water up to one meter for 30 minutes. This makes the Amphe-PRB an excellent choice for outdoor and harsh environment applications. The connectors are also UV-resistant and meet the UL F1 standard for UV degradation resistance, which is crucial for components exposed to outdoor conditions.

To meet modern safety standards, the Amphe-PRB series incorporates a touch-proof design that provides additional protection against accidental contact with live components. Furthermore, it is designed to be cost-effective, making use of high-quality plastic resin and Amphenol’s 3.6mm RADSOK contacts. These contacts enable the connectors to carry high currents of up to 60A, offering a low-cost solution that maintains the high current-carrying capacity required in many applications.

The Amphe-PRB series also excels in its mechanical and electrical performance, making it suitable for various industries. It has a rated current of 46A for standard contacts and up to 60A for RADSOK contacts, with a rated voltage of 600VAC. Its dielectric withstanding voltage is 2000VAC, and it has an insulation resistance of 5000 MΩ, ensuring reliable electrical performance even in challenging conditions. The series operates effectively in temperatures ranging from -40°C to +100°C, allowing it to function in extreme environments, and it is designed to endure up to 500 mating cycles, offering long-lasting performance for demanding applications.

This connector series is designed to serve a wide array of applications. It is particularly suited for energy storage systems, which are becoming increasingly important in today’s energy landscape. As the demand for efficient and reliable energy storage solutions grows, the Amphe-PRB series provides a cost-effective solution for these high-volume applications. It is also ideal for use in solar inverters and converters, where reliability and cost-efficiency are crucial.

The outdoor lighting sector also benefits from the UV resistance and IP67 rating of the Amphe-PRB connectors, making them a perfect fit for systems that need to withstand harsh outdoor conditions. In the data/telecom and industrial automation industries, the Amphe-PRB’s rugged design and ability to resist shock and vibration ensure consistent performance, which is essential in these high-stakes environments.

In conclusion, the Amphe-PRB series expansion is a significant milestone for Amphenol Industrial as it continues to innovate and provide solutions that address the evolving needs of modern industries. As industries demand more from their components, particularly in terms of cost-effectiveness and reliability, Amphenol’s Amphe-PRB series offers a solution that meets both current and future needs. Whether for energy storage, industrial automation, alternative energy, or outdoor applications, the Amphe-PRB series delivers a combination of performance, durability, and affordability that positions it as a leader in the market.

Amphenol Industrial Operations has expanded its SurLok Plus™ Series with a broader range of connector sizes and technology tailored to meet the evolving needs of the energy storage and electric vehicle markets. The expansion includes the SurLok Plus™ 10.3mm inline plug 2.0 generation, SurLok Plus™ 5.7mm and 8.0mm 2.5 generation, and the SurLok Plus™ 14.0mm EMI, each designed for specific high-power connections and energy transfers.

The 10.3mm inline plug 2.0 generation connector is now available to address the growing demand in the 1500VDC market, making it ideal for applications in electric vehicles and heavy equipment requiring a 360A power connector. The 5.7mm and 8.0mm 2.5 generation connectors, rated for 120A and 200A respectively, continue to serve high-power applications in the energy storage sector, with enhancements including advanced safety features like anti-mis-insertion and ingress protection. The 14.0mm EMI connector, now part of the lineup, provides EMI shielding, a high voltage range, and robust temperature tolerance, making it suitable for electric vehicles, battery solutions, and industrial applications.

All connectors in the expanded SurLok Plus™ Series maintain their ease of use, with features like a keyway design to prevent incorrect mating, a flexible quick-lock system, and Amphenol's latest R4 RADSOK® technology that enhances performance by increasing amperage, reducing insertion force, and minimizing temperature rise and voltage drop. Additionally, these connectors are environmentally sealed, rated IP67, and certified under UL4128/TUV 2PfG2740 standards, ensuring reliability and durability across a wide range of demanding applications.

Introducing the Amphenol Industrial GTC-E Series – A Revolution in Heavy-Duty Connectors!

We're thrilled to announce the expansion of our GTC-E Series product line, now encompassing an even broader range of applications. The GTC-E Series is engineered for exceptional performance in the most demanding environments.

Why is the GTC-E Series a game-changer for heavy-duty applications? Here’s what sets it apart:

Enhanced Design for Rugged Environments:
The GTC-E Series is designed with a robust reverse bayonet coupling mechanism, ensuring quick and positive coupling. With audible and tactile indicators of full coupling, the connectors are ideal for environments requiring high shock and vibration capabilities. The rugged construction guarantees durability and reliability in the toughest conditions.

Versatile Compatibility:  
The GTC-E Series accommodates a wide range of applications, from rail mass transit and heavy equipment to factory automation and robotics. Its compatibility with the GT Series connectors ensures seamless integration, making it a comprehensive solution for diverse industrial needs.

Field Installation Ease:  
Engineered for simplicity, the GTC-E Series connectors feature UL94-V0 hard plastic inserts and removable contacts. This innovative design simplifies the installation process, reducing labor time and cost while ensuring secure and reliable connections. Perfectly suited for field installations, these connectors make maintenance straightforward and efficient.

Superior Environmental Protection: 
With IP67 sealing protection when mated, the GTC-E Series connectors provide excellent resistance to dust and water ingress. This high level of protection is crucial for maintaining functionality in harsh industrial environments, ensuring long-term performance and reliability.

Certifications for Safety and Performance:
Emphasizing safety and reliability, the GTC-E Series is designed to meet rigorous performance standards. Its construction and materials, including aluminum shells and copper alloy contacts, adhere to stringent industrial requirements, providing users with confidence in its quality and performance.

By integrating innovative design with practical features, the GTC-E Series stands out as a premier choice for heavy-duty industrial applications. Ready to meet the evolving needs of various sectors with unmatched efficiency, reliability, and environmental responsibility.

Contact us now to learn more about the GTC-E Series and how it can benefit your designs. We are excited to support your projects with our latest technology and to continue advancing industrial connectivity together.

GTC-E Series visit Amphenol Industrial Operations.

Amphenol Industrial Operations Commences Operations at Its U.S. Solar Manufacturing Facility 

The facility, which has a total potential manufacturing capacity of 1.2M pieces per month, is now shipping solar junction boxes to U.S. customers to support the continued growth of domestic solar manufacturing and development.

Mesa, AZ, April 3, 2024 – Amphenol Industrial Operations, a global leader in interconnect systems, announced that manufacturing operations are underway at its new solar product factory in Mesa, AZ. As of January 2024, Amphenol is manufacturing and shipping U.S.-made solar junction boxes to solar manufacturers and developers across the country on a daily basis.

Amphenol’s Mesa solar product factory can accommodate a dozen state-of-the-art manufacturing lines, each with a capacity of around 100,000 pieces a month. Currently, the first line is operational and producing approximately 3,000 solar junction boxes per day, with two more lines currently being added.

The facility is also equipped to manufacture connectors and other advanced interconnect assemblies for solar arrays. Manufacturing lines to support production of these components are expected to be operational by the end of 2024. To date, Amphenol has hired 70 new team members to support junction box manufacturing efforts in Mesa, a number that is anticipated to grow with customer demand and as additional manufacturing capacity comes online.

“By manufacturing and shipping high-quality, reliable solar products every day at our expanded Mesa facility, we’re building on our mission to help create a more efficient and sustainable U.S. solar supply chain,” said Mark Cunningham, General Manager of Amphenol Industrial Operations. “As we grow our manufacturing footprint and add more local, specialized talent to our Mesa team, we remain committed to helping our customers, partners and the broader community navigate the transition to a cleaner energy future.”

Announced in September 2023, the 58,000 square-foot solar products facility expands Amphenol’s existing manufacturing presence in Mesa and will help the Company support the growing domestic solar market. Amphenol solar products manufactured in Mesa can help developers achieve the IRS’s 10% domestic content bonus adder for manufactured content created by the Inflation Reduction Act of 2022. As Amphenol continues to grow its customer pipeline and manufacturing operations in Mesa, it remains committed to helping the broader U.S. solar industry reduce reliance on imported components and work toward supply chain independence.

About Amphenol Industrial Operations

Amphenol Industrial Operations, headquartered in a 30,000 square foot facility in Endicott, N.Y., provides a full range of high reliability power/signal connectors and interconnection systems specifically for the industrial markets including rail/mass transit, process control, automotive manufacturing, heavy equipment, wireless base stations and petrochemical/power generation.

Products include ruggedized-for-industry cylindrical, fiber optic, rectangular, and industrialized versions of Amphenol’s MIL-DTL-5015 cylindrical, MIL-DTL-26482 miniature cylindrical and GT reverse bayonet cylindrical connectors. It employs more than 900 people and is ISO9001, TS96949 and MIL-STD-790 certified. Amphenol Industrial Operations is a division of Amphenol Corporation, Wallingford, CT, one of the largest manufacturers of interconnect products in the world, with 2022 sales topping $12.6 billion.

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Introducing the Amphenol Industrial RadCrimp®  for 8~6 AWG – A Solar Industry Game-Changer!

We're excited to unveil the expansion to our RadCrimp product line now with 8~6 AWG. RadCrimp® offers unparalleled performance in solar installations and related applications.

Why is RadCrimp®  a game-changer for the solar industry? Here's what sets it apart:

Simple and Efficient Termination Process: Engineered for ease and efficiency. Its design allows for quick and straightforward field termination and sealing, eliminating the need for specialized crimp tools. This simplicity accelerates the installation process, enabling secure and reliable connections with reduced labor time and cost.

Versatile Wire Compatibility: Accommodating a wide range of photovoltaic (PV) wire sizes from 12 to 6 AWG. This flexibility ensures that it can be used in various solar installations and configurations, one piece design by design to eliminate any cross mating of manufacturers, making it a comprehensive solution for diverse solar energy needs.

IP68 Sealing Protection: Engineered for durability, RadCrimp® offers IP68 sealing protection. This high level of protection ensures that connections are safeguarded against dust ingress and water immersion, crucial for maintaining functionality in the demanding environments typical of solar energy applications.

Certifications for Safety and Performance: Emphasizing safety and reliability, RadCrimp® is certified according to UL6703 and IEC62852 standards for 1500V DC. These certifications affirm its suitability and safety for high-voltage solar applications, providing users with assurance in its quality and performance.

By integrating innovative design with practical features, RadCrimp® stands out and is ready to meet the evolving needs of sustainable energy solutions with unmatched efficiency, reliability, and environmental responsibility.

RadCrimp® Solar Splice with Melni Spiral Termination Technology visit Amphenol Industrial Operations.

Introducing the SurLok Plus Series - Now Even More Dynamic at 1500V DC!

We're thrilled to share some electrifying news with you! At Amphenol Industrial Operations, we're constantly pushing the boundaries of innovation to provide you with cutting-edge solutions. Today, we're delighted to introduce an upgraded version of our SurLok Plus series, now boasting an impressive voltage capacity of 1500V DC!

What does this mean for you? It's simple – more power, less space! The SurLok Plus connector continues to revolutionize the industry by allowing you to carry higher voltages within the same compact envelope as its 1000V DC predecessor.

But that's not all! Our new SurLok Plus connector is ideal for a wide range of applications, including:

🔋 Energy Storage Market

🚗 Electric Vehicles

🔋 Battery Solutions

🌟 Fuel Cell Technology

🏭 Industrial Applications

Why choose SurLok Plus? Well, it's not just about the voltage; it's about versatility, reliability, and environmental responsibility. This field-installable connector offers a highly reliable alternative to common compression lugs, providing efficient power distribution in a small, compact form factor.

With the capability to be used in DC to DC and AC to DC power transfers, SurLok Plus is your go-to solution for various power distribution needs. Whether you're looking to transfer power from a battery cluster to a PCS or from a battery pack to the rest of your system, SurLok Plus has got you covered!

Join us in embracing the future of interconnect systems and power distribution with SurLok Plus. Experience the difference that 1500V DC of power can make in your applications!

Ready to supercharge your projects? Contact us today to learn more about this groundbreaking connector and how it can elevate your solutions to new heights.

Thank you for choosing Amphenol Industrial Operations as your trusted partner for interconnect solutions. We look forward to empowering your innovations with our state-of-the-art technology!

For more information about the SurLok Plus™ 1500V DC visit Amphenol Industrial Operations.