HAWKE International AI364 InstrumEx Connector User Manual

HAWKE International AI364 InstrumEx Connector

Product Information

• Product Name: Instrum Live Demateable Connector
• Manufacturer : Hawke International
• Model Number : AI364
• Rev : 17
• Suitable for Multi-voltage applications in circuits : 4 / 9 way up to 250V AC

Product Usage Instructions

1. Unscrew the middle nut and back nut from the connector body and remove the armor clamping ring, spigot, and insert.
2. If you have purchased a connector with the optional back nut clamp and/or flange, slide these down the cable now (clamp first).
3. Remove the two seal assemblies from the box and choose the required seal to suit the diameter of the cable outer jacket.
4. Insert the seal into the back nut, ensuring that the flange on the seal goes past the thread.
5. Screw the back nut onto the middle nut without compressing the seal.
6. Slide the middle nut, back nut, and armor clamping ring over the cable, ensuring that the clamping ring is pointing in the required direction for the size of the armor/braid.
7. Strip back the outer jacket and armor (if present) of the cable.
8. Strip back the inner sheath level with the armor to expose the insulated conductors.
9. Push the inner sheath of the cable through the spigot and spread the armor/braid over the spigot until the end is against the shoulder of the spigot.
10. Position the armor clamping ring onto the armor/braid and inspect that it has been successfully clamped between the armor spigot and the clamping ring.
11. If the earth is to be terminated to the connector shell, strip back the earth conductor accordingly. Otherwise, proceed to step 15.
12. Crimp the flat blade earth crimp onto the earth conductor, ensuring that the blade is outermost and pushed up to the insulation of the earth conductor.

Please refer to the provided diagrams and images in the user manual for a better understanding of the steps mentioned above.

IMPORTANT NOTE

1. Hawke International does not recommend the use of the InstrumEx Connectors in applications where rigid PVC / SWA / PVC power cabling is used in portable / semi-portable
2. Hawke Ex Connector products are designed to be used in multi-voltage applications in circuits: 4 / 9 way up to 250V AC, 4 / 9 way up to 60V DC, and 8 way up to 60V AC/DC. It is possible that on certain installations, there may be a mix of applications utilizing 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

CP / CR PROCEDURE

1. Unscrew the middle nut and back nut from the connector body and remove the armour clamping ring, spigot and insert. If you have purchased a connector with the optional back nut clamp and/or flange, slide these down the cable now (clamp first).
2. Remove the two seal assemblies from the box and choose the required seal to suit the diameter of the cable outer jacket.
3. Insert the seal into the back nut, ensuring that the flange on the seal goes past the thread as shown
4. Screw the back nut onto the middle nut. Do not compress the seal at this stage.

5. Slide the middle nut, back nut, and armor clamping ring over the cable ensuring that the clamping ring is pointing in the required direction for the size of armor/braid. The alternative ring is supplied in the box
   STANDARD RING

   R ING P ART

N O .

| A RMOUR / B RAID T HICKNESS
O RIENTATION 1| O RIENTATION 2
Os / O| 0.8 – 1.25| 0.0 – 0.8
A| 0.8 – 1.25| 0.0 – 0.8
B| 1.25 – 1.6| 0.0 – 0.7
C| 1.6 – 2.0| 0.0 – 0.7
ALTERNATIVE RING

R ING P ART N O .| A RMOUR / B RAID T HICKNESS
O RIENTATION 1| O RIENTATION 2
B| 0.9 – 1.25| 0.5 – 0.9
C| 1.2 – 1.6| 0.6 – 1.2

6. Strip back the outer jacket and armour (if present) as shown below
7. Strip back the inner sheath level with the armour to expose the insulated conductors as shown below. If unarmoured, strip back to the outer jacket ARMOURED / BRAIDED CABLE
8. Push the inner sheath of the cable through the spigot. Spread the armour / braid over the spigot until the end of the armour / braid is up against the shoulder of the Position the armour clamping ring onto the armour / braid.
9. ) Place the connector body over the spigot engaging the octagonal portion of the spigot. Move the middle nut up to meet the connector body. Place a spanner on the flats of the connector body and hold it in position. Hand tighten the middle nut to the connector body, then turn a further ½ to ¾ turn with a spanner
10. Unscrew the middle nut and visually inspect that the armour has been successfully clamped between the armour spigot and the clamping ring UNARMOURED CABLE
    (If earth is to be terminated to connector shell. Otherwise proceed to step

11. Strip back the earth conductor as shown below. If the earth is being carried through a contact as well as being connected to the shell, see fig b.
12. Crimp the flat blade earth crimp onto the earth conductor as shown below. Ensure the blade of the crimp is outermost, as shown and that the crimp is pushed all the way up to the insulation of the earth conductor
13. Push the conductors through the spigot and place the blade of the crimp on the taper of the spigot
14. Push the armour clamp (orientation 2 – see step 5) onto the blade of the crimp and lock into position by following steps 9 and 10 of the armoured / braided cable
15. Strip back the conductors as shown below
    CONTACT| CONTACT SIZE| X| Y
    ---|---|---|---
    8 Core| 0.14 – 0.37mm²| 5mm| 23 – 28mm
    4 / 9 Core 0.5mm2 – 1.0mm2| 0.5mm² 1.0mm²| 10mm 5mm| 28 – 33mm

23 – 28mm

4 / 9 Core

0.5mm2 – 2.5mm2

| 1.5mm²

2.5mm²

| 10mm

5mm

| 28 – 33mm

23 – 28mm

16. Remove the contacts from the contact retainers. Crimp the contacts onto the conductors using the Hawke crimp tool only (Astro Crip Corp – 615708 Crimp Tool M22520/1-01 Large). Ensure that the insulation of the conductor is up against the shoulder of the contact. When terminating 0.5mm² or 1.5mm² wire, ensure the conductor is pushed all the way into the smaller hole of the contact and that the contact is square in the crimp tool.
    • CAUTION : EXCESSIVE FORCE MAY BEND THE CONTACTS
    • Alternatively, conductors may be soldered into the contacts. Ensure that the cable installation is the same on the mating half. Hawke recommends that wiring details are placed on the cable outer jacket near to the connector.
17. Splay out the contacts and fit them through the slots in the rear contact retainer, ensuring they line up with the relevant numbered hole on the front contact retainer (ensure keys are aligned – see step 18). Unused contacts should be omitted if not required to ease assembly
18. ) Slide the front contact retainer over the contacts and snap into place with the rear contact retainer. Push the clips of the rear contact retainer firmly down to ensure they are not protruding (will only fit in the correct orientation).
19. Slide the insert into the connector body, aligning the half round key on the rear contact retainer with the required half round keyway in the connector (The colour coded or numbered keying position is shown on the front of the connector body. No colour coding or numbering for default 12 o’clock position – see picture inset). It should be noted that colour coded and numbered connector bodies are mutually interchangeable. Push the octagonal portion of the spigot into the connector body.
20. Slide the middle nut over the clamp / spigot and hand tighten onto the connector body, then further tighten ½ to ¾ of a turn with a spanner while holding the front shell with a spanner
21. Tighten the backnut onto the middle nut until a seal is formed. Further tighten 1 to 1 ½ turns with a spanner while holding the middle nut with a spanner
22. If the optional mounting flange is required, slide the flange over the backnut and position on the middle nut. Align the grub screw with one of the flats and tighten
23. If the optional cable clamp has been purchased, tighten the screws on the clamping bars equally until the clamping bars touch the Tighten each screws a further 2-4 turns or until adequately clamped.
    • DO NOT OVERTIGHTEN AS THIS COULD DAMAGE THE CABLE.
    • If the cable clamp is being used with unarmoured cable, the connector should be earthed via the crimp with a 4mm² conductor
24. Screw the cap back onto the connector. Stick the corresponding round colour coded / numbered sticker onto label in the circular space provided. (white = 12 o’clock / Position 1)
25. The connector is now ready for hook Please refer to the hook-up procedure.

BR PROCEDURE

1. The BR connector is supplied ready terminated with tails. Simply fit into suitable junction box / equipment as required. To maintain the IP rating of the equipment, a sealing washer should be used (available separately) as shown below
2. Terminate the conductors and earth wire inside the junction box /
3. The connector may also be earthed externally via the crimp with a 4mm² conductor if required
4. The connector is now ready for hook up. Please refer to the hook up procedure.

HOOK UP PROCEDURE

WARNING: Only the socket insert is allowed to remain energised while de- mated. If being used with bi-directional signals, isolate elsewhere before connecting / disconnecting.

Before commencing hook up, a visual inspection should be carried out on the cable / 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 connector assembly.

1. Remove connector

2. Ensure the connectors are both set to the same keying position colour or numbered (no colour or number for default 12 o’clock position on BR/CR) and are of the same insert
   It should be noted that colour coded and numbered connector bodies are mutually interchangeable

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

4. Engage the two connectors by screwing the engaging nut clockwise without interruption onto the BR/CR shell. If the threads will not engage, the connectors are set to different keying positions

5. If anti-vibration protection is required, tighten the grub screw on the CP shell

6. To disconnect, slacken the tightened grub screw, turn the engaging nut anti-clockwise and remove the connector. Fit the caps

SCHEDULE OF LIMITATIONS

• Following disconnection, the energised power supply must only be connected to the connector part incorporating the socket
• The connector part containing the pin connections must not be connected to equipment containing a power supply or energy storage devices likely to cause the plug to remain energised after
• The protection caps are to be fitted immediately following separation.
• The bulkhead connector is not to be fitted to the enclosures / bulkheads where the interface temperature may exceed 80°C. In addition, the integral cables shall be mechanically protected.
• When used in dust environments, the bulkhead mounting thread is to be sealed in accordance with the installation code of practice to ensure that an ingress protection level of IP6* is
• External sources of heating or cooling shall maintain the temperature limits of the
• Flameproof joints are not intended to be

TECHNICAL SPECIFICATION

EU Declaration of Conformity in accordance with European Directive 2014/34/EU and UK Statutory Instrument 2016/1107

• Manufacturer: Hawke International
• Address: Oxford Street West, Ashton-under-Lyne, OL7 0NA, United Kingdom
• Equipment Type: Range of Connectors: InstrumEx
• Provisions of the Directive fulfilled by the Equipment:
• Group II Category 2GD Ex db eb IIC Gb T6, Ex tb IIIC T80 Db – IP66
• Notified Body for EC-Type Examination: SGS-Fimko 0598 Helsinki Finland
• EC-type Examination Certificate: Baseefa06TEX0061X
• Notified Body for production: 0598
• Approved Body for UK-Type Examination: SGS-Baseefa 1180 Buxton UK
• UK-type Examination Certificate: BAS21UKEX0061X
• Approved Body for production: 1180
• Harmonized Standards used: EN 60079-0:2018, EN 60079-1:2014, EN 60079-7:2015+A1:2018, EN 60079-31:2014

On behalf of the above named company, I declare that, on the date the equipment accompanied by this declaration is placed on the market, the equipment conforms with all technical and regulatory requirements of the above listed directives

A. Reid Technical Manager

Read User Manual Online (PDF format)

Download This Manual (PDF format)

Download this manual  >>