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PL511

Increased Safety Exe
Dual Certified ATEX - IECEx
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PL513

Increased Safety Exe
Dual Certified ATEX - IECEx
PL520 Enclosure

PL520

Increased Safety Exe
Dual Certified ATEX - IECEx
PL612 Enclosure

PL612

Increased Safety Exe
Dual Certified ATEX - IECEx
PL615 Enclosure

PL615

Increased Safety Exe
Dual Certified ATEX - IECEx
PL620 Enclosure

PL620

Increased Safety Exe
Dual Certified ATEX - IECEx
PL626 Enclosure

PL626

Increased Safety Exe
Dual Certified ATEX - IECEx
PL630 Enclosure

PL630

Increased Safety Exe
Dual Certified ATEX - IECEx
PL642 Enclosure

PL642

Increased Safety Exe
Dual Certified ATEX - IECEx
PL644 Enclosure

PL644

Increased Safety Exe
Dual Certified ATEX - IECEx
PL712 Enclosure

PL712

Increased Safety Exe
Dual Certified ATEX - IECEx
PL722 Enclosure

PL722

Increased Safety Exe
Dual Certified ATEX - IECEx
EJB-Series Stainless Steel Enclosures

EJB Range

Increased Safety Exe
Dual Certified ATEX - IECEx
Size 1 Enclosure

Size 1

Increased Safety Exe
Dual Certified ATEX - IECEx
Size 2 Enclosure

Size 2

Increased Safety Exe
Dual Certified ATEX - IECEx
Size 2L Enclosure

Size 2L

Increased Safety Exe
Dual Certified ATEX - IECEx
Size 3 Enclosure

Size 3

Increased Safety Exe
Dual Certified ATEX - IECEx
Size 4 Enclosure

Size 4

Increased Safety Exe
Dual Certified ATEX - IECEx
Size 4L Enclosure

Size 4L

Increased Safety Exe
Dual Certified ATEX - IECEx
Size 5 Enclosure

Size 5

Increased Safety Exe
Dual Certified ATEX - IECEx
Size 6 Enclosure

Size 6

Increased Safety Exe
Dual Certified ATEX - IECEx
Size 7 Enclosure

Size 7

Increased Safety Exe
Dual Certified ATEX - IECEx
Size 8 Enclosure

Size 8

Increased Safety Exe
Dual Certified ATEX - IECEx
Size 9 Enclosure

Size 9

Increased Safety Exe
Dual Certified ATEX - IECEx
EA 231513 Enclosure

EA 231513

Increased Safety Exe
Dual Certified ATEX - IECEx
EA 262620 Enclosure

EA 262620

Increased Safety Exe
Dual Certified ATEX - IECEx
EA 303020 Enclosure

EA 303020

Increased Safety Exe
Dual Certified ATEX - IECEx
EA 352620 Enclosure

EA 352620

Increased Safety Exe
Dual Certified ATEX - IECEx
EA 403020 Enclosure

EA 403020

Increased Safety Exe
Dual Certified ATEX - IECEx
EA 463820 Enclosure

EA 463820

Increased Safety Exe
Dual Certified ATEX - IECEx
EA 484820 Enclosure

EA 484820

Increased Safety Exe
Dual Certified ATEX - IECEx
EA 553522 Enclosure

EA 553522

Increased Safety Exe
Dual Certified ATEX - IECEx
EA 624522 Enclosure

EA 624522

Increased Safety Exe
Dual Certified ATEX - IECEx
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MKIV Controlex logo

Hazardous Area Connector

Tamb: -40°C to +60°C. ex logo II2 GD Exdb IIC Gb, Extb IIIC Db T95 IP66, 67 & DTS01 deluge protected.

ControlEx Connector

Overview

The 4th generation of Controlex logo connectors include many features and refinements as a result of consumer feedback, which makes them particularly suitable for control and low/medium power applications. The robust stainless steel body can hold up to 60 contacts and will accept conductor sizes ranging between 0.5mm² and 35mm², operating up to 125A and 750V.

MKIV Controlex logo 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.

Assembly Instructions

AI 500
Inserts
Dimensions

MKIV Controlex logo Connector Dimensions

ControlEx Connector Dimensions

The flameproof cap must be fitted to the connector before the power is restored to the disconnected circuit. The receptacle cap and plug cap are available in acetal and provide an IP rating of IP66/67. They may only be used when the socket or plug is not re-energised following disconnection. For connector plugs and connector receptacles cable glands are required to terminate incoming cables. Hawke recommend the ICG 653/UNIV cable gland is used.

HAWKE Ex SERIES DIMENSIONS (MM)
Dimension Ex16 Ex25 Ex32 Ex40 Ex50 Ex63
A 127 152 152 152 152 148
B 105 128 129 129 129 126
ØC 36 46 53 60 66 83
ØD 37 49 57 65 76 90
E 128 152 152 152 152 152
ØF 32 45 51 59 70 83
G 15 15 15 15 15 15
H (nominal) 20 20 20 20 20 20
J (Aperture clearance hole) 55 65 75 85 95 115
* Thread L (1.5mm Pitch) M25 M32 M40 M50 M63 M75
M 54 54 56 56 56 56
N A/F 36 46 55 65 80 95
R 15 15 15 16 16 17
S 38 38 38 39 39 40
ØT 28 34 42 51 60 73
U 40 40 40 40 40 40
Thread V (1.5mm Pitch) M20 M25 M32 M40 M50 M63
X (nominal) 54 70 70 70 70 67
ØY 66 76 83 91 102 117
49 59 66 74 85 100
ØZ 87 99 105 117 129 147
70 82 88 100 112 130
* Bulkhead entry thread L can be adapted to other sizes. This may affect the overall length of unit.
Contact us for details.

MKIV Controlex logo Inserts

ControlEx Connector Inserts

Cup Sizes and Selection Table

CUP DIAMETERS
Insert
Size
Internal Diameter of cup (mm)
Nominal
Soldered Crimped
1.5mm² 2 2
2.5mm² 3 3
6mm² 3.5 3.2
10mm² 7 4
16mm² 7 5
25mm² 8 6.5
35mm² 8 8.3
INSERT SELECTION TABLE
Shell Size 16 Shell Size 25 Shell Size 32 Shell Size 40 Shell Size 50 Shell Size 63
3 x 1.5mm² + Earth 4 x 1.5mm² + Earth 12 x 1.5mm² + Earth 24 x 1.5mm² + Earth 37 x 1.5mm² + Earth 49 x 1.5mm² + Earth
4 x 1.5mm² + Earth 9 x 1.5mm² + Earth 19 x 1.5mm² + Earth 30 x 1.5mm² + Earth 27 x 2.5mm² + Earth 60 x 1.5mm² + Earth
- 12 x 1.5mm² + Earth 10 x 2.5mm² + Earth 19 x 2.5mm² + Earth 13 x 6mm² + Earth 37 x 2.5mm² + Earth
- 4 x 2.5mm² + Earth 12 x 2.5mm² + Earth 4 x 25mm² + Earth - -
- 7 x 2.5mm² + Earth 4 x 6mm² + Earth 4 x 35mm² + Earth - -
- 4 x 6mm² + Earth 6 x 6mm² + Earth - - -
- - 3 x 10mm² + Earth - - -
- - 4 x 10mm² + Earth - - -
- - 3 x 16mm² + Earth - - -
- - 4 x 16mm² + Earth - - -
Note: Inserts for use in bulkhead receptacles are solder termination only, for contact sizes of 6mm² and above.
Hawke Controlex logo connectors have a maximum working voltage of 750V DC (750V AC) as standard.
3rd & 4th generation Controlex logo connectors can be connected together within certification.
Other voltages available on special request.

MKIV Controlex logo Calculations

To select the shell size of the connector, it is essential that you calculate the dissipated wattage of the arrangement. This ensures that the arrangement does not exceed the maximum permitted temperature classification with regard to the upper ambient temperature for the area of installation. (please refer to table 1 below for the maximum allowable dissipated wattage per connector size).

TABLE 1
Connector Size Upper Ambient
Temperature of +40°C
Upper Ambient
Temperature of +50°C
Upper Ambient
Temperature of +60°C
Temperature Class Temperature Class Temperature Class
T6 T5 T6 T5 T6 T5
Ex16 5W 7W 4W 6W 2.6W 4.6W
Ex25 8W 11W 6W 10W 4W 7W
Ex32 10.5W 14.5W 8W 12W 5.4W 9W
Ex40 12W 17W 9W 14W 5.5W 10.5W
Ex50 13W 20W 10W 17W 6.5W 12.5W
Ex63 17W 29W 13W 24W 8.5W 17W
  Maximum allowable dissipated wattage
Other ambient temperature options can be extrapolated from
table 1 above, or contact Hawke International for more information.
TABLE 2
Contact Size Combined Cable And Contact Resistance (Ohms) Contact
Current
Rating
Soldered Crimped
1.5mm² 0.0166Ω 0.0173Ω 10 amps
2.5mm² 0.0102Ω 0.0109Ω 17 amps
6mm² 0.0047Ω 0.0054Ω 30 amps
10mm² 0.0027Ω 0.0033Ω 78 amps
16mm² 0.0018Ω 0.0024Ω 78 amps
25mm² 0.0012Ω 0.0018Ω 125 amps
35mm² 0.0009Ω 0.0015Ω 125 amps

Dissipated Wattage Calculation

Equation definitions:

W = Dissipated wattage factor of the connector

N = The number of conductors to be terminated/number of contacts required. (Note: A contact comprises of a pin and socket).

I = The current requirement per contact. (Note: This must be equal to or less than the maximum current rating of the contact, as shown in table 2 above).

R = The combined cable and contact resistance (see table 2 above).

Values pertinent to these definitions must then be input into the relevant fields below to calculate the dissipated wattage (W) of your chosen arrangement:

1. W = N x I ² x R
N I R Dissipated Wattage
(Watts)
W

(Note: The results must be lower than the maximum figure shown in table 1 above, for the appropriate temperature class and ambient temperature).

e.g. T6 40°C ambient application with 9 x 1.5mm² conductors running at 7 amps.
N = 9 contacts
I = 7 amps
R = 0.0166 Ω (1.5mm² soldered combined cable and contact resistance)

Therefore W = 9 x 49 x 0.0166 = 7.32 watts.
Therefore an Ex25 Connector should be specified for this application as the shell size can accommodate the required 9 x 1.5mm² pin / socket inserts (see insert selection table) and the resultant dissipated wattage (7.32 watts) is below the maximum permitted 8 watts (see table 1 above).

This equation can also be transposed to facilitate the calculation of the maximum number of conductors permitted in your selected connector (calculator 2 below ) and the maximum allowable current within the upper ambient temperature of your location (calculator 3 below).

2. number of conductors formula
W R I Maximum Number Of
Conductors
N
3. maximum current formula
W N R Current
(Amps)
I
Note: The result must not exceed the maximum current rating of the contacts (see table 2 above)

Note: Unless otherwise requested, connectors will be marked as T5 with an upper ambient temperature of +40°C.

Order Codes

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 or equivalnts) is used in portable/semi-portable applications.

When ordering, select the relevant code from each block as shown in the example below:
Controlex logo/Exd-32-S-CP-V-19 x 1.5-S-C-FL-FPC-P-R25-A-1-T

Controlex logo Select Code Description Example Code
Protection Exd Flameproof Exd
Shell Size 16 16 32
25 25
32 32
40 40
50 50
63 63
Material S Stainless Steel S
Connector Style CP Connector Plug CP
CR Connector Receptacle
BR Bulkhead Receptacle
Keying System V Variable Keyway (All) V
F Fixed Keyway
(only available if purchasing terminated)
Number Of Contacts   See insert selection 19
X No Insert
Contact Size   See insert selection 1.5
Insert Type P Pin S
S Socket
X No Insert
Termination Style
* Note: Inserts for use in Bulkhead receptacles are solder termination only for contact sizes of 6mm² and above.
S Solder* C
C Crimp*
X No Insert
Flange Type ♦
Note: CP or CR only - one per mating pair.
FL Mounting Flange FL
SF Split Flange
(can be retro fitted after termination)
Cap Type FRC Flameproof Receptacle Cap FPC
FPC Flameproof Plug Cap
PRC Plastic Receptacle Cap
PPC Plastic Plug Cap
Locking Pin ♦ P Locking Pin
(only one required per mating pair)
P
Alternative Cable Gland Entry ♦ R20 Reduced Cable Gland Entry M20
(Ex25 only)
R25
R25 Reduced Cable Gland Entry M25
(Ex40 & Ex32 only)
R32 Reduced Cable Gland Entry M32
(Ex50 & Ex40 only)
R40 Reduced Cable Gland Entry M40
(Ex63 & Ex50 only)
R50 Reduced Cable Gland Entry M50
(Ex63 only)
Certification A ATEX/IECEx/EAC/Inmetro A
N ATEX/IECEx/EAC/Inmetro/NEC 505
Voltage reduced to 600V
Ambient Rating and Temperature Class
T5 +40°C will be supplied as standard if alternative not specified.
1 T5 +40°C Standard 1
2 T5 +50°C
3 T5 +60°C
4 T6 +40°C
5 T6 +50°C
6 T6 +60°C
Termination ♦ T Termination Required T

♦ If not required omit selection character from order code.

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Ordering Information

For ordering information and codes, please see order codes tab.

Download Data Sheet

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