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Falcon Series Ex Connectors Robust, rapid-assembly, power, data and fibre Ex Connectors for use in hazardous areas. Oil and gas installations, offshore applications, wellhead control panels, mobile skid units, mining, tunnelling, process plants, portable equipment and mobile machinery.
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Falcon Series Ex Connectors - PEI-Genesis

May 06, 2023

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Page 1: Falcon Series Ex Connectors - PEI-Genesis

Falcon Series Ex ConnectorsRobust, rapid-assembly, power, data and fibre Ex Connectors for use in hazardous areas.

Oil and gas installations, offshore applications, wellhead control panels, mobile skid units, mining, tunnelling, process plants, portable equipment and mobile machinery.

Page 2: Falcon Series Ex Connectors - PEI-Genesis

Falcon Connectors: In partnership with PEI-Genesis

PEI-Genesis are the number one stocking distributor for the world leaders in harsh environment connector products. With over $75 million of component level stock, PEI-Genesis are known as the world’s fastest assembler of precision connectors for all rugged applications. With manufacturing sites on three continents, PEI-Genesis can offer global engineering support throughout our whole product portfolio in both copper and fibre optic solutions. Oil and gas, pharmaceutical and petrochemical applications are key to our Engineered Solutions group within PEI-Genesis. With specialists teams both in the US and UK, we’re able to provide certified ATEX / IECEx connector, harness and associated systems’ solutions for copper signal, power and fibre optics.

Page 3: Falcon Series Ex Connectors - PEI-Genesis

01

Connections you can trust from Trolex

Falcon Series Ex Connectors

The Falcon Series Connectors from Trolex have been engineered for the purpose of bringing you the world’s most robust and easy to use Ex connection systems for heavy-duty power, data and fibre cables.

Incorporating live disconnect possibility in the most hazardous areas, a virtually instantaneous connect/disconnect system, and a making-off procedure that reduces assembly times from hours to minutes, the Falcon series connectors will save you both time and money, and deliver connections that you can really trust.

Who says Ex Connectors are hard to use?Contact our distribution partner today for a demonstration and to find out how we’ve solved the problem.

PEI-Genesis UK LTD, George Curl Way, Southampton, SO18 2RZ T +44 (0) 23 8062 1260 F +44 (0) 23 8062 1270 [email protected]

Page 4: Falcon Series Ex Connectors - PEI-Genesis

Falcon Series Ex ConnectorsTrolex

The Falcon Ex Connector Range

Falcon 25 Solid, reliable and easy-to-use Ex Connector with live disconnect capability. Available with 4 to 10 contacts, for control circuits and medium power applications.

Falcon 40 High capacity Ex Connector for multi-way control circuits and power distribution. Live disconnect capability and up to 37 contacts.

Falcon 25 Fibre

Carrying premium quality Cinch expanded beam optical fibre connectors with 2, 4 or 8 single or multi-mode channels for high speed, high density data transfer applications.

Falcon 25 Flash

Flash drive connector for download of data or control devices housed in Ex d enclosures in the hazardous area. Available with desktop reader for PC downloads, and comes with standard 32 GB data storage.

Page 5: Falcon Series Ex Connectors - PEI-Genesis

Through the application of simple and elegant design principles we’ve created a range of Ex Connectors that I believe are the safest, most robust, and easy-to-use in the world.

Kyle HudsonEngineer - Brand Integrity and Mechanical Design

02 – 03

Page 6: Falcon Series Ex Connectors - PEI-Genesis

Rapid Assembly

Reduce assembly time to a matter of minutes instead of hours.

The Falcon Series rear-loading assembly system allows complete cable termination in just a few minutes and requires no specialist tools or equipment. The incoming cable is independently terminated on the removable end-cap in the normal way and prepared ready for connecting the cores to the contact insert.

A cutting gauge is incorporated to ensure that the cable conductors are trimmed to the optimum length. Connections can be crimped or soldered and easily hand assembled into the double-insulated contact cartridge. The cartridge is then simply loaded into the rear of the connector and fixed in place with two screws to complete the operation. This two-point radial fixing has the added benefit that cable rotation is completely eliminated.

Falcon Series Ex ConnectorsTrolex

Our website features a videoof a connecter being assembled.www.trolex.com/products/ex-connectors

Page 7: Falcon Series Ex Connectors - PEI-Genesis

Rapid Connection

Live Disconnect

Fast, simple connect/disconnectwithout compromising safety integrity or robustness.

Engage or separate connectors with live power applied.

The Falcon Series revolutionary two- stage bayonet coupling system provides exceptionally fast mating and de-mating with maximum safety and a high tolerance of debris and contamination in tough site conditions. A solid and robust connect or disconnect in an instant. Flame paths are shrouded at all times and are never exposed to potential damage.

Falcon may be parted in the hazardous area for short periods to allow maintenance or change out of equipment, following normal risk assessment procedures. The electrical power source must originate from the socket side of the connector. Socket contacts can be user installed in either the plug or receptacle to suit the application.

In combination with the live disconnect facility this rapid connection protocol will save time and money in the harshest industrial environments where safety and productivity need to be maximised. The result is increased uptime for rigs, key machinery and temporary equipment.

Alternatively, as all contact operations are contained within full Ex d protection, pilot circuit interlocking can be employed where regulation demands, to automatically isolate the system before disconnection is completed.

04 – 05

Page 8: Falcon Series Ex Connectors - PEI-Genesis

In my 40 years of working at Trolex, the Falcon connector is one of the highest quality and well-structured products that I have worked on. Engineered for ease of build and operation, it’s a product that can be used worldwide for many applications.

Garry RossProduction Operative

Page 9: Falcon Series Ex Connectors - PEI-Genesis

06 – 07

Direct Enclosure Mounting Connect directly into Ex d and Ex e enclosures and equipment. Fixed versions of the Falcon receptacles are equipped with mounting bushes for direct fitting with Ex gland entries. Electrical connections are fully encapsulated for explosion protection with a choice of wire length to suit the application.

Flash Drive Data Collection The Falcon 25 Flash provides a quick and convenient USB link to collect and store data from PCs and data systems that are operating within Ex d enclosures in hazardous areas.

Data can be safely acquired when the Falcon Flash-drive is connected to a pre-installed Falcon Fixed Receptacle, without the need to enter the apparatus enclosure. Comes with 32 GB of storage as standard and data can be later transferred to a PC port using a standard Falcon USB docking accessory.

Optical Fibre Capability The Falcon 25 Fibre Connector comes with a choice of 2, 4 or 8 way optical fibre contacts utilising Cinch expanded beam fibre couplers for high-end applications in hazardous areas. Certified for inherently safe and protected optical radiation standards. The high precision contact elements have low attenuation losses for single and multi-mode fibres which are easy to clean and are field repairable using standard tooling. Accurate lens conformity is assured by a unique active spring-supported alignment device providing reliable performance in the most demanding environments on repeated duty cycles.

Page 10: Falcon Series Ex Connectors - PEI-Genesis

Key Features

12345

In-built ingress protection caps are permanently attached and ready to hand. Integrated resilient fender for impact protection.

Passivated silver-plated contact Pins suitable for solder or crimp connections.

Precision investment-cast and machined Plug (3a)/ Receptacle (3b) in aluminium or stainless steel. Sealed for IP66 ingress protection.

Internal earth connection permits the use of non-armoured cable.

Cable entries are certified for use with most types of compatible Ex approved cable glands. Rear loading with screw fastenings makes for simple and fast cable termination accommodating both compression and standard sealed glands.

Falcon Series Ex ConnectorsTrolex

65

7

4 2

1

Receptacle - 3B

Page 11: Falcon Series Ex Connectors - PEI-Genesis

6789

10

Internal ‘double insulated’ cable connection cartridge.

Removable precision investment-cast and machined End Cap for terminating the incoming cable.

High grade glass filled polymer Contact Insert carrying slide-in contact Pins and Sockets. Pins and Sockets can be loaded into any preferred configuration.

User configurable Security Interlock to prevent non-valid mating.

Passivated silver plated contact Sockets with longitudinal multi-contact springs for high reliability and low insertion force, providing exceptionally low contact resistance.

08 – 09

8

6

7

5

49 10

Plug - 3A

Page 12: Falcon Series Ex Connectors - PEI-Genesis

Technical Information

Housing format

Housing material

Cable entry

Fixed receptacle mounting

Fixed receptacle wires

Mating cycles

Security coding

Ingress protection

Temperature limits

Contacts

Cable terminations

Contact protection

Insert material

Fire rating

Insulation

Protective earth connections

WeightTX3706.1 Line PlugTX3706.2 Line ReceptacleTX3706.3 Fixed Receptacle

Conformity

25mm contact insert

Stainless Steel - ANC4BAluminium Alloy - LM25TF - with hard anodised protection (Group II only)

Choice of threaded cable entry sizes for standard Ex d cableglands: M20 and M25

M20 into Ex d or Ex e housingM25 into Ex d or Ex e housing

1.5mm2 x 1m, 2m or 3m (L) flexible insulated wire2.5mm2 x 1m, 2m or 3m (L) flexible insulated wire

10,000 no load(Limited to 200 for live disconnect)

5 Selectable positions

IP66

ATEX/IECEx certified to -50 to +60°C

Multi-spring wire socket and solid pins

4, 6 or 8 point crimp or solder - IEC 60352-2

Passivated silver plate

Glass filled polymer

UL 94 V-0

Class II double insulated

Screw clamp terminals for 2.5mm² conductor

Stainless Steel Aluminium0.5kg 0.2kg0.43kg 0.17kg0.4kg 0.15kg

EN 61984: 2009 - Safety RequirementsEN 60664: 2007 - Insulation Co-ordinationEN60079-0: 2012+A11: 2013 - General RequirementsEN60079-1: 2014 - Flame-proof enclosures EN60079-7: 2015 - Explosive atmospheres. Equipment protected by increased safety “e”EN60079-31: 2014 - Equipment Dust Ignition Protection by Enclosure “t”

Falcon Series Ex ConnectorsTrolex

Certified for use in underground mines and surface industry with explosive gas and dust atmospheres. For full certification details including certificate numbers, Ex marking and conditions of safe use refer to the product user manual - available at www.trolex.com.

Falcon 25 Ex Connector TX3706

Page 13: Falcon Series Ex Connectors - PEI-Genesis

Contact Inserts

4 to 10 100A

25A

250V ac100V dc

1.5 or 2.5mm²

6N per contact

400 μ ohm

2000V

3000V

30V max

The contact inserts are moulded in a high-grade glass filled polymer. Mechanically interlocked male and female pairs of inserts ensure maximum protection for the pins and sockets during engagement. They can be fitted in either orientation in the plug housing or the receptacle housing and all pins are fully shrouded in all configurations.

Pins & Sockets Pins or sockets can be inserted into either the male or female inserts according to application preference. Connections can be crimped or soldered, in two available wire sizes 1.5 or 2.5 mm2.

Protective Earth A leading earth pin can be loaded into an insert, this is slightly longer than the standard pin and provides a first make, last break safety earth connection. Internal earth terminals also permit the use of non-armoured cables.

Pilot Circuit Interlocking A lagging or short pilot pin can be loaded into a pin contact insert. This may be interconnected with the systemcontrol circuits to isolate the system power and ensure that all contacts are dead on final separation.

Contact ways Maximum total current (all contacts)

Maximum rated current (per contact)

Rated voltage

Wire size

Insertion force

Contact resistance

Test voltage

Other voltage transients

Intrinsically safe connections

10 – 11

Page 14: Falcon Series Ex Connectors - PEI-Genesis

Live Disconnect

Dimensions

Connecting and disconnecting Falcon in the hazardous area is permitted for short periods to allow maintenance activities or change-out of apparatus where the system power originates ONLY from the SOCKET CONTACT side of the connector. Contact inserts for LIVE DISCONNECT applications are supplied with high clearance pins to maintain optimum electrical separation.

Falcon Series Ex ConnectorsTrolex

Maximum voltage: 4-way Maximum voltage: 10-way

Power factor (Reactive load)

Maximum contact current

ac

250V

80V

Between 0.6 and 1.0

1A

dc

250V

80V

Between 0.6 and 1.0

1A

TX3706.1 - Line Plug

TX3706.3 - Fixed Receptacle

TX3706.2 - Line Receptacle 102.0

Cable entryM20 or M25

48

61 20.0

M20 orM25

48

99

Cable entryM20 or M25

45

Page 15: Falcon Series Ex Connectors - PEI-Genesis

FINISHMATERIAL

TOLERANCES TO BE AS SPECIFIED BELOW, UNLESS OTHERWISE STATEDOVER 0 30 100 300 1000 2000

30 100 300 1000 2000

FABRICATED

0.1 0.15 0.2 0.3

0.3

0.5

0.5 0.5

0.8

1.0

1.00.5

1.5

1.5

2.0

2.0 3.0 5.0

ORIGINAL SCALE

CHKDDR'NAPP'D

DATE

ISSUE

No.

TITLE

CLIENT /PROJECT

No. IF IN DOUBT ASK

Special Inspection Notes:

ECRNo

Newby Road, Hazel Grove, Stockport, Cheshire SK7 5DY UK. Tel: +44 (0)161 483 1435 E-mail: [email protected] LIMITED

DELETEONE

RANGE

ALL DIMENSIONS IN MILLIMETRESUNLESS OTHERWISE STATED

REMOVE ALL BURRS & SHARP EDGES

MACHINED SURFACES THUSSYMBOLS TO BS1134 um Ra

THIS IS A CERTIFIED RELATED DRAWING. NO MODIFICATIONSARE PERMITTED WITHOUT THE APPROVAL OF THE

"AUTHORISED PERSON", MANUFACTURE EXACTLY AS DRAWN.

THIS IS A CERTIFIED DRAWING AND IT MUST NOT BEMODIFIED WITHOUT AUTHORISATION FROM THE

CERTIFICATION BODY

P5609.28

1:2

P5609.28

<Title>

<client/project>

<Name> 01/06/2007

FINEMACHINEMEDIUM

MACHINE

UP TO & INCLUDING

<Material> Equal to or better than 1.6Ra(N7)

<01/01/1999><app'd by>

<app'l>

DateSample Approved By

Sample Approval Required?(See QS3.65)

<Name> 01/06/2007 A2

FINISHMATERIAL

TOLERANCES TO BE AS SPECIFIED BELOW, UNLESS OTHERWISE STATEDOVER 0 30 100 300 1000 2000

30 100 300 1000 2000

FABRICATED

0.1 0.15 0.2 0.3

0.3

0.5

0.5 0.5

0.8

1.0

1.00.5

1.5

1.5

2.0

2.0 3.0 5.0

ORIGINAL SCALE

CHKDDR'NAPP'D

DATE

ISSUE

No.

TITLE

CLIENT /PROJECT

No. IF IN DOUBT ASK

Special Inspection Notes:

ECRNo

Newby Road, Hazel Grove, Stockport, Cheshire SK7 5DY UK. Tel: +44 (0)161 483 1435 E-mail: [email protected] LIMITED

DELETEONE

RANGE

ALL DIMENSIONS IN MILLIMETRESUNLESS OTHERWISE STATED

REMOVE ALL BURRS & SHARP EDGES

MACHINED SURFACES THUSSYMBOLS TO BS1134 um Ra

THIS IS A CERTIFIED RELATED DRAWING. NO MODIFICATIONSARE PERMITTED WITHOUT THE APPROVAL OF THE

"AUTHORISED PERSON", MANUFACTURE EXACTLY AS DRAWN.

THIS IS A CERTIFIED DRAWING AND IT MUST NOT BEMODIFIED WITHOUT AUTHORISATION FROM THE

CERTIFICATION BODY

P5609.28

1:2

P5609.28

<Title>

<client/project>

<Name> 01/06/2007

FINEMACHINEMEDIUM

MACHINE

UP TO & INCLUDING

<Material> Equal to or better than 1.6Ra(N7)

<01/01/1999><app'd by>

<app'l>

DateSample Approved By

Sample Approval Required?(See QS3.65)

<Name> 01/06/2007 A2

12 – 13

Order Reference

Line Plug

Line Receptacle

Fixed Receptacle

TX3706.1

TX3706.2

TX3706.3

ATEX/IECEx Group I .19

.20

.02

.01

.02

.03

.15

.25

.20

.25

.01

ATEX/IECEx Group II

Aluminium (Group II only)

Stainless steel

Pins. Standard

Sockets

Pins. Live disconnect

Wire size - 1.5mm2

Wire size - 2.5mm2

Cable gland thread - M20

Cable gland thread - M25

ATEX/IECEx Group I

Aluminium

Pins. Standard

Wire Length L - 1m

.19

.02

.02

.02

.03

.03

.20

.01

.01

.01

.20

.25

ATEX/IECEx Group II

Stainless steel

Sockets

Wire Length L - 2m

Mounting - M20 Bush

Pins. Live disconnect

Wire Length L - 3m

Mounting - M25 Bush

.15

.25

Wire size - 1.5mm2

Wire size - 2.5mm2

.04

.10

.05

.11

.06

.12

.07

.13

.08

.14

Insert - 4 way (Position A)

Insert - 10 way (Position A)

Insert - 4 way (Position B)

Insert - 10 way (Position B)

Insert - 4 way (Position C)

Insert - 10 way (Position C)

Insert - 4 way (Position D)

Insert - 10 way (Position D)

Insert - 4 way (Position E)

Insert - 10 way (Position E)

Insert - 4 way .04

.10Insert - 10 way

Page 16: Falcon Series Ex Connectors - PEI-Genesis

Falcon Series Ex ConnectorsTrolex

Order Reference

Accessories

Mounting Clamp

Stainless steel/polypropylene

Ex d Plug cap

Cover cap for combined Ex d and ingress protection after live disconnect or re-application of the power to a Plug

Ex d Receptacle cap

Cover cap for combined Ex d and ingress protection after live disconnect or re-application of the power to a Receptacle

TX3706.51

AluminiumTX3706.41 (Group II only)

Stainless steelTX3706.42

AluminiumTX3706.43 (Group II only)

Stainless steelTX3706.44

1.5mm2

1.5mm2

P5609.23.01

P5609.23.02

P5609.16.01

P5609.16.02

2.5mm2

2.5mm2

Earth pin

Increased insertion length for ‘first make - last break’ safety earth protection

Live disconnect / Pilot pin

Reduced insertion length for ‘first break - last make’ pilot circuit interlocking

Page 17: Falcon Series Ex Connectors - PEI-Genesis

14 – 15

Pre-wired USB connection to a standard Falcon 4 way receptacle. Fitted with an Ex d cap.

Remove the flash drive andreplace the receptacle cap.

The receptacle cap can be temporarily removed with system power still applied. Connect the Falcon Flash to collect data.1 2 3

M20 or M25 gland entry mounting on Ex d or Ex e enclosures (standard Falcon fixed receptacle)

Technical InformationData storage

Housing material

Fixed receptacle mounting

Fixed receptacle wires

Ingress protection

Temperature limits

Connections

32GB as standard

Stainless Steel - ANC4B Aluminium Alloy - LM25TF - With hard anodised protection (Group II only)

M20 into Ex d or Ex e housingM25 into Ex d or Ex e housing

1.5mm2 x 1m, 2m or 3m long

IP66

-10 to +60°C

Pin 1: +VPin 2: D-Pin 3: D+Pin 4: GND

DimensionsTX3706.4 Falcon 25 Flash TX3706.3 Fixed Receptacle

107 45

FINISHMATERIAL

TOLERANCES TO BE AS SPECIFIED BELOW, UNLESS OTHERWISE STATEDOVERUP TO & INCLUDING

0 30 100 300 1000 200030 100 300 1000 2000

FINEMACHINE

FABRICATED

0.1 0.15 0.2 0.3

0.3

0.5

0.5 0.5

0.8

1.0

1.00.5

1.5

1.5

2.0

2.0 3.0 5.0

ORIGINAL SCALE

CHKDDR'NAPP'D

DATE

ISSUE

No.

TITLE

CLIENT /PROJECT

No. IF IN DOUBT ASK

Special Inspection Notes:

ECRNo

Newby Road, Hazel Grove, Stockport, Cheshire SK7 5DY UK. Tel: +44 (0)161 483 1435 E-mail: [email protected] LIMITED

MEDIUMMACHINE

DELETEONE

RANGE

ALL DIMENSIONS IN MILLIMETRESUNLESS OTHERWISE STATED

REMOVE ALL BURRS & SHARP EDGES

MACHINED SURFACES THUSSYMBOLS TO BS1134 um Ra

THIS IS A CERTIFIED RELATED DRAWING. NO MODIFICATIONSARE PERMITTED WITHOUT THE APPROVAL OF THE

"AUTHORISED PERSON", MANUFACTURE EXACTLY AS DRAWN

THIS IS A CERTIFIED DRAWING AND IT MUST NOT BEMODIFIED WITHOUT AUTHORISATION FROM THE

CERTIFICATION BODY

P5609.60

1:2

P5609.60

<client/project>

<Title>

<Name> 01/06/2007

<Material> Equal to or better than 1.6Ra(N7)

Sample Approval Required?(See QS3.65)

Sample Approved ByDate

<app'l>

<app'd by><01/01/1999>

<Name> 01/06/2007 A3

62 15.0 L

M20 or M25

54

FINISHMATERIAL

TOLERANCES TO BE AS SPECIFIED BELOW, UNLESS OTHERWISE STATEDOVERUP TO & INCLUDING

0 30 100 300 1000 200030 100 300 1000 2000

FINEMACHINE

FABRICATED

0.1 0.15 0.2 0.3

0.3

0.5

0.5 0.5

0.8

1.0

1.00.5

1.5

1.5

2.0

2.0 3.0 5.0

ORIGINAL SCALE

CHKDDR'NAPP'D

DATE

ISSUE

No.

TITLE

CLIENT /PROJECT

No. IF IN DOUBT ASK

Special Inspection Notes:

ECRNo

Newby Road, Hazel Grove, Stockport, Cheshire SK7 5DY UK. Tel: +44 (0)161 483 1435 E-mail: [email protected] LIMITED

MEDIUMMACHINE

DELETEONE

RANGE

ALL DIMENSIONS IN MILLIMETRESUNLESS OTHERWISE STATED

REMOVE ALL BURRS & SHARP EDGES

MACHINED SURFACES THUSSYMBOLS TO BS1134 um Ra

THIS IS A CERTIFIED RELATED DRAWING. NO MODIFICATIONSARE PERMITTED WITHOUT THE APPROVAL OF THE

"AUTHORISED PERSON", MANUFACTURE EXACTLY AS DRAWN

THIS IS A CERTIFIED DRAWING AND IT MUST NOT BEMODIFIED WITHOUT AUTHORISATION FROM THE

CERTIFICATION BODY

P5609.28

1:2

P5609.28

<client/project>

<Title>

<Name> 01/06/2007

<Material> Equal to or better than 1.6Ra(N7)

Sample Approval Required?(See QS3.65)

Sample Approved ByDate

<app'l>

<app'd by><01/01/1999>

<Name> 01/06/2007 A3

Falcon 25 FlashTX3706.4

USB data collection and storage in a convenient Ex d package

The Falcon 25 Flash can be temporarily connected to a standard pre-wired Falcon receptacle installed on Ex d or Ex e enclosures.Data can be collected via USB links from PCs and data systems in the hazardous area without the need to isolate the equipment power.

Page 18: Falcon Series Ex Connectors - PEI-Genesis

FINISHMATERIAL

TOLERANCES TO BE AS SPECIFIED BELOW, UNLESS OTHERWISE STATEDOVER 0 30 100 300 1000 2000

30 100 300 1000 2000

FABRICATED

0.1 0.15 0.2 0.3

0.3

0.5

0.5 0.5

0.8

1.0

1.00.5

1.5

1.5

2.0

2.0 3.0 5.0

ORIGINAL SCALE

CHKDDR'NAPP'D

DATE

ISSUE

No.

TITLE

CLIENT /PROJECT

No. IF IN DOUBT ASK

Special Inspection Notes:

ECRNo

Newby Road, Hazel Grove, Stockport, Cheshire SK7 5DY UK. Tel: +44 (0)161 483 1435 E-mail: [email protected] LIMITED

DELETEONE

RANGE

ALL DIMENSIONS IN MILLIMETRESUNLESS OTHERWISE STATED

REMOVE ALL BURRS & SHARP EDGES

MACHINED SURFACES THUSSYMBOLS TO BS1134 um Ra

THIS IS A CERTIFIED RELATED DRAWING. NO MODIFICATIONSARE PERMITTED WITHOUT THE APPROVAL OF THE

"AUTHORISED PERSON", MANUFACTURE EXACTLY AS DRAWN.

THIS IS A CERTIFIED DRAWING AND IT MUST NOT BEMODIFIED WITHOUT AUTHORISATION FROM THE

CERTIFICATION BODY

P5609.28

1:2

P5609.28

<Title>

<client/project>

<Name> 01/06/2007

FINEMACHINEMEDIUM

MACHINE

UP TO & INCLUDING

<Material> Equal to or better than 1.6Ra(N7)

<01/01/1999><app'd by>

<app'l>

DateSample Approved By

Sample Approval Required?(See QS3.65)

<Name> 01/06/2007 A2

Falcon Series Ex ConnectorsTrolex

TX3706.4 - Falcon 25 Flash. Complete with ingress protection cap

TX3706.3 - Fixed Receptacle

Order Reference

TX3706.4

ATEX/IECEx Group I .19

.20

.02

.01

ATEX/IECEx Group II

Aluminium (Group II only)

Stainless steel

TX3706.3

ATEX/IECEx Group I

Aluminium (Group II only)

Sockets

Insert - 4 way (Position C)

Wire size - 1.5mm2

Wire Length L - 1m

Mounting - M20

.19

.02

.02

.03

.02

.06

.15

.20

.01

.01

.20

.25

.25

ATEX/IECEx Group II

Stainless steel

Wire size - 2.5mm2

Wire Length L - 2m

Mounting - M25

Wire Length L - 3m

Page 19: Falcon Series Ex Connectors - PEI-Genesis

16 – 17

Cover cap for combined Ex d and ingress protection after live disconnect or reapplication of the power to a receptacle.

Convenient direct connection of the Falcon 25 Flash to a PC USB dataport.

Complete with USB connection cableLength: 1 metreSafe area only

TX3706.43 (Aluminium)TX3706.44 (Stainless Steel) Ex d receptacle cap

TX3706.5 Falcon Connecting Dock accessory

Certification for TX3706.4

Certified for use in underground mines and surface industry with explosive gas and dust atmospheres. For full certification details including certificate numbers, Ex marking and conditions of safe use refer to the product user manual - available at www.trolex.com.

Page 20: Falcon Series Ex Connectors - PEI-Genesis

The Falcon 25 Series connector is equipped with Cinch expanded beam technology to provide fibre solutions for use in heavy duty applications and hazardous areas. Cinch expanded beam fibre optic inserts are designed for use in harsh industrial environments offering high performance and cost effectiveness, combined with a simple termination process for rapid in-field termination or repair.

Falcon Series Ex ConnectorsTrolex

25mm Fibre Insert

Stainless Steel - ANC4BAluminium Alloy - LM25TF - with hard anodised protection (Group II only)

Choice of threaded cable entry sizes for standard Ex d cableglands: M20 and M25

M20 into Ex d or Ex e housingM25 into Ex d or Ex e housing

To specification 1000

5 selectable positions

IP66 -40 to +60°C 0.5kg0.43kg0.4kg EN 61984: 2009 - Safety RequirementsEN 60664: 2007 - Insulation Co-ordinationEN60079-0: 2012+A11 :2013 - General RequirementsEN60079-1: 2014 - Flame-proof enclosures EN 60079-7: 2015 - Explosive atmospheres. Equipment protection by increased safety “e”EN 60079-28: 2015 - Explosive atmospheres. Protection of equipment and transmission systems using optical radiation EN60079-31: 2014 - Equipment Dust Ignition Protection by Enclosure “t”

Housing format

Housing material

Cable entry

Fixed receptacle mounting

Optical fibres

Mating cycles

Security coding

Ingress protection

Temperature limits

Weight TX3706.6 Fibre Line PlugTX3706.7 Fibre Line ReceptacleTX3706.8 Fibre Fixed Receptacle

Conformity

Certified for use in underground mines and surface industry with explosive gas and dust atmospheres. For full certification details including certificate numbers, Ex marking and conditions of safe use refer to the product user manual - available at www.trolex.com.

Technical Information

Falcon 25 Fibre Ex ConnectorTX3706.6, TX3706.7, TX3706.8

Page 21: Falcon Series Ex Connectors - PEI-Genesis

18 – 19

Arrangements below

Multi Mode: <-1.0dBSingle Mode: <-1.5dB

Single Mode: >32dB

Glass Filled Polymer / Stainless Steel

Custom as specified

Optical fibres

Insertion loss

Return loss

Insert material

Cable assembly

Optical inserts

2 Channel 4 Channel 8 Channel

Page 22: Falcon Series Ex Connectors - PEI-Genesis

Please contact our technical support team for assistance in specifying your exact format and for any pre-assembled optical fibre cable that may be required.

Dimensions

Ordering

TX3706.6 - Fibre Line Plug

TX3706.8 - Fibre Fixed Receptacle

TX3706.7 - Fibre Line Receptacle

Falcon Series Ex ConnectorsTrolex

Page 23: Falcon Series Ex Connectors - PEI-Genesis

20 – 21

Line Plug

Line Receptacle

Fixed Receptacle

TX3706.1

TX3706.2

TX3706.3

Aluminium Connector W/ Brass Gland

Aluminium Connector W/ Brass Gland

01

01

02

02

02

02

S1

M25

C#

1

1

2

2

3

3

A1

M20

B#

04

04

A2

D#

Stainless Steel Connector and Gland

Stainless Steel Connector And Gland

Two Core Connector / Armoured Cable

Two Core Connector W/ 2 x Simplex Fibres

TX3706.1 Line Plug - Stainless Steel

Fixed Receptacle With M25 Thread

Breakout (250mm With M20 Gland)

Four Core Connector W/ Armoured Cable

Four Core Connector W/ 4 x Simplex Fibres

TX3706.2 Line Receptacle - Aluminium (Group II Only)

Breakout (500mm With M20 Gland)

Eight Core Connector W/ Armoured Cable

Eight Core Connector W/ 8 x Simplex Fibres

TX3706.2 Line Receptacle - Stainless Steel

Breakout (1000mm With M20 Gland)

08

08

S2

E#

62.5/125 (Multi-Mode)

62.5/125 (Multi-Mode - Grey Fibres)

50/125 (Multi-Mode)

50/125 (Multi-Mode - Orange Fibres)

9/125 (Single-Mode)

9/125 (Single-Mode - Yellow Fibres)

In 0.1m Increments (Min. 3m)

In 0.1m Increments (Min. 3m)

TX3706.1 Line Plug - Aluminium (Group II Only)

Fixed Receptacle With M20 Thread

Breakout (100mm With M20 Gland)

Standard Keyway Coding

Standard Keyway Coding

C

C

A-E

A-E

Refer To Factory For Keyway Coding

Refer To Factory For Keyway Coding

Order Reference

Where # = L For LC’s / T For ST’s / C For SC’s

Where # = L For LC’s / T For ST’s / C For SC’s

E.G. 0031 = 3.1m

E.G. 0031 = 3.1m

Page 24: Falcon Series Ex Connectors - PEI-Genesis

Falcon 40 Ex Connector TX3740 Technical Information

Housing format

Housing material

Cable entry

Fixed receptacle mounting

Fixed receptacle wires

Mating cycles

Security coding

Ingress protection

Temperature limits

Contacts

Cable terminations

Contact protection

Insert material

Fire rating

Insulation

Protective earth connections

WeightTX3740.1 Line PlugTX3740.2 Line ReceptacleTX3740.3 Fixed Receptacle

Conformity

40mm contact insert

Stainless Steel - ANC4BAluminium Alloy - LM25TF - with hard anodised protection (Group II only)

Choice of threaded cable entry sizes for standard Ex d cableglands: M32 and M40

M32 into Ex d or Ex e housingM40 into Ex d or Ex e housing

1.5mm2 x 1m, 2m or 3m (L) flexible insulated wire2.5mm2 x 1m, 2m or 3m (L) flexible insulated wire

10,000 no load(Limited to 200 for live disconnect)

6 Selectable positions

IP66

ATEX/IECEx certified to -50 to +60°C

Multi-spring wire socket and solid pins

4, 6 or 8 point crimp or solder - IEC 60352-2

Passivated silver plate

Glass filled polymer

UL 94 V-0

Class II double insulated

Screw clamp terminals for 2.5mm² conductor

Stainless Steel Aluminium1.2kg 0.65kg1.1kg 0.5kg1kg 0.45kg

EN 61984: 2009 - Safety RequirementsEN 60664: 2007 - Insulation Co-ordinationEN60079-0: 2012+A11: 2013 - General RequirementsEN60079-1: 2014 - Flame-proof enclosures EN60079-7: 2015 - Explosive atmospheres. Equipment protected by increased safety “e”EN60079-31: 2014 - Equipment Dust Ignition Protection by Enclosure “t”

Falcon Series Ex ConnectorsTrolex

Page 25: Falcon Series Ex Connectors - PEI-Genesis

Contact Inserts

Pins & Sockets Pins or sockets can be inserted into either the male or female inserts according to application preference. Connections can be crimped or soldered, in two available wire sizes 1.5 or 2.5mm2.

Protective Earth A leading earth pin can be loaded into an insert, this is slightly longer than the standard pin and provides a first make, last break safety earth connection. Internal earth terminals also permit the use of non-armoured cables.

Pilot Circuit Interlocking A lagging or short pilot pin can be loaded into a pin contact insert. This may be interconnected with the systemcontrol circuits to isolate the system power and ensure that all contacts are dead on final separation.

The contact inserts are moulded in a high-grade glass filled polymer. Mechanically interlocked pairs of inserts ensure maximum protection for the pins and sockets during engagement. They can be fitted in either orientation in the plug housing or the receptacle housing and all pins are fully shrouded in all configurations.

Dimensions

TX3740.1 - Line Plug 132

Cable entryM32 or M40

75

FINISHMATERIAL

TOLERANCES TO BE AS SPECIFIED BELOW, UNLESS OTHERWISE STATEDOVERUP TO & INCLUDING

0 30 100 300 1000 200030 100 300 1000 2000

FINEMACHINE

FABRICATED

0.1 0.15 0.2 0.3

0.3

0.5

0.5 0.5

0.8

1.0

1.00.5

1.5

1.5

2.0

2.0 3.0 5.0

ORIGINAL SCALE

CHKDDR'NAPP'D

DATE

ISSUE

No.

TITLE

CLIENT /PROJECT

No. IF IN DOUBT ASK

Special Inspection Notes:

ECRNo

Newby Road, Hazel Grove, Stockport, Cheshire SK7 5DY UK. Tel: +44 (0)161 483 1435 E-mail: [email protected] LIMITED

MEDIUMMACHINE

DELETEONE

RANGE

ALL DIMENSIONS IN MILLIMETRESUNLESS OTHERWISE STATED

REMOVE ALL BURRS & SHARP EDGES

MACHINED SURFACES THUSSYMBOLS TO BS1134 um Ra

THIS IS A CERTIFIED RELATED DRAWING. NO MODIFICATIONSARE PERMITTED WITHOUT THE APPROVAL OF THE

"AUTHORISED PERSON", MANUFACTURE EXACTLY AS DRAWN

THIS IS A CERTIFIED DRAWING AND IT MUST NOT BEMODIFIED WITHOUT AUTHORISATION FROM THE

CERTIFICATION BODY

TX3740.1

1:5

TX3740.1

<client/project>

<Title>

<Name> 01/06/2007

<Material> Equal to or better than 1.6Ra(N7)

Sample Approval Required?(See QS3.65)

Sample Approved ByDate

<app'l>

<app'd by><01/01/1999>

<Name> 01/06/2007 A3

TX3740.2 - Line Receptacle 118

Gland entryM32 or M40

75

FINISHMATERIAL

TOLERANCES TO BE AS SPECIFIED BELOW, UNLESS OTHERWISE STATEDOVERUP TO & INCLUDING

0 30 100 300 1000 200030 100 300 1000 2000

FINEMACHINE

FABRICATED

0.1 0.15 0.2 0.3

0.3

0.5

0.5 0.5

0.8

1.0

1.00.5

1.5

1.5

2.0

2.0 3.0 5.0

ORIGINAL SCALE

CHKDDR'NAPP'D

DATE

ISSUE

No.

TITLE

CLIENT /PROJECT

No. IF IN DOUBT ASK

Special Inspection Notes:

ECRNo

Newby Road, Hazel Grove, Stockport, Cheshire SK7 5DY UK. Tel: +44 (0)161 483 1435 E-mail: [email protected] LIMITED

MEDIUMMACHINE

DELETEONE

RANGE

ALL DIMENSIONS IN MILLIMETRESUNLESS OTHERWISE STATED

REMOVE ALL BURRS & SHARP EDGES

MACHINED SURFACES THUSSYMBOLS TO BS1134 um Ra

THIS IS A CERTIFIED RELATED DRAWING. NO MODIFICATIONSARE PERMITTED WITHOUT THE APPROVAL OF THE

"AUTHORISED PERSON", MANUFACTURE EXACTLY AS DRAWN

THIS IS A CERTIFIED DRAWING AND IT MUST NOT BEMODIFIED WITHOUT AUTHORISATION FROM THE

CERTIFICATION BODY

TX3740.2

1:5

TX3740.2

<client/project>

<Title>

<Name> 01/06/2007

<Material> Equal to or better than 1.6Ra(N7)

Sample Approval Required?(See QS3.65)

Sample Approved ByDate

<app'l>

<app'd by><01/01/1999>

<Name> 01/06/2007 A3

TX3740.3 - Fixed Receptacle

22 – 23

Page 26: Falcon Series Ex Connectors - PEI-Genesis

FINISHMATERIAL

TOLERANCES TO BE AS SPECIFIED BELOW, UNLESS OTHERWISE STATEDOVER 0 30 100 300 1000 2000

30 100 300 1000 2000

FABRICATED

0.1 0.15 0.2 0.3

0.3

0.5

0.5 0.5

0.8

1.0

1.00.5

1.5

1.5

2.0

2.0 3.0 5.0

ORIGINAL SCALE

CHKDDR'NAPP'D

DATE

ISSUE

No.

TITLE

CLIENT /PROJECT

No. IF IN DOUBT ASK

Special Inspection Notes:

ECRNo

Newby Road, Hazel Grove, Stockport, Cheshire SK7 5DY UK. Tel: +44 (0)161 483 1435 E-mail: [email protected] LIMITED

DELETEONE

RANGE

ALL DIMENSIONS IN MILLIMETRESUNLESS OTHERWISE STATED

REMOVE ALL BURRS & SHARP EDGES

MACHINED SURFACES THUSSYMBOLS TO BS1134 um Ra

THIS IS A CERTIFIED RELATED DRAWING. NO MODIFICATIONSARE PERMITTED WITHOUT THE APPROVAL OF THE

"AUTHORISED PERSON", MANUFACTURE EXACTLY AS DRAWN.

THIS IS A CERTIFIED DRAWING AND IT MUST NOT BEMODIFIED WITHOUT AUTHORISATION FROM THE

CERTIFICATION BODY

TX3740

1:5

TX3740

<Title>

<client/project>

<Name> 01/06/2007

FINEMACHINEMEDIUM

MACHINE

UP TO & INCLUDING

<Material> Equal to or better than 1.6Ra(N7)

<01/01/1999><app'd by>

<app'l>

DateSample Approved By

Sample Approval Required?(See QS3.65)

<Name> 01/06/2007 A2

Order Reference

Line Plug

Line Receptacle

Fixed Receptacle

TX3740.1

TX3740.2

TX3740.3

ATEX/IECEx Group I .19

.20

.02

.19

.37

.01

.01

.02

.02

.15

.15

.01

.02

.03

.25

.25

.32

.32

.40

.40

.01

ATEX/IECEx Group II

Aluminium (Group II only)

Stainless steel

Insert - 19 way

Insert - 37 way

Pins

Pins

Sockets

Sockets

Wire size - 1.5mm2

Wire size - 1.5mm2

Wire Length L - 1m

Wire Length L - 2m

Wire Length L - 3m

Wire size - 2.5mm2

Wire size - 2.5mm2

Cable gland thread - M32

Cable gland thread - M32

Cable gland thread - M40

Cable gland thread - M40

ATEX/IECEx Group I

Aluminium (Group II only)

.19

.02

.19

.37

.20

.01

ATEX/IECEx Group II

Stainless steel

.03

.03

Pins.standard Live disconnect

Pins.standard Live disconnect

Insert - 19 way

Insert - 37 way

Falcon Series Ex ConnectorsTrolex

Page 27: Falcon Series Ex Connectors - PEI-Genesis

Ex d Plug cap

Cover cap for combined Ex d and ingress protection after live disconnect or re-application of the power to a Plug. Integrated with the flexible cover cap.

Ex d Receptacle cap

Cover cap for combined Ex d and ingress protection after live disconnect or re-application of the power to a Receptacle. Integrated with the flexible cover cap.

Aluminium (Group II only)TX3740.41

Stainless steelTX3740.42

Aluminium (Group II only)TX3740.43

Stainless steelTX3740.44

Accessories

Mounting Clamp

Stainless steel/polypropylene TX3740.51

1.5mm2

1.5mm2

P5623.23.01

P5623.23.02 P5623.16.02

P5623.16.01

2.5mm2

2.5mm2

Earth pin

Increased insertion length for ‘first make - last break’ safety earth protection

Live disconnect / Pilot pin

Reduced insertion length for ‘first break - last make’ pilot circuit interlocking

Order Reference

24 – 25

The unique design and construction flexibility of Falcon means that we can offer a whole range of contact configurations and hybrid power and data combinations for specific or bespoke applications.

Connectors can be supplied complete with dedicated fitted cable systems.

Customised Falcons

Page 28: Falcon Series Ex Connectors - PEI-Genesis

[email protected]

Telephone+44 (0) 161 483 1435

Fax+44 (0) 161 483 5556

Trolex LtdNewby Road, Hazel GroveStockport, CheshireSK7 5DY, United Kingdom

www.trolex.com

trolex-ltd

trolex_ltd

If you’d like to order Falcon series connectors or for a live demonstration, please contact our distribution partner.

To find out more about Trolex and our Falcon Series Ex connectors please give us a call, drop us an e-mail or visit our website.

PEI-Genesis is a global authorized distributor for the Trolex Falcon SeriesPEI-Genesis has sales offices throughout the Americas, Europe and Asia.Call 1-800-642-8750 (in North America), +44 (0) 23 8062 1260 (Europe), or +86 756 7683 08 Email: [email protected] | www.peigenesis.com

PEI-Genesis UK LTD, George Curl Way, Southampton, SO18 2RZ

T +44 (0) 23 8062 1260 F +44 (0) 23 8062 1270 [email protected]