Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
1583555 Phoenix Contact	INSERT MALE 5POS+1GND SCREW	40
1423021 Phoenix Contact	CONTACT INSERT, SIZE: B24, NUMBE	43
1409930 Phoenix Contact	HC-BBB 40-EBUC	9
1406534 Phoenix Contact	HC-HS06-I-UT-M 7-12	0
1607523 Phoenix Contact	INSERT MALE 4POS+1GND SOLDER	0
1584253 Phoenix Contact	INSERT FEMALE 40POS TERM BLOCK	0
1419893 Phoenix Contact	I/O MODULES	0
1636389 Phoenix Contact	INSERT FEMALE 6+36POS+1GND CRIMP	0
1603893 Phoenix Contact	CONTACT INSERT, SIZE: D25, NUMBE	350
1584143 Phoenix Contact	INSERT FEMALE 108POS+1GND CRIMP	0
1648500 Phoenix Contact	INSERT MALE 24POS TERMINAL BLOCK	0
1584127 Phoenix Contact	INSERT MALE 108POS+1GND CRIMP	0
1419897 Phoenix Contact	I/O MODULES	0
1884872 Phoenix Contact	INSERT MALE 6POS SOLDER	5
1636402 Phoenix Contact	HEAVYCON SOCKET INSERT K6/6 SERI	0
1405265 Phoenix Contact	INSERT FEMALE 10+2POS+1GND CRIMP	0
1679469 Phoenix Contact	INSERT MALE 15POS+1GND CRIMP	0
1423827 Phoenix Contact	CONTACT INSERT,SIZE:B24,NUMBER O	0
1583568 Phoenix Contact	INSERT MALE 7POS+1GND SCREW	46
1607502 Phoenix Contact	INSERT FEMALE 4POS+1GND SCREW	0

Heavy Duty Connectors - Inserts, Modules

1. Overview

Heavy duty connectors inserts and modules are specialized electromechanical components designed to establish robust electrical connections in demanding environments. These systems provide modular solutions for power transmission, signal routing, and data communication in industrial and infrastructure applications. Their importance lies in enabling reliable connectivity in harsh conditions involving high currents, extreme temperatures, vibration, and contamination.

2. Major Types & Functional Classification

Type	Functional Features	Application Examples
Modular Insert Systems	Customizable contact arrangements, hot-swappable design	Industrial control cabinets, automated machinery
High-Power Modules	Rated for >100A currents, integrated cooling channels	Electric vehicle charging stations, factory automation
Signal Transmission Inserts	Shielded contacts for <10Gbps data rates	Smart grid monitoring systems, robotics
Hybrid Power-Signal Modules	Combined power and fiber optic transmission	Wind turbine pitch control, mining equipment

3. Structural Composition

Typical construction includes:

Durable thermoplastic or metal housing (IP65-IP69K rating)
Copper alloy contact elements with gold/silver plating
Integrated locking mechanisms (screw, bayonet, or push-pull)
Modular frame supporting mixed contact types
Environmental seals (EPDM or silicone rubber)

4. Key Technical Specifications

Parameter	Importance
Current Rating (10-2000A)	Determines power transmission capacity
Voltage Range (24V-10kV)	Defines insulation requirements
Contact Resistance (<1m )	Impacts energy efficiency and heat generation
Operating Temperature (-40 C to +125 C)	Dictates environmental suitability
Mating Cycles (500-10,000)	Determines service life and reliability

5. Application Fields

Primary industries include:

Industrial Automation: PLC systems, CNC machines
Energy: Wind turbines, solar inverters
Transportation: Rail traction systems, e-mobility charging
Heavy Machinery: Excavators, mining equipment
Marine: Offshore platform systems, shipboard power

6. Leading Manufacturers & Products

Manufacturer	Representative Product
TE Connectivity	DEUTSCH HC Series High-Current Connectors
Amphenol Industrial	MAXdur Hybrid Power/Sig nal Modules
Phoenix Contact	Heavycon Modular Insert Systems
Weidm ller	HA-Modular Hybrid Connection Technology

7. Selection Guidelines

Key considerations:

Calculate maximum current/voltage requirements with safety margins
Assess environmental factors (temperature, vibration, chemicals)
Verify IP rating for ingress protection
Evaluate mating cycle requirements
Check industry-specific certifications (UL, CSA, IEC standards)
Consider modular expandability for future upgrades

8. Industry Trends

Current development trends include:

Miniaturization while maintaining high current capacity
Integration of smart sensing capabilities
Adoption of fiber-optic hybrid transmission
Increased use of corrosion-resistant composite materials
Development of quick-connect systems for reduced downtime

Market growth is driven by electrification in industrial sectors and the rise of renewable energy systems, with a projected CAGR of 6.2% through 2028 (Source: MarketsandMarkets).