Home ITT Cannon Sure-Seal Connector

Sure-Seal® Connector

ITT Cannon Sure-Seal Connector







COST-EFFECTIVE ENVIRONMENTALLY-SEALED CONNECTOR

A low-profile, one-piece, resilient body and rugged, multiple moisture seals make Sure-Seal® connectors a natural choice for outdoor applications where contaminants are a concern. Only two parts are required to complete a Sure-Seal® connector: the connector body and the contacts. Sure-Seal® was developed to address Department of Transportation safety regulations for automotive connectors. Sure-Seal® is used in a range of environmental applications where a small, low-cost connector is needed. These sealed connectors meet or exceed DOT requirements for shock, vibration, temperature cycling, salt water spray and immersion, petroleum derivatives, and industrial gas while insuring low milli-volt drop and low contact resistance. Sure-Seal® connectors are excellent for motorcycles, automobiles, boats, and demanding off-road vehicles. Sure-Seal® will operate -40°F to +221°F under high humidity, severe vibration, ice and/or mud. Connector sealing resists brake fluid, gasoline, diesel fuel, anti-freeze, ultraviolet, ozone, and steam. For full details, please see the product specifications below.
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ITT Cannon

FEATURES

SURE-SEAL® CONNECTOR FEATURES

  • Low Installed Cost
    One piece molded bodies and crimp contacts provide a low cost solution. In addition, these connectors can be easily terminated by the user.

  • Water Submersible
    Not just splash-proof, but truly submersible for short periods of time. Sure-Seal® will seal to the requirements of IP67 and DIN 400 50.

  • Resistant to Automotive/Industrial Environments
    Sure-Seal® will operate in temperatures from -40°F to +221°F under conditions of high humidity, severe vibration, ice and mud. Sealing integrity is maintained with exposure to brake fluid, gasoline, diesel fuel, antifreeze, ultraviolet, ozone, and steam.

  • Wide Range of Wire Gauges and Current Carrying Capability
    Up to 85 amps with wire gauges from size 20 up to size 4 AWG wire.

  • One-Piece Connector
    Sure-Seal® has a simple one-piece molded body. No other parts (other than contacts) are required. Bodies mate using multiple resilient seals and will remain mated even under severe vibration and shock.

  • Field Serviceable
    The use of removable crimp contacts allows Sure-Seal® connections to be changed or modified in the field if necessary.

  • Polarized Against Mis-mates
    Connector halves use both pin and socket contacts. The plug and receptacle must be properly oriented for the connectors to mate. Raised indexing ribs in conjunction with a stepped plane allow blind mating of the connector halves even in dark or cramped spaces.

  • Three Sure-Seal® Versions
    Sure-Seal® is available in three versions. The basic Sure-Seal® line is the broadest and ideal for most applications. Mini-Sure-Seal® provides a slightly smaller connector in a limited range of configurations. Power Sure-Seal® is for single circuit, high power applications.


MATERIALS & FINISHES

SURE-SEAL® CONNECTOR MATERIALS & FINISHES
Body
Elastomeric material (PVC Nitrile standard, Also available in silicone & EPDM)
Contacts
Copper alloy
Contact Platings
Tin standard; gold plating optional


ELECTRICAL DATA

SURE-SEAL® CONNECTOR ELECTRICAL DATA
Operating Voltage
400 Vac Maximum
Dielectric Withstanding Voltage
1,200 Vac at sea level
Current Rating
15 Amps (Sure-Seal®)
8 Amps (Mini Sure-Seal®)
85 Amps (Power Sure-Seal®)
Wire Range Sizes
14-18 AWG (Sure-Seal®)
18-20AWG (Mini Sure-Seal®)
4-10 AWG (Power Sure-Seal®)
Contact Resistance
10 Milliohms maximum
Insulation Resistance
100 Megohms (minimum)


MECHANICAL

SURE-SEAL® CONNECTOR MECHANICAL
Operating Temperature
-40°F to + 221°F (-40°C to +105°C)
Sealing
≈IP67, DIN 400 50, 3 foot depth in 5% salt solution 24 hours min. ≈NEMA 6 p
Wire Sealing Range
See Wire Insulation Diameter under the Contacts and Tooling section
Insulation Strip Length
See Strip Length under the Contacts and Tooling section
Mating Life
50 cycles minimum (stamped& formed) 100 cycles (machined)
Salt Spray
To MIL-STD-202D Method 101D
Heat
+221°F (+115°C) for 1000 hours
Weather, Ozone, & Ultraviolet
In accordance with ASTM D-1149 (100pphm) & ASTM D-1171 (outdoor exposure)
Vibration
5 to 55 Hz .06" DA 1 hour; radial & longitudal axes
Shock
50g 11ms, 30 cycles; radial & longitudal axes
Contact Type
crimp: using hand or semi automatic tooling
Number of Circuits
1 to 10
Contact Insertion
From rear with simple hand tool or simultaneous insertion of multiple contacts with semi-automatic insertion machine. Removable, 5 cycles minimum
Contact Retention
7.5 lbs. (35 N) minimum
Polarization
Stepped plane positive polarization, indexing ribs, and visual polarization all permanently molded into body
Agency Listing
UL (E176866) & CSA (LR109871-1)
Color
Black (alternate colors optional)


CROSS SECTION

SURE-SEAL® CONNECTOR CROSS SECTION



TEST DATA

SURE-SEAL® CONNECTOR TEST DATA

Typical: Power Sure-Seal®, Flange Sure-Seal®, and Mini Sure-Seal® are essentially the same except for mechanical and amperage capacity differences. Sure-Seal® products are designed to meet specification CS-155. Items of most general interest to users and designers are listed below. With its current capability and large size, Power Sure-Seal® contacts and currents are covered in CS-169.


Test/Description

Reference Paragraph

Requirements

Environmental Sealing


3.5.1


Sure-Seal® connectors when mated shall form an environmental seal against water, moisture, aqueous solutions, oils and certain chemicals as well as dust and dirt. Tests include immersion in 3 feet depth in water solution containing 5% salt.

Contact Tensile
Strength – Crimp

3.6.12

The minimum tensile load required to separate the wire from the contact, either by pulling the wire out of the crimp joint or breaking the wire within the crimp joint, shall not be less than the applicable limits as specified. Wire breakage, or contact damage not due to crimping, at less than tensile loads shall not constitute failure.

Crimp Tensile Strength, Pounds Minimum

Wire Size AWG

Without Insulation Support Contacts

With Insulation Support Contacts

4

140

-

6

100

-

8

90

-

10

80

-

14

35

35

16

35

35

18

25

25

20

-

20

Insulation Resistance






4.4.1






Properly assembled and mated connectors shall be tested in accordance with MIL-STD-202, Method 302, except a potential of 500 ± 15 volt DC shall be used. The resistance shall be measured between adjacent parts of contacts (or contacts to ground for SS-1) and shall not be less than 100 M. If the specimen has been immersed in fluid in the preceding test, it shall be placed wet on a conducting surface and insulation resistance measured within 5 minutes between each contact and also between each contact and the conducting surface (except for SS-1 to be measured contact to ground while immersed).

Dielectric Withstanding Voltage

4.4.2


Assembled and mated connectors shall show no evidence of breakdown between adjacent contacts (or contact to ground for SS-1) when tested in accordance with MIL-STD-202, Method 301, and a test voltage of 1200 ± 15 volts AC.

Contact Resistance




4.4.3




The contact resistance of mated contacts shall be such that the resistance measured across the contacts and 5/8" behind the crimp junction shall not exceed 10 mΩ. Test current to be 1 amp, and MIL-STD-202, Method 307.

Shock




4.4.4




Mated connectors properly mounted shall be subjected to the shock test in accordance with MIL-STD- 202, Method 213B, CONDITION B. The shock test shall be repeated three (3) times in each of X, Y & Z axis. Suitable means shall be employed to monitor the current flow. Current discontinuity of 1 microsecond or more, disengagement of the mated connectors, evidence of cracking, breaking or loosening of parts shall be cause for rejection.

Vibration
















4.4.5
















Properly assembled and mated connectors shall be mounted to the vibration table, with the wire leads strapped to a vibrating member approximately 3 inches from each end of the connector body and vibrated with a peak-to-peak amplitude of .25 inch across a frequency range of 5 to 39Hz, and a ±20g acceleration across 39 to 55 Hz, swept up in one minute and down in another minute. The vibration shall be swept up and down for a total of 36 hours under the following conditions:

Six (6) hours at 180°F (82°C) along the longitudinal axis
Six (6) hours at 180°F (82°C) along a perpendicular axis
Six (6) hours at room temperature along the longitudinal axis
Six (6) hours at room temperature along a perpendicular axis
Six (6) hours at -40°F (-40°C) along the longitudinal axis
Six (6) hours at -40°F (-40°C) along a perpendicular axis

The connectors shall be connected in a series circuit with a minimum of 0.1 ampere flowing through the contacts. Electrical continuity shall be continually monitored. Breaks in continuity longer than one microsecond shall be cause for rejection.

Durability


4.4.6


The connectors shall be subjected to 25 cycles of mating and unmating at -10°C and another 25 cycles at 50°C. There shall be no evidence of damage to the contacts, the contact plating, the insulators or sealing rings, which would be detrimental to connector function.

Contact Retention


4.4.7


With the connector plug or receptacle held firmly, an axial dead weight of 7.5 lbs. shall be imposed on each wire for one minute without the contacts being dislodged from the connector. Plugs and receptacles to be tested separately.

Maintenance Aging



4.4.8



Each wired receptacle and plug shall be subjected to 5 cycles of contact insertion and extraction in the same cavity using the approved tools. Plug and receptacle are to be tested separately. After the 5 cycles of insertion and extraction, each plug and receptacle in turn will be subjected to the contact retention test of 6 lbs. per paragraph 4.4.7.

Connector Separating Force

4.4.11

Using an assembled and mated connector with the receptacle held firmly by the wires, a load shall be applied to the wires of the plug until the connector is completely separated. The rate of loading shall be one inch per minute. The sample shall fall within the limits specified as follows:

Connector Size

Unmating Force (lbs) Max.

Unmating Force (lbs) Min.

SS-1

12

6

SS-2

15

6

SS-3

18

8

SS-4

20

9

SS-5/7

30

10

SS-8/10

55

10

Solvent Resistance






4.4.13


4.4.14


4.4.15

4.4.16


4.4.17

4.4.18

4.4.19


Wired and mated connectors shall be subjected to the applicable fluids for the length of time specified. Following the test the connectors shall be immersed to a depth of 3 feet in salt water for 24 hours at room temperature. At the completion of the salt water immersion test and while still immersed insulation resistance shall be measured. Failure to meet the insulation resistance requirements shall be cause for rejection.

Gasoline Splash

1 second dip - 3 minute air dry for 80 cycles at room ambient temperature.

Diesel Fuel Splash

1 second dip - 3 minute air dry for 80 cycles at room ambient temperature.

Automotive Lubricating Oil

Immersed in S.A.E. 30 weight lubricating oil for 1 hour.

Antifreeze

Immersed at 120°F (49°C) for 48 hours. Brake Fluid Immersed at room ambient temperature for 24 hours.

Brake Fluid

Immersed at room ambient temperature for 24 hours.

Automatic Transmission Fluid

Immersed at 120°F (49°C) for 48 hours.

Gasoline Vapor

Immersed in a gasoline vapor atmosphere at room temperature for 48 hours

Weather and Ozone Resistance



4.4.20




Wired and properly mated connectors shall be subjected to ozone test per ASTMD-1149 except that 100 ppm of ozones shall be used. The duration of the test shall be 7 days. Outdoor exposure to be conducted per ASTM D-1171. The connector shall show no cracking or other degradation which would result in loss of sealing integrity.

High Temperature
Long-Term



4.4.23




Wired mated connectors shall be tested in accordance with MIL-STD-202 Method 108A, Test Condition D at 105°C for 1000 hours. Following the test, they shall be subjected to 3 feet salt water immersion for 24 hours. While immersed, insulation resistance shall be determined. Failure to meet the insulation resistance requirements shall be cause for rejection.

UV



-



Sure Seal Connections has recently completed testing of the Sure Seal PVC Nitrile material (SM 3400-06) for UV resistance. The material was tested in accordance with ASTM G-26 (Xenon Arc), 720 hours exposure with no loss in tensile strength and greater than 75% retention of elongation.




Caution: “Sure-Seal® connectors are rated for use between temperatures of -40 to + 105 degrees Celsius. However, if a Sure-Seal® connector is exposed for long periods of time to temperatures exceeding 85 degrees Celsius and is unmated, it may lose its environmental sealing integrity upon remating. Thus, we recommend that both the plug and receptacle be replaced if environmental sealing is required after remating.”

 
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