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ATEX

FALCON SERIES
EX D CONNECTORS
Robust, explosion-proof, multi-pin
Ex d connectors for use in hazardous areas
Applications: Wellhead control panels, mobile skid units, oil and gas,
mining, tunnelling, offshore applications, steel processing, process plants,
portable equipment, mobile machinery

TX3706 FALCON SERIES EX D CONNECTORS

CONNECTIONS
YOU CAN TRUST
FROM TROLEX
The Falcon Series Connectors from Trolex have been engineered
for purpose to bring you the worlds most robust and easy to use
Ex d connection systems for heavy-duty power and data cables.
Incorporating live disconnect possibility in the hazardous area,
a virtually instantaneous connect/disconnect system, and a
making-off procedure that reduces assembly times from hours
to minutes, the new series connectors will save
you both time and money, and deliver connections that
you can really trust.
Who says Ex d Connectors are hard to use?
Contact us today for a demonstration of how weve solved the
problem.
Trolex:
e: sales@trolex.com
t: +44 (0) 161 483 1435
www.trolex.com
PEI Genesis (global authorized distributor):
e: sales@peigenesis.com
t: 1-800-642-8750
www.peigenesis.com

TX3706 FALCON SERIES EX D CONNECTORS

Falcon Series Connectors are suitable


for a wide range of offshore, onshore
and underground applications
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TX3706 FALCON SERIES EX D CONNECTORS

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 cap-head screws to complete the operation.
This two-point radial fixing has the added benefit that
cable rotation is completely eliminated.
Terminate; load; fix; done - complete assembly
in a matter of minutes.

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RAPID
CONNECTION

TX3706 FALCON SERIES EX D CONNECTORS

Almost instantaneous connect /


disconnect without compromising safety
integrity or robustness
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. Terminate; load; fix; done.
A solid and robust connection or disconnect in an instant.
Flame paths are shrouded at all times and are never exposed to
potential damage.
In combination with the live disconnect option of
the products, 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.

LIVE
DISCONNECT
Engage or separate connectors
with live power applied
Falcon may be parted in the hazardous area for short periods
to allow maintenance or change out of equipment, following
normal risk assesment proceedures. The electrical power
source must originate from the socket side of the connector so
the socket can be user installed in either the plug or receptacle
to suit the application.
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.

DIRECT
BOX 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 d or Ex e gland
entries. A flange mounting version is also available for surface
mounting onto Ex e enclosures. Electrical connections are fully
encapsulated for explosion protection with a choice of wire
length to suit the application.

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TX3706 FALCON SERIES EX D CONNECTORS

10

8
7

3b

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KEY
FEATURES
1

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 (a)


/ Receptacle (b) in aluminium or stainless steel.
Triple sealed for IP66 ingress protection.

Internal earth connection permits the use


of non-armoured cable.

Choice of cable gland entry thread to specification:


M20 and M25

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TX3706 FALCON SERIES EX D CONNECTORS

8
7

3a

Certified for use with most types of Ex approved cable


glands. Rear loading with screw fastenings makes for
simple and fast cable termination accommodating both
compression and standard sealed glands.

Internal double insulated cable connection cartridge.

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.

10

User configurable Security Interlocks to prevent


non-valid mating.

11

Passivated silver plated contact Sockets with


longitudinal multi-contact springs for high reliability
and low insertion force, providing exceptionally
low contact resistance.

07

TX3706 FALCON SERIES EX D CONNECTORS

TECHNICAL
INFORMATION
Housing format:

25 mm contact insert

Housing material:

Stainless Steel - ANC4B


Aluminium Alloy - LM25TF - with hard anodised protection
Choice of threaded cable entry sizes for standard Ex d cable
glands:
M20 and M25
Surface fix on to Ex e housing
M20 into Ex d or Ex e housing
M25 into Ex d or Ex e housing
1.5 mm2 x 1 m, 2 m or 3 m (L)
2.5 mm2 x 1 m, 2 m or 3 m (L)
100,000 with no load connected
(limited to 200 for live disconnect)
5 coding selectable positions
IP66 - triple sealed
-50 to +60C
Stainless Steel
Aluminium

Cable entry:

Fixed receptacle mounting:

Fixed receptacle wires:


Mating cycles:
Security coding:
Ingress protection:
Temperature limits:
Weight:
TX3706
TX3706.001 Free Plug
TX3706.002 Free Receptacle
TX3706.003 Fixed Receptacle
Conformity:

0.5 kg
0.43 kg
0.4 kg

0.2 kg
0.17 kg
0.15 kg

EN 61984: 2009 - Safety Requirements


EN 60664: 2007 - Insulation Co-ordination
EN60079-0: 2012+A11 :2013 - General Requirements
EN60079-1: 2014 Flame-proof enclosures
EN60079-31: 2014 - Equipment Dust Ignition Protection
by Enclosure t

Ex explosion protection:
Undergrouond mines (stainless steel versions only)
CML 15ATEX1143X
I M2
IECEx CML 15.0070X
Surface industry with explosive gas and
dust atmouspheres
CML 15ATEX1143X
IECEx CML 15.0070X

08

II 2GD

Ex db I Mb

Ex db IIC T4 Gb

Ex tb IIIC T135C Db

TX3706 FALCON SERIES EX D CONNECTORS

CONTACT
INSERTS
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.

Cable terminations:
Wire size:
Insert material:
Fire rating:
Contacts:
Insertion force:
Contact protection:
Contact resistance:
Test voltage:
Insulation:
Over voltage transients:
Protective earth connections:

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


1.5 or 2.5 mm2
Glass filled polymer
VL94, V-0
Multi-spring wire socket and solid pin
6 N per contact
Passivated silver plating
400 ohm
2000 V
Class II double insulated BS 61140
3000 V
Screw clamp terminals for 2.5 mm cables

Contact ways:
Maximum rated current
Rated voltage:
Maximum live disconnect voltage
Maximum total current (all contacts):
Load breaking current (up to 200 mating cycles):
Creepage and clearance: (IEC 60664-1)

10
25 A
250 V ac
100 V dc
80 V ac
100 A
1A
2 mm

4
25 A
250 V ac
100 V dc
250 V ac
100 A
1A
5 mm

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TX3706 FALCON SERIES EX D CONNECTORS

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 system control
circuits to isolate the system power and ensure that all contacts are dead on final separation.

INTRINSICALLY
SAFE CIRCUITS
All contact inserts are clearance compatible for use with approved intrinsically safe circuits up to 30 V where safety
circuits may be exiting an Ex d enclosure.

LIVE
DISCONNECT
Contact inserts for live disconnect applications are supplied with high clearance pins to maintain optimum
electrical separation.

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TX3706 FALCON SERIES EX D CONNECTORS

DIMENSIONS
TX3706.1 -Free Plug

TX3706.2 -Free Receptacle



99

45

Cable entry
M20 or M25

TX3706.3 -Fixed Receptacle


M20 or M25 gland entry mounting or Exd or Exe enclosures

TX3706.3 -Fixed Receptacle


Surface mounting. Exe enclosures

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TX3706 FALCON SERIES EX D CONNECTORS

ORDER REFERENCE

TX3706.1 - Free Plug - complete with protection cap


TX3706.1 .
ATEX/IECEx Group I
ATEX/IECEx Group II

.19
.20

Aluminium
Stainless steel

.02
.01

Insert - 4 way
Insert - 10 way

.04
.10

Pins. standard
Sockets
Pins. Live disconnect

.01
.02
.03

Wire size - 1.5 mm2


Wire size - 2.5 mm2

.15
.25

Cable gland thread - M20


Cable gland thread - M25

.20
.25

TX3706.2 - Free Receptacle - complete with protection cap


TX3706.2 .
ATEX/IECEx Group I
ATEX/IECEx Group II

.19
.20

Aluminium
Stainless steel

.02
.01

Insert - 4 way
Insert - 10 way

.04
.10

Pins. standard
Sockets
Pins. Live disconnect

.01
.02
.03

Wire size - 1.5 mm2


Wire size - 2.5 mm2

.15
.25

Cable gland thread - M20


Cable gland thread - M25

.20
.25

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TX3706 FALCON SERIES EX D CONNECTORS

ORDER REFERENCE

TX3706.3 - Fixed Receptacle - complete with protection cap


TX3706.3 .
ATEX/IECEx Group I
ATEX/IECEx Group II

.19
.20

Aluminium
Stainless steel

.02
.01

Insert - 4 way
Insert - 10 way

.04
.10

Pins. standard
Sockets
Pins. Live disconnect

.01
.02
.03

Wire size - 1.5 mm2


Wire size - 2.5 mm2

.15
.25

Wire Length L - 1 m
Wire Length L - 2 m
Wire Length L - 3 m

.01
.02
.03

Mounting - flange
Mounting - M20
Mounting - M25

.01
.20
.25

A FREE PLUG engaged with a FREE RECEPTACLE to form a line connection in a cable run.

Free Receptacle
TX3706.2
Free Plug
TX3706.1

Fixed Receptacle
TX3706.3
A FREE PLUG engaged with a FIXED RECEPTACLE for terminating into an Ex d or Ex e housing.

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TX3706 FALCON SERIES EX D CONNECTORS

ORDER REFERENCE
Accessories

Mounting Clamp
Stainless steel/polypropylene:

TX3706.51

Earth pin
Increased insertion length for first make - last break
safety earth protection

1.5 mm2
P5609.23.01

2.5mm2
P5609.16.01

Pilot pin
Reduced insertion length for first break - last make
pilot circuit interlocking

1.5 mm2
P5609.23.02

2.5mm2
P5609.16.02

Checkpoint
Fitting a Earth pin or Pilot pin displaces a normal pin.

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

TX3706
Aluminium
TX3706.41
Stainless steel
TX3706.42

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
Aluminium
TX3706.43
Stainless steel
TX3706.44

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TX3706 FALCON SERIES EX D CONNECTORS

CERTIFICATES
For full TX3706 certification information, including certificate numbers, downloads and conditions of safe use, refer to
the Trolex website.

Copyright and Trademarks


2016 Trolex Limited.
Trolex is a registered trademark of Trolex Limited. The use of all trademarks in this document is acknowledged.
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PEI-Genesis is a global authorized distributor for the Trolex Falcon Series


PEI-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 088 (China)
Email: sales@peigenesis.com www.peigenesis.com