Introducing Amphenol SurLok Plus: Heavy-Duty Connectors for High-Reliability Applications

Estimated Reading Time: 6 minutes

Key Takeaways

• Amphenol SurLok Plus connectors feature advanced R4 RADSOK technology for superior electrical performance in high-current applications
• Available in current ratings from 50A to 500A with voltage options of 1000V DC and 1500V DC for diverse industrial requirements
• IP67 sealing protection and UL 94V-0 flammability rating ensure reliable operation in harsh environments
• Quick-lock mechanism with press-to-release design enables fast, secure connections without specialised tools
• Multiple termination options including crimp connectors, busbar connectors, and threaded posts provide flexible installation solutions
• EMI shielded connectors and HVIL function available for enhanced electromagnetic compatibility and safety

Revolutionising Industrial Connectivity with Advanced Power Solutions

Industrial applications demand connectors that deliver unwavering reliability under extreme conditions. From energy storage systems to heavy equipment manufacturing, engineers require power connectors that maintain secure electrical connections whilst withstanding harsh environmental factors. Traditional compression lugs often fall short when projects demand both high performance and operational flexibility.

The Amphenol SurLok Plus series addresses these challenges through innovative engineering and proven RADSOK technology. These heavy-duty connectors combine high-current handling capabilities with environmental protection, offering engineers a comprehensive solution for demanding applications. Through TRX Electronics' partnership with Mouser Electronics, accessing these cutting-edge heavy-duty power connectors has never been more straightforward.

Advanced R4 RADSOK Technology: The Foundation of Reliability

At the heart of every SurLok Plus connector lies the revolutionary R4 RADSOK technology. This fourth-generation contact system utilises a stamped and formed, high-conductivity alloy grid that creates multiple contact points simultaneously. Unlike traditional single-point contacts, this design distributes electrical load across a larger surface area, reducing resistance and heat generation.

The technology employs laser welding techniques developed through three years of dedicated research into copper-based alloys. This manufacturing approach ensures consistent contact performance across the connector's operational life, maintaining low insertion forces whilst delivering superior electrical conductivity. Engineers benefit from reduced connection resistance, improved thermal management, and enhanced long-term reliability.

Comprehensive Range for Diverse Applications

Current and Voltage Specifications

The SurLok Plus series spans five distinct sizes, each engineered for specific current requirements:

3.6mm RADSOK Size: 50A-70A capacity, ideal for moderate power applications in compact spaces

5.7mm RADSOK Size: 100A-120A rating, perfect for standard industrial power distribution

8.0mm RADSOK Size: 120A-200A capability, suitable for heavy-duty manufacturing equipment. Popular models include the SLPIRBBPSO1 for standard busbar applications and the SLPIRBBPSO1EH with EMI shielding and HVIL function for enhanced safety in high-voltage applications.

10.3mm RADSOK Size: 250A-350A capacity, designed for high-power industrial systems. The SLPIRCBPSO1 offers 300A current rating with 1000V DC capability for demanding applications.

14mm RADSOK Size: 250A-500A rating, engineered for maximum power transmission requirements

Voltage options include both 1000V DC and 1500V DC variants, with EMI shielded connectors available for applications requiring electromagnetic compatibility. This range ensures engineers can select precisely the right connector for their specific power requirements.

Environmental Protection and Safety Features

All SurLok Plus connectors achieve IP67 rating when properly mated, providing complete protection against dust ingress and temporary water immersion. The connector housings meet UL 94V-0 flammability standards, ensuring safe operation in industrial environments where fire prevention is critical.

Touch-proof design prevents accidental contact with live conductors, whilst the integral latching system guarantees secure mechanical and electrical connections. Optional HVIL function adds an additional safety layer for high-voltage applications, automatically disconnecting power when connectors are not properly engaged.

Flexible Installation Options

Termination Methods

The series offers multiple termination approaches to suit various installation requirements:

Crimp Connectors: Support cable sizes from 6mm² to 150mm², accommodating everything from control circuits to main power feeds. Factory-supplied crimping barrels ensure consistent, reliable connections that meet industry standards.

Busbar Connectors: Direct connection to copper or aluminium busbars eliminates the need for intermediate cable connections. This approach reduces installation complexity whilst improving electrical performance in power distribution applications.

Threaded Post Termination: Provides secure screw connections for applications requiring field-serviceable joints. Specified torque values ensure optimum contact pressure without damaging connector components.

Quick-Lock Installation System

The innovative quick-lock mechanism enables rapid connector engagement without requiring specialised tools. A simple push-and-rotate motion secures the connection, whilst the press-to-release system allows equally fast disconnection when maintenance access is required. This design significantly reduces installation time compared to traditional compression fitting systems.

Many variants feature 360° rotating plugs, allowing optimal cable routing regardless of panel orientation. This flexibility proves particularly valuable in confined installation spaces where cable management is challenging.

Applications Across Key Industries

Energy Storage Systems

Battery energy storage installations benefit from the series' high-current capabilities and environmental protection. The connectors' low contact resistance minimises power losses during charge and discharge cycles, whilst IP67 sealing protects against moisture in outdoor installations.

Electric and Hybrid Vehicle Manufacturing

Automotive production lines require connectors that withstand repeated connection cycles whilst maintaining electrical integrity. SurLok Plus connectors deliver over 100 mating cycles, with EMI shielding options ensuring compliance with automotive electromagnetic compatibility requirements.

Process Control and Automation

Industrial automation systems demand reliable power distribution to critical control equipment. The series' touch-proof design and positive locking mechanism prevent accidental disconnections that could disrupt production processes.

For engineers seeking specific connector solutions, TRX Electronics offers direct access to products like the SLPRIRBTPSB0 through our extensive distribution network. Mouser Electronics provides comprehensive technical documentation and specifications, ensuring engineers have all the information needed for successful project implementation.

Frequently Asked Questions

What makes R4 RADSOK technology superior to traditional contact systems?

R4 RADSOK technology creates multiple contact points through a stamped alloy grid design, distributing electrical load across a larger surface area. This approach reduces contact resistance, minimises heat generation, and maintains consistent performance throughout the connector's operational life. The laser welding manufacturing process ensures precise contact geometry that traditional stamping methods cannot achieve.

How does the IP67 rating benefit industrial installations?

IP67 rating provides complete protection against solid particle ingress and temporary water immersion up to 1 metre depth. This environmental protection enables reliable operation in harsh industrial conditions including wash-down areas, outdoor installations, and dusty manufacturing environments where traditional connectors might fail.

Are SurLok Plus connectors compatible with existing industrial power systems?

Yes, the series supports standard cable sizes from 6mm² to 150mm² and offers multiple termination methods including crimp, busbar, and threaded post connections. This flexibility ensures compatibility with existing electrical infrastructure whilst providing upgrade paths for enhanced performance and reliability.

Advancing Industrial Connectivity Standards

The Amphenol SurLok Plus series represents a significant advancement in industrial connector technology, combining proven RADSOK contact systems with innovative mechanical design. These high-reliability connectors deliver the performance and environmental protection that modern industrial applications demand.

At TRX Electronics, we understand that selecting the right connector technology can determine project success. Our strategic partnerships with industry leaders like Mouser Electronics ensure access to cutting-edge solutions that meet the evolving needs of South African industry. Whether your application requires standard power distribution or specialised high-current connections, the Amphenol SurLok Plus range provides the reliability and performance your projects demand.

Ready to explore how SurLok Plus connectors can enhance your next industrial project? Contact TRX Electronics at 086 111 2844 or visit our Pretoria facility at 697 Jacques St, Moreleta Park to discuss your specific connector requirements with our experienced technical team.