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Image of Smiths Interconnect HBB Connector

Ruggedized High Performance Circular Power Connectors for Harsh Environments.

The newly re-launched HBB series of single pole high power 300A and 500A circular connectors from Smiths Interconnect offer a compact, lightweight and ruggedized heavy duty connector designed for use in all types of harsh environment applications, including electric motor drives, military ground vehicle turret systems, rail transport and industrial applications. Now assembled by Aerco, they are available with low MOQs and short lead-times.

Available in a RoHs compliant Black Zinc Nickel finish, the HBB delivers a more efficient, higher current transmission in a more compact and lighter connector and with a superior endurance of 5000 mating cycles. Design SWaP goals of delivering high power within a small size and minimal weight interconnect solution are realised with 300A delivery implemented in a size 17 shell and 500A delivery in a size 21 shell. The robust aluminium shell is available in three different shell polarizations, fully sealed to IP67 ingress protection and featuring 360° EMI/RFI shielding via a customer serviceable conductive ‘O’ ring, which is fitted as standard to receptacles.

The HBB series is rated for surge/inrush currents of 6 kA for the 300A and 10kA for the 500A for 1 sec, making it suitable for deployment in applications like induction motors and power converters.

The tactile ‘push mate’ mating provides confirmation of a full mate preventing “attached not locked” condition. The design facilitates the easy mating and un-mating with simple push to lock and 1/8 turn to unmate while in close proximity to neighbouring devices, supporting applications where higher density packing is required in space constrained environments. Safety protection includes a safety interlock last make, first break with finger protection on pin and socket contacts.

Compliant to the MIL-DTL-5015 specification for heavy-duty circular electrical connectors for harsh environments, the connectors feature the best electrical performance and high levels of shock and vibration immunity due to the use of Smiths Interconnect’s hyperboloid contact technology. The ultra-low resistance and smooth and light wiping action of the hyperboloid contacts results in low fretting fatigue/corrosion and long contact life with minimal degradation in performance. The hyperboloid contact design ensures this high degree of immunity to shock and vibration, guaranteeing electrical continuity in all circumstances. Contact resistance figures as low as 0.03mΩ keeps resistive losses and generated heat at a minimal, facilitating maximum transmission performance

The plugs and receptacles are gender reversible, being available with either pin or socket contacts and they can be ordered with optional straight or right angle back shells. Accessories include crimp lugs, heat shrink boots and additional O-rings

Standard operational temperature range is -55°C to +150°C, voltage rating at sea level is 750vdc, and dielectric withstand voltage at sea level is 2250vdc.

For for more information or to request a quote please contact Mark Ogden by email or call on +44(0)1403 260206.

Image of Steadi Shield Connector

High power, modular connectors for all on-board power applications within the rail market.

The Transformer Series HeavyPower (TSH) connectors from Smiths Interconnect are a range of ruggedized, high reliability, high power, heavy duty interconnects which offer a modular solution for all on board power applications within the harsh environment rail market.

The TSH are available in 1 to 4 pole versions and employ Smiths Interconnect’s latest evolution of their Hypertac® hyperboloid technology: the Tortac® contact. The contact’s single piece hyperboloid construct supports higher current ratings than bifurcated designs and features very low fretting corrosion, allowing TSH to support currents of 300A per pole with an endurance of over 500 mating cycles. Connector styles include straight and right-angle versions and a ‘Y’ branch variant supporting additional use as a power junction box.

Comprising a polyamide insulator with a passivated aluminium frame, the design conforms to rail fire and smoke standards EN 45545-2, NF F 16-101 and NFF16-102 and has an environmental ingress protection rating of IP66/IP67 when mated. The design of the insulator ensures that correct voltage creepage distance clearances are met, providing high electrical protection in severe environments. It is fully compliant to EN50124 Pollution Degree 4, allowing external deployment of TSH on train roofs, under car on bogies and between vehicles as inter-carriage jumpers, without the need for cleaning

To support inter-coach jumper applications, an integrated anti-swaying device on the connector backend mitigates potential cable degradation and obviates the need for additional cable support clamping. An optional ‘Y’ branch connector style, TSHY, is available which splits each pole input into two outputs, replacing the need for junction boxes and so saving space and weight and simplifying maintenance. Typical design use would be a three pole ‘Y’ connector taking in the train’s three phase power and then branching each input phase into two output feeds, with each output supplying separate motors on the bogies.

The modular range employs a unique do-it-yourself system, offering a configurable architecture which enables customers to design their own platform solutions with just a few elementary piece parts. This allows many connector configurations to be supported by holding a minimal amount of piece part stock, reducing supply chain, cabling and maintenance costs and facilitating quick and flexible time to market. No special tools are needed except crimping tools, resulting in a further reduction in stock and kitting/logistic management.

TSH connectors have a voltage rating of 3600V, and a standard temperature range rating of -55°C to +125°C.


For a quote or for more information contact Mark Ogden by email or call on +44(0)1403 260206.

Image of ELED

Reliable Harsh Environment Interconnect Solution, Optimised for Rail and Embedded Applications.

The REP series from Smiths Interconnect is a panel or cable mounted multi-pole, sealed, light weight, polycarbonate plastic connector, which delivers optimal durability in harsh environments. The connectors provide a cost effective, quick and secure connection for embedded equipment such as sensors, brakes, lighting, air conditioning and communications.

Plugs and receptacles with crimp terminated contacts are available for cable to cable solutions, with the receptacle also supporting panel mounting. Receptacle versions are also available loaded with straight or bent contacts with solder terminations for PCB or panel mounting. Both versions are available in 2, 6 and 12 way layouts, all with polarized guides, and providing over 500 mating cycles. Connection is fast, simple and secure with push to mate and press and release to un-mate.

A shunt accessory is available for the 6 and 12 way receptacles, enabling electrical derivation inside the connector for transmission of information to different locations. Other accessories available include cable retainers, panel seals, panel mounting brackets, plastic dummy contacts and filler plugs.

The connector employs Smiths Interconnect’s proven Hypertac® hyperboloid contact technology which, with its superior performance, ensures excellent reliability even under high levels of shock and vibration. Contact features include a 360 wiping action, low insertion/extraction forces, minimal contact resistance, immunity to fretting corrosion and a long life cycle in harsh environments. The hyperboloid contact supports a 30% higher current carrying capacity than standard contacts of the same size, with a rating of 18A.

The REP series is qualified to stringent European rail safety standards, conforming to the fire and smoke requirements of NFF 16-101, NFF 16-102, EN 45545-2 and UL94V0 standards and shock resistant levels to EN 61-373. Environmental protection ratings of IP66 and IP67 are achieved through the integration of over-moulded silicone grommets and interfacial seals.

The single sized crimp contact caters for cables from 0.50mm² to 2.5mm² (24-12AWG), offering a significant cost of ownership saving in terms of reduction in inventory holding and maintenance costs. Further, no special tools are required for assembly with the consequent reduction of supply chain, maintenance and cabling costs.

Voltage rating is 230V, with a standard temperature range rating of -55°C to +110°C (panel mount version up to +250°C).


For a quote or for more information contact Mark Ogden by email or call on +44(0)1403 260206.

Image of Snaptac Connector

Featuring High Reliability Hyperspring spring-loaded hyperboloid contacts; sealed to IP67

The SnapTac® series of circular and rectangular miniature snap fit connectors from Smiths Interconnect is a lightweight, robust, high durability, quick release connector, offering exceptional signal integrity and designed to meet demanding operational specifications, such as those required in Future Combat Soldier programs, including communication, identification / recognition, and other critical tasks.

The connector series is available in both circular (7, 13, 19 ways) and rectangular (12, 21, 30 ways) geometries, with the plugs available in versions with or without over-moulding, while the receptacle offers straight through and solder cup termination styles. Circular extenders (7, 13, 19 ways), with and without over-moulding, are also available for applications requiring in-line connections. Eight housing polarizations are supported to avoid connector mismatching and a 90° over-moulded version is also available for the circular plug connector.

The locking mechanism is easy and fast, with the circular connector range featuring a snap on locking arrangement. The 12 and 21 way rectangular connectors have a push pull locking, with the 30 way version employing a quick turn locking mechanism.

A key innovation with the Snaptac® connector is in the design of the Hyperspring® spring-loaded contacts, which are designed to protect the electrical interface against extreme environmental conditions. For the first time, Smiths have combined their hyperboloid contact technology with the mechanical features of a spring loaded plunger. This compressible contact arrangement produces mated connectors with improved signal integrity, high reliability and proven parametric stability over time and realises characteristics of very low and stable contact resistance, high current carrying capability and extremely low wear mechanisms.

Hyperspring’s target and chisel blade contact mechanism also provides an inherent self-cleaning wiping action which removes surface contamination and ensures that the connector can’t be damaged by the build-up of surface films. This makes the SnapTac® connector system ideal for dirty and contaminated harsh environments where reliability is paramount, such as in land-based military scenarios where fast and easy mating and un-mating are needed.

The connectors support up to 10,000 mating cycles and are IP67 sealed according to IEC529 when in the mated and unmated condition. They incorporate full 360° EMI shielding, with dust caps available to ensure full EMI shielding and protection when in the unmated condition, providing for high robustness throughout their lifetime. Current rating is 3A per contact at 25°C and operating temperature range is -55°C to +85°C.

Key markets are high reliability military and commercial interconnect applications, such as tactical communications, FCS wearable electronic systems, commercial airframe sensors and auto-sport diagnostics.


For a quote or for more information contact Aerco by email or call on +44(0)1403 260206.

Hypertac REP series connectorsThe Hypertac REP connector series, a multi-pole, sealed, rectangular, plastic connector that provides quick and easy connection, is now available from Aerco.

This high performance connector uses well-proven Hypertac® Hyperboloid contact technology that guarantees excellent reliability even under high levels of shock and vibration and is ideal for many electronic applications in the railroad, industrial equipment, test and measurement, automotive and defence industries.

The REP connector conforms to UL94VO fire smoke standards and is made of polycarbonate with a silicone backshell.  It is protected to IP66 and available in 2, 6 and 12-way formats and allows up to 500 mating cycles.  Rated up to 13A, the series offers a significant savings in terms of inventory and maintenance because one size of contact caters for cables from 0.50mm²  to 2.5mm² (24-12AWG).

No special tools are required for assembly, connection is simple with push to mate, press and release to unmate and the series is available in cable to cable, clips and front and back panel mount configurations.  Pre-wired version can also be supplied to customers’ specifications.

AE486 2/6/2011

Hypertac HPH Connectors

Investment means two-week delivery with no MOQs 

Aerco has increased its commitment to UK customers of Smiths Connectors by extending its assembly capability to include the rectangular, high-density PCB range of Hypertac HPH connectors.

The HPH range of high reliability, vibration-proof connectors uses the well-proven Hyperboloid socket contact design, ensuring low insertion and separation forces, an excess of 2000 mating operations, low contact resistance and high current and voltage ratings making it ideal for mil/aero and industrial applications.

Aerco will supply versions with up to 202 contacts, with options for straight and 90° PCB contacts with a wide range of mating guide styles on a two-week lead-time with no MOQs.  The high density is achieved with 4A rated contacts that are 0.6mm diameter set on a staggered pitch of 1.905mm.  

This investment by Aerco will ensure that UK customers wishing to upgrade to higher density connector systems can rely on high levels of support for both prototype and production quantities.


Contact us now for more information or for a RFQ

Hypertac M12 connectorsThe new range of Hypertac M12 connectors that incorporates innovative features in a compact design while taking full advantage of traditional Hypertac hyperboloid contact technology is now available on quick delivery and low MOQs from Aerco. 

Developed to meet the growing demand for miniaturisation, these new M12 connectors are available with 3, 4, 5 or 8 way contacts with options of over-moulded or free assembly and with straight or 90° versions to meet all the recognised standards and industry requirements.

An anti-vibration arrangement comprising a floating female hyperboloid crimp socket within a robust connector insulator and shell provides maximum security.  Additional benefits are easy handling characteristics and rapid contact assembly with a unique, sideways clip insulator.

Insulator assembly is simplified with an easy to use touch, look and feel system that ensures correct orientation and the design provides the highest possible connector-to-connector density.  The free-assembled right-angle version has an adaptable cable entry termination that allows for a change to a straight version in the field without compromising the IP67 reliability.

Company Reg. No. 572109


VAT Registration No. GB 602 4417 81