Designed to complement the style of the current extensive range of Bulgin’s vandal resistant switches, Bulgin’s new vandal resistant indicators will suit applications where a separate circuit condition indication is needed. Front panel sealed to IP67, the indicators are available with red, blue, green or yellow high brightness LED's for daylight visibility.  The indicators are designed and constructed to meet the shock, vibration and impact requirements demanded by hostile applications. The rear moldings are color coded so that each type can be easily identified. Individual indicators are housed in a strong, corrosion resistant marine grade stainless steel body for the necessary strength and long life while maintaining aesthetic appeal. The lens is a tough V-0 rated polycarbonate. The two body styles, proud of panel with a beveled edge and flush to panel are styled to match the existing vandal resistant switches. Voltage options are available for 12V and 24V supplies or alternatively with no ballast resistor to give complete user choice. Operating temperature range is -40 C to +85 C. Termination options include 2.8mm tags/solder tabs or flying lead connection.

Features:

·         Available in Flush Panel Profile or Proud of Panel Profile

·         Stainless Steel body

·         Sealed to IP67

·         Solder Tag/2.8mm Tag Termination or Flying Lead Termination

·         Red, Green, Yellow or Blue LED Options

·         Wide Viewing Angle

·         Shock and Vibration Resistant

·         Operating Temperature Range –40ºC to +80ºC

·         LED Voltage: 12Vdc, 24V dc or 12Vdc/24 V dc or no ballast resistor

·         RoHS Compliant

Typical Applications:

·         Entry Access Systems

·         Vending Machines

·         Marine Control Panel

·         Public Interactive Kiosks

·         Metering Equipment

·         Intercom System

·         Parking Lot Ticket Machines

·         Rental Equipment

·         Water Monitoring Meters

·         Portable Equipment

·         Test Equipment

·         Motorized Equipment –Preventative Maintenance

·         Inspection/Cleaning Interval Reminder

·         Electrical Safety Check

For more information, samples, or price and delivery on these Bulgin vandal resistant indicators, contact TLC Electronics at 651-488-2933, fax 651-488-3246 or email tlcsales@gmail.com.

Printed with permission from Jim Kalb, President, Optifuse

www.optifuse.com

Although care is taken to properly design electrical and electronic circuits; overcurrents in the form of short-circuits and overload can occur.  The sole purpose of fuses and circuit breakers is to protect personnel and/or equipment from serious harm when an overcurrent condition arises.  This guide is intended to help create a better understanding the various parameters of overcurrent protection and the proper application of circuit protective devices.  This guide creates a basic understanding of overcurrent principles and applications but is not intended to supplant sound engineering principles or replace specific application testing.
 

Overcurrents

An overcurrent is a condition which exists in an electrical circuit when the normal load current is exceeded.  The two basic forms of an overcurrent are overloads and short circuits.  Fuses and circuits breakers primary role in a circuit is to protect personnel and equipment when dangerous overcurrents do happen.

Short Circuit

A short-circuit is an overcurrent condition where an abnormal, low-resistance, circuit path is introduced into the circuit.  This low-resistance path bypasses the normal load and can create extremely high currents (up to 1000x the normal current under some conditions).

Under normal conditions a typical circuit may be described by Ohm’s Law as follows:

 When a short circuit occurs, a low-resistive, abnormal path is created which will cause the circuit current to increase as the circuit resistance is decreased.  The current when a short circuit is introduced can exceed 1000 times the normal current of the circuit.  The circuit diagram of a short circuit is shown below:

Over Load

An overload is an overcurrent condition where the current exceeds the normal full load-capacity of the circuit but where no fault condition (short-circuit) is present.  A momentary overload condition (also known as “in-rush” currents) may also occur when a circuit is first initialized due to capacitor charging and/or motor-startup.  A over load circuit diagram is shown below:

In order to select the proper protective device, the following parameters and criteria need to be considered:

1. What is the normal operating current of the circuit?
2. What is the operating voltage?
3. Is the circuit AC or DC?
4. What is the operating ambient temperature?
5. What is the available short-circuit current?
6. What is the maximum allowable I²t?
7. Are there in-rush currents available?
8. Is the protective device being used for short-circuit protection, over-load protection, or both?
9. What are the physical size limitations?
10. Is the PCB surface mount or thru-hole?
11. Does the fuse need to be "field-replaceable"?
12. Is resettability an issue?
13. What safety agency approvals are needed?
14. How will I mount the device?
15. What are the cost considerations?

What is the normal operating current of the circuit?

In order to select the right amperage of the fuse, you first need to know the full-load steady-state current of the circuit at an ambient temperature of 25º C (68º F).  Once the current value is determined, then a fuse rating should be selected as to be 135% of this value (taken to the next standard value).

For example, if the normal steady-state current is calculated to be 10 amps, then a 15A fuse rating should be selected [10 amps x 135% = 13.5 amps, the next larger standard size is 15A].

It is important to note that if the fuse is intended to be used in an environment with possibly very high or low ambient temperatures, then the nominal fuse current would need to be sized significantly higher or lower (see ambient temperature below).

What is the operating voltage?

The basic rule of thumb is that the voltage rating of the fuse must always higher than the voltage rating of the circuit that it is protecting. 

For example, if the circuit voltage is 24 volts, then the fuse voltage rating must be higher than 24 volts (yes...it can be 250 V...just so long as it’s higher than the circuit voltage).

Is the circuit AC or DC?

There exist two distinct types of circuits AC (alternating current) and DC (direct current). 

AC power is what you will typically find in your home from the electrical utility.  AC power is created primarily by moving machines such as generators and delivered through the electric grid. 

DC power is typically used in electronic and automotive applications.  DC power generally is created via a chemical reaction (as batteries and solar cells) or converted AC power through the use of AC to DC power supplies.

With AC power, the current and voltage oscillate back and forth.  This oscillation helps the fuse to clear quickly.  DC power on the other hand doesn’t oscillate so the fuse must find other means to clear itself when opening.

Because of these differences, some fuses are designed specifically to be used in DC applications (such as automotive fuses).  Some AC rated fuses may be used in DC applications, however there may be a voltage de-rating in these cases. 

What is the operating ambient temperature?

Ambient temperature is a fancy way of saying the “outside air” surrounding the fuse.  Normally, the fuses are tested in "laboratory conditions" by the safety agencies such as UL and CSA.  The lab conditions are almost always set at 25°C or 77°F.  Unfortunately, most real world conditions are not those found in a laboratory. 

Fuses are heat sensitive devices meaning that it takes heat (via the overcurrent) in order to melt the fuse element inside the fuse.  The more heat...the faster it takes to melt the fuse element...the less heat...the longer it takes to melt the fuse element.

If a fuse will be subjected to a higher temperature than 25°C, then the fuse amperage will need to be increased as to compensate for the higher temperature (to avoid "nuisance tripping").  Likewise, if the fuse will be used at a lower temperature, then the fuse amperage needs to be lowered (or else it might never open).

The rule of thumb is that for every 20°C higher or lower in temperature, the fuse should be re-rated higher or lower 10-15%.

An example of a fuse re-rating when higher ambient temperatures are present:

Conversely, when a fuse is intended to be used in extreme low temperature conditions, the fuse must have a lower rating than that in normal conditions. 

An example of the fuse re-rating when lower ambient temperatures are present:

What is the available short-circuit current?

 The available short circuit current is the measured or calculated current that can be delivered to a circuit by a power source when a short circuit is present.  This information is extremely important as an overcurrent protective device has only a finite ability to safely open a circuit when a fault condition occurs.  Therefore the amount of fault current available is a critical piece of information in order to select the proper protective device.

The available short circuit calculation can be very complex and generally should be left to qualified engineers to calculate.  These calculations are generally based on the following factors:

• How much short-circuit current is available from the utility?
• What is the resistance of the wiring from the utility to the piece of equipment where the fuse is installed?
• What is the internal resistance of the piece of equipment where the fuse is installed

Once all of these factors are known, then the engineer can calculate the available short circuit current to the fuse. 

The fuse must be selected as to have a greater short circuit rating than what is available in the circuit (otherwise the fuse can explode and cause great harm to people and equipment!)

What is the maximum allowable I²t?

All overcurrent protective devices take a certain amount of "reaction time" when they open to clear a circuit fault.  During the time it takes for the fuse to open, there is energy flowing through the fuse. That energy is measured in I²t.  There two parts to the fuse’s "reaction time". 

1)  The time it takes to melt the fuse element (also known as the melting time, T_m)

2)  The time it takes to quench the electrical arc (also known as the arcing time, T_a)

The total time open the fault is known as the total clearing time.  T_c + T_m + T_a

During this clearing time, there is energy is being "let-thru" the fuse. The downstream components are then subjected to this extreme energy as it passes through the fuse (if only for a few milliseconds). 

In order to specify the proper fuse or circuit breaker in a circuit, the engineer must know the withstand capabilities of the downstream circuit components and select a fuse whose let-thru energy is below that of those components.

Are there "in-rush" currents available?

Depending on the circuit, there are times when a large amount of current is required when a piece of equipment is turned on.  The types of components that can cause this type of in-rush include motors, fans, and capacitors.

The in-rush current can be as high as 6-10 times that of the normal current (for example a typical TV might draw 3A but the in-rush could be as high as 30A).  These currents are typically harmless and subside within 1-2 seconds of startup.

During an in-rush, the fuse should not open.  The specified fuse in this case should be a time-delay fuse allowing the piece of equipment to start up properly without a nuisance opening of the fuse when the overcurrent occurs. 

Is the protective device being used for short-circuit protection, over-load protection, or both?

If the device is to be used as short-circuit protection, the fuse or circuit breaker must interrupt the fault quickly (generally less than 4 milliseconds) in order to give the maximum protection to equipment and personnel.

If the fuse or circuit breaker is intended for over-load protection only, then it can be much slower in reacting to the over-current - seconds or even minutes as compared to milliseconds...

All fuses offer some form of both short-circuit protection as well as over-load protection whereas many circuit breakers however are over-load protection ONLY and have no capabilities to protect against dangerous short-circuits.

What are the physical size limitations?
 
Many times the fuse or circuit breaker needs to be mounted into a place with physical size limitations. 

It is this reason that fuse and circuit breaker manufacturers have created a wide selection of components with varying physical sizes.  Typically however, there are a trade-offs that the engineer must consider. 

Generally speaking, the smaller the fuse, the less current and/or capabilities that the fuse or circuit breaker may have.  For example, a subminiature fuse maybe limited to 15A where as the larger 1/4" x 1 1/4" glass tube fuse can accommodate up to 40A.

Additionally, although the fuse can be smaller, the corresponding fuse holder maybe substantially bigger adding to the consideration.

Is the PCB surface mount or thru-hole?

There are several different options for both surface mount fuses and thru-hole fuses.

With surface mounted fuses, there are multiple sizes available from a 6125 (6.1 x 2.5 mm) package all the way down to a 0603 (0.6 x 0.3 mm) package.

The thru-hole options are even greater with axial-leaded options available on all of our standard glass and ceramic fuses as well as a variety of leaded subminiature and micro fuses.

These same options are available in resettable fuses as well.

Additionally, the fuse mounting can also play a part in the designers" decision especially if the fuse needs to be field-replaceable.

Does the fuse need to be "field-replaceable"?

Fuses are intended to open a circuit when an overcurrent occurs; whether it be a short-circuit or an over-load.  A decision by the engineer needs to be made as to whether or not the fuse should be field replaceable.

The primary reason for making the fuse replaceable is simply convenience for the end-user in getting their equipment back up and running.

The reasons for choosing not to have the fuse field replaceable are two-fold:

1. There can be a significantly greater cost to the manufacturer to include a fuse holder as opposed to directly soldering the fuse into or onto the PCB
2. The manufacturer may not want the end-customer to access the interior of the equipment to replace the fuse for liability issues.  This is especially true when a short-circuit was the cause of the problem in the first place.
3. The manufacturer may have some "planned obsolesce" of their parts and may want to replace the entire circuit board rather than have someone replace just the fuse

Is resettability an issue?

There are one-time use fuses and resettable type fuses available to the engineer.

Both types of fuses provide short-circuit and over-load protection.  Resettable fuses are limited to circuit applications below 9 amps (at 12V) and even less current at higher voltages.

Circuit breakers can also provide resettability and can range from 1A to 6000A.

One-time fuses are just as their name implies.  Once they are called upon to act, the interior link melts and the fuse must be replaced.  Just because the fuse is replaced, there can still be a short-circuit or over-load still present in the circuit which can cause the newly replaced fuse to open as well.  Care should be taken to correct whatever problem that may have occurred when the fuse opened in the first place...before replacing the open fuse with a new fuse.

What safety agency approvals are needed?

There is an entire alphabet soup of world-wide safety agencies out there.  UL, CSA, IEC, CCC, PSE, VDE, Nemko, Semko and TUV are some of the most popular agencies.

The agency approvals needed by manufacturers depends solely on what type of equipment they are making and where in the world they hope to sell their equipment. 

Fuses typically are available with several approvals (for example UL and CSA).  Even within a single agency, there can be multiple types of approvals such as UL listing versus UL recognized. .

Certain equipment does not require any agency approvals such as many automotive or low-voltage applications.

The biggest issues as it relates to safety agency approvals for fuses is that there are several different test methodology and standards depending on the agency involved.  This might mean two different fuse characteristics for what are apparently the same fuse and/or application.

How will the fuse be mounted?

One of the most careful considerations that need to be made is the mounting of the fuse in the circuit.  There are several options at hand:

1. Direct Solder- In this method, the fuse is directly soldered into or onto the printed circuit board (PCB).  The drawback to this design is the lack of field replaceable parts as discussed in great detail in section 11 but cost can be significantly reduced with this mounting method.
2. Fuse Clips- Fuse clips are relatively inexpensive and allow for field replacement.  Fuse clips are typically mounted on a PCB so any attempt at replacing the fuse will require opening of the piece of equipment by the end-user.  Additionally, removing a fuse from a PCB without disconnecting the power source could lead to an electrical shock when touching the fuse.  Fuse clips are available for all "tube" fuses as well as microfuses.  Typically fuse clips are limited to 15A of normal current.  Fuse clips are generally not listed or recognized by any safety agencies.
3. Panel Mounted Fuse holders- Panel mounted fuse holders allow for easy access for the end-user to replace the fuse in the field.  The panel mount fuse holder is shock-safe meaning that the fuse is removed safely when the cap of the fuse holder is removed preventing the possibility of electrical shocks.  Fuse holders are typically tested and approved by safety agencies such as UL and CSA.  Fuse holders are typically available up to 30A.
4. Fuse Blocks- Fuse blocks are like fuse clips however they do not need to be mounted on the PCB.  Fuses mounted in fuse blocks are typically only accessible by opening the piece of equipment which could lead to electrical shocks if the equipment is not disconnected from the power source.  Fuse blocks are one of the few methods to mount fuses of large amperage.
5. Inline Fuse Holders- Inline fuse holders are typically used as a part of a wire harness assembly or where no surface is available to secure another type of fuse mount.  Inline fuse holders are generally available up to 100A in lower voltage applications and up to 30A in higher voltage applications.

What are the cost considerations?

The costs considerations can vary by several degrees depending on the size, performance, and mounting of the fuse.  Generally speaking, the larger a fuse is; the most it will cost (due to higher material costs to build the fuse).

The performance characteristics of a particular fuse are also a large cost consideration.  A low voltage automotive fuse might a fraction of the cost as compared with a 500V super high-speed, ceramic tube fuse both rated at 10A.

Safety agency approvals will also add to the overall cost of the fuse.

One of the largest costs of a fuse is the fuse holder.  A typical panel-mount fuse holder may cost in upwards of 10 times than that of the fuse itself. 

Contact TLC Electronics at tlcsales@gmail.com, 651-488-2933, 1-800-852-6694 or see the web site www.tlcelectronics.comfor more details on circuit protection solutions from Optifuse and TLC Electronics.

TLC Electronics is pleased to announce the release of RIA Connect's NEW reflow compatible Springcon terminal blocks.

Integrating RIA Connect's unique Springcon technology in a reflow compatible housing, the AST23X series of terminal blocks feature a compact forty-five degree design in 3.5mm (AST233) and 5.0mm (AST235) centerlines. Tool-less termination is achieved with the terminal blocks allowing use of solid wire up to 16 AWG. UL and VDE approvals are pending.

Go to www.tlcelectronics.com or call TLC Electronics at 651-488-2933 for free engineering evaluation samples.

RIA CONNECT manufactures high quality RoHS compliant Eurostyle terminal blocks, modular jacks & USB Ports for the global market. Located in Tinton Falls, New Jersey, RIA CONNECT is a Metz Connect Company. See www.riaconnect.com for more details.

Based in St. Paul, MN, TLC Electronics, Inc. is a value-added distributor of electromechanical components and subassemblies including the RIA Connect product line-up.  See www.tlcelectronics.com or call 651-488-2933 for more details on the electromechanical products and value-added services offered by TLC Electronics.

In an effort to increase sales in the southwestern United States area, TLC Electronics signed a manufacturer representative agreement (consulting agreement) with D.E.R. Sales effective June 1, 2011. The agreement is for D.E.R. Sales to generate new opportunities at select customers and prospects in the territories of Arizona, New Mexico, Southern Nevada and Utah. 

D.E.R. Sales is currently the JST rep in their respective region and has brought many opportunities for JST value added solutions to TLC Electronics.  The expectations are for D.E.R. Sales to represent TLC Electronics’ value added services for processed wire, wire and cable harnesses, cut and/or marked heat shrink tubing and subassemblies including but not limited to LCD integration, fan trays, modified power supplies as well as turn-key box build applications. 

Doug Rittenhouse is the president of D.E.R. Sales and he will be TLC’s main contact at the rep organization. Please join me in welcoming Doug and D.E.R. Sales to the TLC sales team.  Please see the D.E.R. Sales’ web site at http://www.dersalesinc.com/for more details on their product offering.

TLC Electronics, Inc. is a Minnesota based value added distributor of electromechanical components.  Please see our line card at http://www.tlcelectronics.com/linecard.html.

TLC specializes in electromechanical components, precision interconnects and small gauge wires processed on high speed automated equipment at prices competitive with many off-shore manufacturers.  Our value added services include:

• Wire and cable harnesses, solder and crimp style
• Cutting tape and reel contacts for loose piece applications
• Repackaging of components in smaller lot sizes
• Cutting and marking heat shrink tubing
• LCD integration
• Fan tray assembly
• Power supply modifications
• Turn-key box build

Founded in 1984, TLC has emerged as one of the premier North American suppliers with responsive service, automated equipment, knowledgeable personnel, quick turnaround, competitive pricing and quality products.  TLC is registered with Perry Johnson Registrars, Inc. as an ISO 9001:2008 supplier and is a recognized UL and CUL supplier. 

Please see www.tlcelectronics.com for more details on the products and services offered by TLC Electronics.  If you would like a sample or price and delivery on any of the components on our line card or a value added cable, fan, speaker or power supply assembly, please contact Angela 651-488-2933, via fax 651-488-3246 or a.williams@tlcelectronics.com.

 CONEC, a manufacturer of high-quality connectors, has developed a line of sensor actuator  circular connector  solutions for the industrial automation market. 

The SAL Series connectors are sealed to IP67 and IP69K requirements with specific configurations designed especially for the industrial automation and food/beverage industries operating at extreme temperatures up to 125°C. The dimensions and construction of the SAL series circular connectors complies with IEC 61076-2-101 standards for harsh environments.

"As more and more factories become automated with robotics, motion control systems and servomotors, the need for a variety of I/O connectors increases," said Peter Persico, technical support specialist for CONEC. "This product series consists of overmolded cable assemblies, panel mounted plugs and sockets with flying leads and field attachable connectors in both axial and right angled configurations."

SAL series connectors are available in a variety of overmolded sizes and styles, including M12, M8 and 7/8".  To meet the high demand for performance in harsh environments. The M12 connector is available in 4-12 positions, the M8 is available in 3 and 4 positions and the 7/8" is offered in 3, 4 and 5 positions. CONEC also offers the M12 connector series for BUS systems such as Profibus DP and 100MHz Industrial Ethernet applications.

Contact yourTLC Electronics' solutions provider today at 651-488-2933 or tlcsales@gmail.com to learn more about the interconnect products available from Conec and TLC Electronics.   

TLC Electronics, Inc. is an authorized distributor of electromechanical components from several manufacturers of high quality products including Conec.  For more information on the electromechanical solutions and services available from TLC Electronics, seewww.tlcelectronics.com.

Bulgin's Buccaneer SMB Antenna is a robust and completely waterproof antenna specifically developed for three popular frequency bands.

Integrating the antenna with its waterproof connector reduces the total number of connectors in the RF chain, thus reducing insertion losses and effectively increasing the total system gain.

The PX0407 covers the 2.4GHz band popular for wireless LAN, Bluetooth and Zigbee, while the PX0408 covers the UHF 440-470MHz band popular for general purpose radio applications. The PX0409 covers the 850-900/1800/1900MHz bands popular for GSM/Cellular applications.

Designed similar to the Bulgin's SMB Buccaneer connector system, the sealed antenna has an integrated SMB connector with an overall diameter of just 19mm.  The IP68 rated antenna provides complete protection from harsh environments plus gold plated electrical connections to ensure system performance and reliability.

The mating panel connector with an SMB jack (PX0414) is terminated with RG-174 cable in 0.5m, 1.0m or 1.5m lengths.  The PX0414 mating panel connector has a panel fixing hole of 16mm diameter.   

A two-part interconnect solution with removable antenna and a panel connector simplifies the installation and testing process.  The sealed system ensures an environmental seal at the interconnect point to maintain enclosure integrity.

Typical applications include industrial, scientific and medical (ISM) radio for instrumentation and telemetry systems.  Additional applications may include base stations and outdoor hotspot installations, specifically for wireless LAN, GSM and Bluetooth communication equipment.

Bulgin designs and manufacturers world-class electromechanical components and is part of the Elektron PLC Group.

Contact a TLC Electronics' solutions provider today at 651-488-2933 or tlcsales@gmail.com for price and delivery of this SMB antenna or other Bulgin products.   

Bulgin specializes in the design and manufacturing of sealed interconnect products, sealed switches, sealed fuse holders, EMI filters, IEC power input modules and indicators that are designed to meet a wide variety of applications and to provide solutions to OEM manufacturers of electronic and electro-mechanical equipment. Bulgin provides competitively priced, top quality products built at their own ISO9001 accredited factories.

TLC Electronics, Inc. is a leading distributor of interconnect and electromechanical products offering a wide range of services to meet customer specific applications.  Services offered include precision wire and cable assembly, fan and blower assembly, power supply modification and electromechanical subassembly.   

“We are pleased to officially sign an agreement with Elektron to add Bulgin to our line card. Bulgin is a world-class organization that develops, produces and markets high quality electro-mechanical components.” stated Rich Crofford, President, TLC Electronics, Inc.  “TLC’s distribution logistics and expertise in providing customer specific solutions will help increase Bulgin’s market share in our target markets.”

Bulgin is headquartered in the UK with additional operations in the US, China and the Far East.  See www.bulgin.co.uk for more information.

TLC Electronics is certified under ISO9001:2000 and is UL/CUL approved.  TLC’s account managers and inside sales personnel are trained in precision interconnect product lines and are prepared to assist customers and prospects with interconnect and other electro-mechanical solutions for their specific applications.  See www.tlcelectronics.com for more information.

For additional information, please contact Steven Olson, TLC Electronics’ Sales and Marketing Director at 651-558-2582 or via email s.olson@tlcelectronics.com.

Celebrating their 25th year in the electronics business, TLC Electronics, Inc. is a leading distributor of interconnect and electromechanical products offering a wide range of products and services to meet customer specific applications. 

TLC provides products to meet requirements for audible alert devices, circuit protection components, interconnects, displays, fans, blowers, cable management devices, power inputs, power supplies, relays, switches, indicators, terminal blocks, and wireless components.

Value added services offered include inventory management of electromechanical components, precision wire and cable assembly, fan and blower assembly, power supply modification, electromechanical subassembly and complete turn-key box build.   

TLC sales and marketing director Steven Olson noted, “The on line ordering feature simplifies the process of searching for and placing orders for products from TLC’s franchised electromechanical component suppliers.  The overall cost of procurement for our on line ordering customers will be reduced as a result of the streamlined process.” 

"We are excited that TLC has used DistiSuite eCommerce to power its online ordering feature," said Cheyne Rood, director of sales and marketing at DistiSuite.  "TLC Electronics is building its web presence and expanding business opportunities by connecting with customers online.  The web is an increasingly important channel for distributors, and we are pleased to partner with TLC on this effort."

 “In addition to stocking franchised components for resale,” commented Joel Root, TLC’s director of operations, “our precision value added services allows TLC to purchase and manage non-franchised components on the bill of materials. This may lead to excess inventory of non-franchised components available from TLC. The excess inventory feature is available as a separate link on the TLC web site.”

TLC Electronics is certified under ISO9001:2008 and is UL/CUL approved.  TLC’s account managers and inside sales personnel are trained in electromechanical product linesand are prepared to assist customers and prospects with interconnect and other electro-mechanical solutions for their specific applications.  See www.tlcelectronics.com for more information.                                                               

For additional information, please contact Steven Olson, TLC Electronics’ sales and marketing director at 651-558-2582 or via email s.olson@tlcelectronics.com.

TLC Electronics' QRM program provides a full range of subassembly services including processing of fine gauge wires intended for fine pitch interconnect solutions to meet many of today's applications that are decreasing in physical size. TLC's extensive experience with wire and cable and their investment in tooling enables TLC to prep and terminate wires from the larger wire gauge sizes down to ultra-fine 36 AWG wire. Precision processes and equipment allow TLC to help OEMs meet their requirements for fine pitch interconnect in portable and miniature applications as well as meeting requirements for electromechanical subassemblies.

TLC's QRM capabilities include cutting wires or cables to specific lengths, stripping or prepping to your specifications, tinning, crimping, soldering, IDC termination, crimp-and-poke and other technologies. Working with a broad selection of insulation materials from simple PVC to Teflon allows TLC to meet the needs of a wide variety of customers.  From discrete hook-up wire to phone cord, coax, TRIAX, multiconductor and flat ribbon cables, TLC is prepared to meet the needs of many applications.

Based on material availability, complexity and quantity, many requirements may be delivered within one week or even days. QRM quotes are typically back to the customer within 24 hours, allowing the customer to make an informed decision to shorten their time to market.

TLC Electronics, Inc. is a leading distributor of interconnect and electromechanical products offering a wide range of services to meet customer specific applications.  Services offered include precision wire and cable assembly, fan and blower assembly, power supply modification, electromechanical subassembly and complete turn-key box build.   

TLC Electronics is certified under ISO9001:2000 and is UL/CUL approved.  TLC’s account managers and inside sales personnel are trained in precision interconnect product linesand are prepared to assist customers and prospects with interconnect and other electro-mechanical solutions for their specific applications.  See www.tlcelectronics.com for more information.

For additional information, please contact Steven Olson, TLC Electronics’ Sales and Marketing Director at 651-558-2582 or via email s.olson@tlcelectronics.com.

New Age Enclosures specializes in designing and manufacturing standard and custom plastic molded enclosures ranging in size from small FOB and USB drive enclosures to larger project boxes and vented utility cases.  New Age Enclosures’ capabilities include designing, manufacturing, machining, and other value-added enclosure services (i.e. marking/printing).  All operations are performed at the New Age Enclosure ISO9001:2000 registered production and warehouse facility in San Luis Obispo, California.

TLC Electronics, Inc. is a leading distributor of interconnect and electromechanical products offering a wide range of services to meet customer specific applications.  These services include precision wire and cable assembly, fan and blower assembly, power supply modification and electromechanical subassembly including turn-key enclosure assembly.   

“We are pleased to add New Age Enclosures to our line card broadening our products and services to our customers and prospects”, stated Steven Olson, sales and marketing director, TLC Electronics, Inc.  “TLC’s distribution logistics and demand creation efforts of our sales staff providing customer specific solutions will help increase New Age Enclosures’ market share in our target markets.”

“New Age Enclosures’efforts to increase our market presence for customer specific value added solutions include increasing our distribution channels with selected distributors focusing on strategic electromechanical solutions including enclosures,” said Cameron Boyne, marketing director of New Age Enclosures. “TLC Electronics’ strategy for providing solutions to customer specific requirements will enable customers to fulfill their electromechanical assembly needs with one supplier.”

New Age Enclosures is a division of Alltec Integrated Manufacturing, Inc., a 34 year old injection molding company based in San Luis Obispo, CA.  As an employee owned corporation, New Age has a high level of commitment from its employees to provide outstanding customer service for standard, modified standard and engineered products.  See www.newageenclosures.com for more information.

TLC Electronics is certified under ISO9001:2008 and is UL/CUL approved.  TLC’s account managers and inside sales personnel are trained in the New Age Enclosure product line and are prepared to assist customers and prospects with solutions for their specific application.  See www.tlcelectronics.com for more information.

For additional information, please contact Steven Olson, TLC Electronics’ sales and marketing director at 651-558-2582 or via email s.olson@tlcelectronics.com.

This new service offering is part of TLC Electronics’ value added services to meet customers' prototype through production requirements. TLC offers drafting services as a lower cost alternative to using in house resources.  Engineering drawings for processed wire, cable assemblies, wire harnesses and electro-mechanical sub-assemblies are created in VISIO.   The engineering drawings are created in accordance with standardized conventions for layout, nomenclature, interpretation, appearance and size or TLC will use the customer’s specific drafting procedures if available and the procedures are within TLC's capabilities.  

Steven Olson, TLC’s sales and marketing director commented, “We realized that during the economic downturn, many companies learned to do more with less, including fewer employees.  Now as business activity increases and management is hesitant to add staff, it is vital to ensure that key employee resources are used cost-effectively.  This may include outsourcing of drafting requirements as opposed to using design engineers to accomplish this task.  TLC has experienced personnel on staff for creating drawings; therefore, we decided to offer this service to our customers.”

ABOUT TLC ELECTRONICS, INC.

TLC Electronics, Inc. is a leading distributor of interconnect and electromechanical products offering a wide range of services to meet customer specific applications.  These services include precision wire and cable assembly, fan and blower assembly, power supply modification, electromechanical subassembly including turn-key enclosure assembly and drafting services.

TLC Electronics is certified under ISO9001:2008 and is UL/CUL recognized.  TLC’s account managers and inside sales personnel are trained in the electromechanical product lines and services offered and are prepared to assist customers and prospects with solutions for their specific application.  See www.tlcelectronics.com for more details on the products and services offered by TLC Electronics.

For additional information, please contact Steven Olson, TLC Electronics’ sales and marketing director at 651-558-2582 or via email s.olson@tlcelectronics.com.

ABOUT TLC ELECTRONICS, INC.

TLC Electronics, Inc. is a leading distributor of interconnect and electromechanical products offering a wide range of services to meet customer specific applications.  These services include precision wire and cable assembly, fan and blower assembly, power supply modification, electromechanical subassembly including turn-key enclosure assembly and drafting services.

TLC Electronics is certified under ISO9001:2008 and is UL/CUL recognized.  TLC’s account managers and inside sales personnel are trained in the electromechanical product lines and services offered and are prepared to assist customers and prospects with solutions for their specific application.  See www.tlcelectronics.com for more details on the products and services offered by TLC Electronics.

For additional information, please contact Steven Olson, TLC Electronics’ sales and marketing director at 651-558-2582 or via email s.olson@tlcelectronics.com.

New Age Enclosures 

 In today's market, electrical engineers and marketing personnel are faced with a growing selection of off-the-shelf enclosures for their electronic equipment. This may sound like a nice problem to have because choices are good. Right? But this may be a problem if it is not addressed early in the development process.

Historically the number of standard enclosures has been limited and the designs have been quite simple. Due to limitations in the manufacturing process they were square or rectangular shaped with few color choices.
 

New options for enclosure selection

With manufacturers like New Age Enclosures developing a true line of Market-ready Enclosures©, the enclosure market is taking on an improved form. Now electronic enclosures boast ergonomically contoured surfaces and enhanced aesthetics. New Age is even capable of producing their entire enclosure line in any color a customer may want.

This has not changed the "when form should lead function" selection process recommended by New Age president Randall Dennis.  He recommends a reverse selection process for selecting electronic enclosures. He notes that typically, when selecting a custom enclosure for a new application, it is standard practice for the development team to develop their board, populate it with electronic components, prove the software and functionality, and then consider the design and shape of the enclosure to encase their new electronic device. After all, form follows function, right? Mr. Dennis recommends designers and marketing teams consider reversing that process when developing a program they know will run in lower volumes and therefore financially require an off-the-shelf enclosure.

Although the selection within the standard enclosure market is growing, there will still be limitations and challenges that the development team will encounter. The enclosures they have to choose from may be too long or short, too wide or narrow, or perhaps too short or tall to accommodate their PCB. If this is discovered after the PCB has been established, it can cause many headaches, development delays and may lead to cost-related over runs.
 

The simple solution is to select the enclosure earlier in the process. Dennis stated, "If the design team feels this is putting the cart before the horse, let's at least suggest to them to allow the horse to stand side by side with the cart." He understands this can be uncomfortable due to our natural resistance to change. The engineers may have previously worked on different, higher volume programs that provided the comfort of designing the PCB first and validating the components on that board with a budget to build a custom enclosure. But with standard enclosure products, they may run into the fact that the required size and shape does not exist and modifying that enclosure to fit the application may prove cost prohibitive.
 

Best practices to selecting an off-the-shelf enclosure

1 - Identify the program requirements (i.e. we are developing a transceiver that will be outside and requires its own power source).

2- Initiate a web search on sites such as New Age Enclosuresto determine which plastic enclosure manufacturer provides an enclosure that meets the requirements such as NEMA compliant and gasketed battery compartment. Because this enclosure application will be outside in the elements, it will inevitably require a mounting method so the search should include a method to attach the unit to a wall, a pole or other substrate.

3 - During the search, the development team finds out quickly that there may be a very limited number of enclosures meeting their exact requirements. Finding this out early in the process will help prevent many of the headaches, time delays and cost overruns. Samples of standard product can be ordered from a value-added distributor such as TLC Electronics.  The samples can then be reviewed by the development team prior to having a major investment in tooling and prototypes. Distributors often have the standard enclosures in stock and can quickly provide development teams with samples and material specifications. The numerous benefits include selection of the enclosure within the category that best meets the application requirements allowing the designers to know in advance that the case size and layout can influence the electronics design.  This process can lead to selection of the most cost-effective solution.

4 - With an enclosure in hand that meets their application, the designer can proceed with the PCB development knowing they have an affordable, in-stock solution. In following these steps, the designers are able to quickly establish the PCB footprint and the mounting hole locations. Sizing a PCB to fit an enclosure is far less expensive than designing and building a custom box to fit the PCB.

5 - This process should lead to satisfied engineers and marketing personnel because they all had an opportunity to have voice in the selection process on the front end as opposed to being stuck with an enclosure only because it was the only box that fits the board. Or worse yet, be stuck with the cost of a complete custom box that created cost overruns.
 

6- The marketing staff will then be able to work on finalizing the outside appearance of their end product. Companies like New Age Enclosures are able to print the company's logo or other artwork directly onto the case for a true Market-ready© product.

For additional information on this subject and specific electronic enclosures visit: NewAgeEnclosures.comand TLCelectronics.com.

The RS240-XXXis a resettable fuse rated at 240 V AC/DC.  This series is available in current ratings from 50 mA to 2A.  The fuses are listed by UL and CSA with UL approval pending above 550 mA.
 

In an effort to meet your specific manufacturing requirements, both the RS120 and RS240 series of resettable fuses are available in tape & reel or tape & ammo packaging. 

Currently only Optifuse and Tyco / Raychem supply equivalent products (Tyco series LVR - 240 VAC and LVRL - 120 VAC).  Other major suppliers of resettable fuse devices have not yet released products for line voltage circuit protection applications.

In an effort to meet your cost objectives, the Optifuse pricing is very competitive when compared to the competitor's product offering.  In addition, OptiFuse's lead time for the line voltage resettable fuses is only 2-3 weeks as compared to 8-10 weeks quoted from the Optifuse competitor.  TLC will stock to your specific requirements, reducing production lead times even further. 

A limited amount samples are available for immediate delivery should you have a prototype application that will require engineering testing and approval.  To receive a free sample, select a part number from the Optifuse web site and contact TLC Electronics for sample delivery information. 
 
To learn more about  the resettable fuse solutions offered from Optifuse, please contact one of the TLCsolutions providers today at 651-558-2560 or tlcsales@gmail.com.

This is just a sampling of TLC Electronics' solutions for circuit protection. To learn more about TLC's products and services, click here.

Radial leaded resettable fuses are generally defined by their voltage.  Resettable fuse voltages range from 16 VDC to 600 VDC...but here's the "rub"...the higher the voltage...the less current range is available.  Therefore, although Optifuse manufactures a 600 VDC resettable, the maximum current is only 160mA whereas the 16VDC resettable fuse has a maximum current of 14A.

One of the most popular applications of a resettable fuse is the protection of rechargeable battery packs.  Each battery pack is required by law to be protected.  The resettable battery strap is one solution to accomplish the protection needed.

To learn more about Optifuse and resettable fuses, visit the Optifuseweb site and review the circuit protection product solutions and sign up for Jim Kalb's blog.  Link to Wikipedia for more information on resettable fuses http://en.wikipedia.org/wiki/Resettable_fuse.

For MOSFETS, diodes, TRIACs, and rectifiers, World Products, Inc. (WPI) is the North American marketing channel for Lite-On semiconductor solutions. For power supply designers, WPI also provides thermally protected varistors, metal oxide varistors, photo couplers and RFI suppressors.   To learn more about WPI power solutions, click here.

APX Technologies provides numerous power related solutions including signal, pulse, power and HF transformers and toroids.  Packaged power solutions include standard and custom AC and DC output adapters, regulated linear power supplies, battery chargers, international power supplies and external switchmode power supplies. For more information on APX standard and medical grade products, click here.

Sceptre Power's line of power supplies range from 2 watt wall plug versions up to 1000 watt fully enclosed units with designs for indoor or outdoor solutions.  From simple AC-DC linear power adaptors and battery chargers to multi-purpose switching power supplies for applications in consumer, commercial, telecom, computer peripherals, industrial and portable electronics applications. Click here for more Sceptre Power solutions.

Excelsys provides user configurable, high efficiency, low profile  power solutions.  These industry leading power supply solutions range from 100W to 5kW for the industrial, medical, communications, computing and military markets. If your application requires the flexibility to configure custom power outputs using standard agency approved modules, Excelsys has a solution for you. For more details on Excelsys configurable power supplies, click here.

This is just a sampling of TLC Electronics' solutions for power applications, to learn more click here .

agreement to provide standard, cost-effective enclosure solutions for applications ranging from USB enclosures to instrument cases.  TLC has placed an initial stocking package that includes many of these standard products that can be shipped "off-the-shelves" of TLC's St. Paul, MN warehouse. 

If one of the standard products does not meet your specific needs, New Age Enclosures or TLC Electronics will provide a modified standard or a complete custom enclosure.

New Age's experienced engineers produce market-ready designs© sized to fit today's electronics. New Age is a division of Alltec Integrated Manufacturing, Inc., a leader in custom injection molding. New Age Enclosures is ISO quality registered to the stringent aerospace standard AS9100B. New Age proudly embeds this high level of quality into the New Age products and services delivered by TLC Electronics.

To learn more about New Age Enclosures or TLC Electronics, contact one of TLC's solutions providers at 651-488-2933 or see the Contact Sales for more specific contact information.

The low profile mini automotive blade fuses are now becoming the new fuse standard in Detroit and in Japan.  They are small but powerful and they have found applications outside of the automotive market.

OptiFuse fields calls almost daily from engineers who are looking for ways to mount these new fuses for their specific application.  Currently, the only place available is to mount the fuses is in the OEM supplied fuse block or in a PCB clip.  With new non-automotive applications surfacing, a need has been created for fuse holders not supplied by the automotive OEM.

OptiFuse is pleased to announce that it has now developed an inline fuse holder exclusively for the low-profile mini fuse.

Optifuse LPS-01B-16R






The LPS-01 fuse holders are manufactured from high temperature thermoplastic allowing them to be used in the harshest of environments.  The integrated snap-on cover and sealed wires help to protect the fuse from water, dust and other pollutants.

The low profile form factor allows the inline fuse holder to be easily integrated into any wire harness assembly.

OptiFuse and TLC Electronics can help you to create customized solutions with the availability of different colors, wire gauges and customized lengths depending on your specific application.  OptiFuse's low-profile mini fuses may be pre-inserted to help reduce your labor content.

The LPS fuse holder is rated to 30A at 32 VDC.

Samples are currently available with production parts available in 6-8 weeks.

Click here to link to the TLC Electronics web site to learn about the electromechanical product and service solutions available from TLC Electronics.

LEDs are now available that deliver the brightness, capacity, lifetime, color temperatures and stability required for general lighting applications. LED-based applications are also lower in overall cost  due to their long life and reduced energy consumption.

FEMA Corporation's LED solutions include a range of lighting  products from surface mount discrete LEDs to cluster and light strip assemblies.  Since 1980, FEMA has supported applications in machine vision, medical, security and general lighting applications. Click here to learn more about FEMA LED lighting solutions.

For LED power requirements, Sceptre Power's line of LED drivers range from 8 watt versions up to 150 watts. For outdoor applications, Sceptre offers several IP67 sealed power supply solutions.  With both constant current and constant voltage models, the Sceptre brand of drivers are designed to specifically vary electrical characteristics to allow LEDs to operate optimally.  Click here for more information on Sceptre Power's line of LED power solutions.

For enclosure lighting applications, Jamicon provides LED light bars and driver solutions.  These LED light bars provide instant start up and create less heat without "flicker" and ultraviolet rays.  For more details on Jamicon lighting solutions, click here.

As part of JST's dedication to advanced connection systems, JST provides fine pitch interconnect solutions for LED applications.  The XSR series of 0.6mm pitch IDC connectors are available in circuit counts from 2 to 22 positions. The wire-to-board  miniaturized connectors offer a mounting height of 1.45mm and a depth of 3.0mm.  For more details on the JST product solutions, click here.

If your requirement includes panel mount indicators, Arcolectric offers solutions for LED indicator assemblies and LED lampholders. Combine the simplicity of neon lamps with the technology of LED lamps in industry standard sizes. Numerous mounting and bezel options allow flexibility for your design.  Click here for more on Arcloectric lighting solutions.

AVC America provides standard luminaires designed specifially for  solutions to packaging and cooling LED clusters for indoor applications.   Ranging from 2 watt to 18 watt, the luminaires allow for configurations to meet your stringent lighting requirements. For AVC America solutions click here.

This is just a sampling of TLC Electronics' solutions for LED lighting applications, to learn more click here .

• 0 No protection
• 1 Full penetration of 50mm diameter sphere not allowed and shall have adequate clearance from hazardous parts. Contact with hazardous parts not permitted.
• 2 Full penetration of 12.5mm diameter sphere not allowed. The jointed finger shall have adequate clearance from hazardous parts.
• 3 The access probe of 2.5mm diameter shall not penetrate.
• 4 The access probe of 1.0mm diameter shall not penetrate.
• 5 Limited ingress of dust permitted (no harmful deposit).
• 6 Totally protected against ingress of dust.

Second Numeral Protection against harmful ingress of water

IP Requirements

• 0 No protection
• 1 Protected against vertically falling drops of water. Limited ingress permitted.
• 2 Protected against vertically falling drops of water with enclosure tilted 15º from the vertical. Limited ingress permitted.
• 3 Protected against sprays to 60º from the vertical - limited ingress permitted.
• 4 Protected against water splashed from all directions - limited ingress permitted.
• 5 Protected against low pressure jets of water from all directions - limited ingress permitted.
• 6 Protected against strong jets of water.
• 7 Protected against the effects of immersion between 15cm and 1m.
• 8 Protected against longer periods of immersion under pressure.

For example, an IP 67 rating would be totally protected against ingress of dust & protected against the
effects of immersion between 15cm and 1m.

Contact TLC Electronics at 651-488-2933, email tlcsales@gmail.com, fax 651-488-3246 or see our web site www.tlcelectronics.com.

Print (if available):
Bill of Material (BOM if available):
Quantity to Quote:
Release Quantities:

If there is no print or no BOM available, the customer should supply the following information:

For a simple prepped wire:

Wire AWG:
UL Style:
Wire Color(s):
Length of Finished Wire:
Overall Length Tolerance:
Blunt Cut:
Strip and Retain (Strip Length and Tolerance):
Strip and Tin (Strip Length and Solder Type):
Packaging Requirement (bundled, bagged, boxed, etc.):

Don't forget there are two ends to the wire.  Do you want both ends prepped the same?

For a wire with a contact crimped on one or both ends:

The same information listed above would be required but you should also include the following:

Contact part number used on the left side:
Contact part number used on the right side:
Length measured from inner side of contacts:
Pull test requirements:  

For an assembly with one connector:

Same information as above but include:

Connector housing part number:
Pin 1 designated:
Pin out and color code:
Length from inside edge of connector to end of wire:
Manual continuity test:

For an assembly with a connector on each end:

Once again, all of the information above must be provided along with the following:

Contacts and housings for the other end of assembly:
Length from inside to inside of connectors:
Automatic continuity test:
Other test requirements:

For all terminations, ensure the insulation thickness of the wire is compatible with the contacts on both ends of the assembly.

Many other options exist even for these "simple" interconnect solutions.  For example, if labeling is  required, the label size, label type, print copy, and position of label must be specified.  For cable ties, cable tie part number and position on cable should be included.  For heat shrink, specify heat shrink manufacturer, part number, color, length of recovered heat shrink, and position of heat shrink.  For shielded cable assemblies, the shield termination should be clearly identified.

If cross references are acceptable to reduce lead time, to replace obsolete components or to avoid costly tooling charges, make sure this is clearly noted. When possible, specify generic wire call outs to ensure that your cable assembly supplier can use the wire best suited for their machines. Small wire spools tend to curl wire and jam up machines, increasing scrap and downtime, thus increasing costs.

Does TLC have this written down in an easy to use format?  Yes, we have a standard quote cover sheet and "boiler plates" for prepped wire, crimped wire, one connector assembly and two connector assemblies.  These boiler plates and the quote cover help our solutions providers define the required information at the beginning of the quote process.  For more complex assemblies, the boiler plates can be modified for the specific application or your TLC solutions providercan assist you with a preliminary drawing.

Click here to link to the TLC Electronics web site to learn about the assembly solutions available from TLC Electronics.

TLC Electronics, Inc. operates out of a 38,500 square foot corporate headquarters located in St. Paul, Minnesota.

About HellermannTyton

HellermannTyton is a leading, global manufacturer of systems and solutions which help world-class customers better manage and identify wire, cable, and components. Located in over 30 countries, HellermannTyton offers an integrated approach in the design, manufacturing, and delivery of its products which result in higher quality and lower costs for our customers.

Seewww.hellermanntyton.us or www.tlcelectronics.com to learn more about these and other cable management products.

• Cooltron: AC and DC fans, blowers and accessories
• Jamicon: DC fans, ballasts and LED drivers
• Qualtek: AC and DC fans and accessories
• Shyuan Ya: AC fans and blowers

For more information about thermal management products available from TLC, contact your TLC Electronics sales representative at

651-488-2933,tlcsales@gmail.comor see Contact Sales.

As part of TLC Electronics, Inc. value added services to meet our customers' prototype through production requirements, TLC offers drafting services as a lower cost alternative to using your in house resources.  Engineering drawings for processed wire, cable assemblies, wire harnesses and electro-mechanical sub-assemblies are created in VISIO.   The engineering drawings are created in accordance with standardized conventions for layout, nomenclature, interpretation, appearance and size or TLC will use your specific drafting procedures if available and the procedures are within TLC's capabilities.  

The guidelines for this service are as follows:

• One hour minimum
• 15-minute increments
  • Including ECOs or other changes
• Time Log maintained by TLC for each program
  • TLC drafting maintains internal log of changes and internal REV levels
• Drawings will be marked as "DRAFT" until approved by customer
• Customer invoiced monthly and will be provided a copy of the Time Log
• Bill Of Material (BOM) for desired components to be supplied by customer
• Prototypes are billed separately as TLC-PT part numbers
• Upon satisfactory payment to TLC Electronics, customer owns the Intellectual Property and the customer will be provided an electronic copy of the drawing.

Contact your TLC Electronics' solutions provider today to learn more about drafting services from TLC Electronics.   

TLC Electronics, Inc. is an authorized distributor of electromechanical components from several manufacturers of high quality products.  For more information on the electromechanical solutions and services available from TLC Electronics, see www.tlcelectronics.com.

To learn more about these cooling solutions click here.

To learn more about Conec or to check price and delivery of Conec interconnects, contact your TLC Electronics sales representative at 651-488-2933, tlcsales@gmail.com or see the Contact Sales page

Originally published in MDT: Medical Design Technology   (www.mdtmag.com).

Practicing Sound Medicine

Audible devices are playing an increasingly critical role in modern healthcare. Unfortunately, device manufacturers may not be aware of all the options available to them when it comes to sound components. This article reviews a variety of characteristics and important features companies should keep in mind when electing to add an audible aspect to their finished medical device.

By Ely Zofan

There’s an alarming trend occurring throughout the healthcare marketplace, and it is providing numerous growth opportunities for the instrumentation manufacturers that can fulfill demand for products that provide—among other things—clear, reliable audible signals for a cost-conscious audience.

The use of sounding devices in medical instrumentation is ubiquitous to say the least. One can visit any wing or department of a health center and hear a range of electronic tones as this form of electronics does what it does best—provide audible data to operators in exchange for a response or action. Yet as the technology advances and becomes even more integral to patient care, there is a steady increase in the demand for devices that can generate specific tones to help medical technicians and staff distinguish one priority from another. And like so many other electronics, these devices are migrating towards smaller packages and footprints.

Multi-Sensory Solutions

Research shows that people absorb data more effectively through multiple senses. The human eye alone can only focus on one visual stimulus, with peripheral vision used for scanning. Faced with multiple, often unpredictable, visual alerts, doctors, nurses, and med techs may quickly reach a point of visual overload, particularly in acute care settings including emergency rooms, surgical suites, and maternity departments.

Auditory senses are generally more complex, enabling the human brain to process greater amounts of unrelated data simultaneously. Combining visual and auditory senses has been an essential part of the medical profession, especially in critical care where immediate response to warnings is essential to saving lives. Moreover, the integration of audio technology serves to increase personnel productivity and efficiency without compromising quality of care. Harnessing human auditory cognition requires a clear hierarchy of auditory signals, as all sounds are not of equal importance. The introduction of new sounds or tones requires careful consideration based upon the level of medical or diagnostic emergency. Selecting the right audible device involves cost and performance considerations such as size and weight, type of sound required, variability of sound, loudness and frequency, expected service life, lead free (RoHS) compliance, and other key variables.

This group shotof sounding devices available through Challenge Electronics represents several specifically mentioned in the article: CE-C80, CSPT, and CSET series.

Medical Alarms and Annunciators

Audible devices such as speakers, alarms, transducers, and microphones are in all types of bench top instruments and hand-held devices. These components offer high performance, high quality audible characteristics for communications and signaling. Microphones and speakers are often used to communicate data between patient and nurses, or between doctors and nurses. In some instances, speakers are used to signal codes to alert hospital staff without causing undue concern for the patient.

Portable or Hand-Held Devices

We live in a mobile world, and as a result, portable and hand-held medical devices are commonplace. During the full cycle of a surgical patient’s stay in a hospital, he might encounter dozens of data collection points that involve scanning, monitoring, and verification for a variety of purposes—from basic metabolic readings to bedside medication dispensing or patient identification verification. Key performance parameters include size, weight, and energy efficiency, as comfort and convenience are primary considerations. However, as portable devices become increasingly miniaturized, quality and reliability can become major concerns.

Hand-held devices typically use a sound transducer to generate audio signals. These devices allow the manufacturer to conserve space, power, and cost. Piezoelectric transducers are typically used for low power and higher operating voltage applications (5 to 30 VDC). As a rule, the smaller the size of the piezoelectric transducer, the higher the resonant frequency and the lower the sound level. A 15-mm diameter piezoelectric diaphragm is typically 4,000 to 6,000 Hz, while a 25-mm diameter and larger diaphragm can produce 3,000 Hz and lower frequencies. Magnetic transducers are typically used in low voltage power sources, as well as for lower sound frequency applications, including pagers, wireless monitors, patient identification systems, and other portable devices.

These transducers are typically mounted on printed circuit boards and are driven by the electronics circuit provided by the equipment manufacturer. Use of a transducer gives the OEM the flexibility of producing multiple sounds. For example, the CSPT23A09-4.0F piezoelectric transducer measures 23 X 23 X 10.8 mm, with 1 to 25 Vpp operating voltage, 4,000 ±500 Hz resonant frequency, and 100 dB output at 10 cm. The CSET8.5A3.6-16-2.7F magnetic transducer measures 8.5 X 8.5 X 4.0 mm, with 2 to 4 V op operating voltage, 2731 Hz resonant frequency, and 88 dB output at 10 cm.

Many portable and hand-held medical devices now rely on miniature SMD and PCB microphones and speakers. There are SMD speakers such as the CSMS15A, which measures just 20 X 20 X 4.3 mm, with 8 ohms impedance, and 0.3 W rated power. This low footprint speaker saves space on the printed circuit board while delivering about 89 dB of sound at 0.1 meter at 0.3 watts. Typical applications for SMD speakers include portable and wearable devices utilized in surgical suites, specialty labs, critical care facilities, home healthcare, and nursing homes.

Alarms for Stationery Instruments

Many stationary systems and portable devices currently in use were built with lower cost alarms and sounding devices. These systems, while economical, have often proven less effective because of lower life expectancy or an inability to perform up to specifications. Poorly designed alarms may not turn on, or the sound levels may vary depending upon what is located in front of the sound port.

Some medical instruments routinely go through a cleaning cycle to reduce bacteria growth. If the alarms are not hermetically sealed, washing solution could leak into the alarm and short the alarm, causing severe damage to the instrument. Alarms with stainless steel terminals attached with a brass quick-connect terminal may lose their conductivity over time due to dissimilar material.

Alarms with self-driven oscillators require proper loading of the sound port for effective operation. These alarms are typically low-cost and produce continuous, intermittent, or chime tones. If the sound port is obstructed or covered to reduce the sound, it may cause a shift in the frequency output, or, in extreme cases, the alarm may not operate or may fail to produce the desired sound.

Direct driven alarms are commonly recommended for medical instruments, since the sound oscillator works independently of the loading of the sound port, and is more reliable for driving a piezoelectric disc to produce the desired tone. Direct driven alarms may be designed to produce any desired tone. Also, with self-driven oscillators, loading of the sound port may result in reduced sound levels, but will not shift the frequency or affect the alarm’s ability to operate.

Loudness and Type of Sound

When specifying a sounding device, design engineers need to factor in the desired volume as well as the type of sound. A primary consideration is to make sure that the alarm can be heard above environment noise, but not be so loud as to drown out other alarms and annunciators.

Alarms can produce a variety of tones, including continuous, chirp, intermittent, chime, warble, or siren. Continuous tone alarms produce a steady sound. Therefore, when specifying a continuous tone alarm, make sure that the sound does not blend in with environmental noises and thus be ignored. The CE-CM530AS continuous tone, panel mounted alarm is medium in volume, operating from 5 to 30 VDC. Output sound is about 97 ±3 dB (A) at 24 in. (61 cm). A chirp tone delivers a very short continuous sound, while an intermittent tone can be set with different pulse durations and frequencies to conserve power and to not be as “aggressive” as the continuous tone. The intermittent tone can be modified to reflect the urgency of the alarm by changing the interruption rate from a slow rate to a fast rate. The CE-BM530ASS, for example, is a panel-mounted alarm that delivers a medium loud intermittent tone, 1 pulse per second, operating from 5 to 30 VDC. Output sound is about 97 ±3 dB (A) at 24 in. (61 cm).

A chime tone delivery is a more pleasant sound, with the volume decaying exponentially. Typical applications for chime tones include nurse monitoring stations. The CE-HM530ASS is a panel-mounted alarm with a medium loud chime tone, 1 pulse per second, operating from 5 to 30 VDC. Output sound is approximately 95 ±3 dB (A) at 24 in. (61 cm).

A warble tone is designed to be more attention-getting, creating a sound that alternates between two distinguished frequencies. The CE-WM530ASS is a panel-mounted alarm with a medium loud warble tone, alternating at 1 Hz operating from 5 to 30 VDC. Output sound is about 97 ±3 dB (A) at 24 in. (61 cm).

A siren tone creates a sweeping sound between a low and high frequency, producing very loud sounds that are commonly utilized for noisy environments. The CE-US515BSS is a panel-mounted alarm with an ultra loud siren tone, 6 sweeps per second, operating from 5 to 15 VDC. Output sound is about 108 ±3 dB (A) at 24 in. (61 cm).

In addition, there are dual function alarms that combine two different sounds in one unit, thus minimizing the cost of the alarm. For example, in a dual function unit, there might be intermittent and continuous tones, chime and continuous tones, and warble and continuous tones. Another hard-to-find feature is a volume control to attenuate the sound level in special environments. The CE-EV offers a unique volume control rotor that can be mounted by the manufacturer or customer to attenuate the sound output level up to 20 dB from its loudest output.

ONLINE

For additional information on the technologies and products discussed in this article, visit Challenge Electronics at www.challengeelectronics.com.

Ely Zofanis the director of engineering for Challenge Electronics. He is responsible for all aspects of design and quality of piezoelectric alarms and transducers as well as assisting customers with their sound device needs. Zofan can be reached at 800-722-8197, x1009 or ezofan@challelec.com.

Challenge Electronics, Inc., Audible Products, 95 E. Jefryn Blvd., Deer Park, NY 11729

By Michael Balekdjian, Application Engineer, METZ CONNECT (RIA CONNECT)

Unlike traditional office settings, Ethernet has spread into environments where protection from noise, solids, liquids and even gases is of concern. Manufacturing equipment and automated test environments are just some of the more common areas where standard RJ45 based connectors do not offer protection from these sources of contamination. Conditions in these environments warrant the use of industrial grade connectors and connection systems. The primary evolution involves encasing or shrouding the standard RJ45 in either a plastic or metal housing, depending on the application and required durability.

It is common to measure a connection system’s resistance to the aforementioned contaminants by what is known as the IP (ingress protection) rating, as defined by the International Electro-technical Commission (IEC 60529). Typically, connectors which carry can IP-67 rating are capable of provided adequate protection in even the harshest environments. Without outlining the specifics between various grades, the use and meaning behind IP-67 grade connection systems is as follows. The first digit represents the resistance against solids. In this case “6”, which happens to be the highest classification, and means the connector is dust tight or impervious to solids. The second digit represents resistance to liquids. A rating of “7” means the connection system can be submersed in one meter of water for up to one hour before leaking, and also resist moderate pressure water spray. This level of ingress protection can be provided by many of today’s industrial grade plastic housings. However, there are applications in which a metal solution is desired, especially if resistance to fire and even explosions is of concern. These normally consist of die-cast Zinc or nickel plated alloy housings, which also inherently provide complete protection from EMI.

Oil and gas exploration is one such area where network connections are not only subjected to liquids and gas, but also ultraviolet light, extreme temperatures, mud and very severe handling. All of these influences can increase the likelihood of network failures. Only the highest grade industrial strength connection systems will offer the protection required to maintain a working and reliable network connection in such an environment. For example, in a top-drive control application, it is imperative that control and data signal transmission be maintained.

This heavy and powerful piece of equipment is responsible for supplying the rotational force, or torque to facilitate the drilling of a well. It is also able to traverse vertically and is hydraulically actuated. Speed control, elevation and line pressure are important parameters to monitor to ensure adequate safety on the drilling platform. In addition, keeping the rig from becoming inoperable is second only to safety. The only time a rig should be inoperable is during a scheduled shut-down, such as when repositioning for a new well. Start-up and shut-down may account for just a few percent of operating time, but it is during this time that many incidents can occur. One such incident involves the disconnection and subsequent reconnecting of data signal and control cables. Most electrical related issues can be attributed to poor electrical contact. As if the abusive handing from rig operators is not enough to consider during this time, the connectors may be left free and become encrusted with mud, or even rolled on by heavy equipment while left dangling on the ground below. Protective caps are offered with many connectors so as to protect unused or temporarily disconnected ports from contamination. A ¼ turn bayonet style locking feature is used to facilitate quick connections, while providing high tensile strength support, which keep plugs from being pulled out of their receptacles. There is another industrial grade connection type connector, which was not enhanced or modified to bring Ethernet connectivity into harsh settings, as was the case with the traditional RJ-45. This connector type is known as an M-12 connector, and it has already been quite a popular choice for connecting devices used in industrial automation and control applications.

From inception, the design concept of the M-12 was to address the need for data acquisition and control functions in harsh environments. The strengthening and sealing of the RJ45 connector may provide a connection system comparable to that of an M-12 in terms of its IP rating, but the M-12 is inherently more robust and more compact than most RJ45 based systems. The attractiveness of the RJ45 based system is the lower upfront integration cost of some of the plastic based solutions, as well as using open protocols such as TCP/IP. This begins to phase out, once you consider metal based options, and it is arguable which offers superior performance. The M-12 was not necessarily designed with high speed data transfer in mind. However, much like the evolution of RJ45 based industrial connectors addressed the need for mechanical robustness and ingress protection; M12 connectors have been evolving to accommodate high speed networks, and two pair connectors can support data rates up to 100Mbs. Designs are currently underway to enhance the transmission performance of the M12, but don’t expect to see them replacing the traditional RJ45 style (8P8C) connector in the office. Doing so would be analogous to burning premium fuel in an engine designed to burn regular. This is a needless expense, as there is no net performance gain.

As is the case with most decision making, some of it will come down to pride of ownership, and certain beliefs which are formed based on others advice or experiences. Cost is always going to play a factor, and some of the metalized connection systems are on the high-end of that spectrum. Therefore, their use is best justified in applications like the one cited earlier in this discussion. Tradeoffs have to be analyzed and connectors chosen which offer the attributes necessary to ensure repeatable operation over the network’s, or at least the connector’s lifespan.

For more information, see www.riaconnect.com

METZ CONNECT (RIA CONNECT)

200 Tornillo Way

Tinton Falls, NJ 07712

(732) 389-1300

TLC Electronics, Inc. is an authorized distributor or METZ CONNECT (RIACONNECT) products.  See www.tlcelectronics.com for more information on the products and services available from TLC Electronics, Inc.

As one of TLC's leading interconnect manufacturers, TLC has made many of the JST part numbers available for purchase on our on line ordering page.  See TLC's web page for more details on the use of our shopping cart feature. 

For miniature IDC wire-to-board applications, the XSR series insulation displacement connectors offer a mounting height of 1.45mm and depth of 3.0mm.  These IDC connectors utilize 36AWG, 7-strand wire providing the toughness and flexibility for reliability and freedom in wiring along with the space saving features. Available in circuit sizes from 2 to 22 positions, this wire-to-board solution also provides a secure locking feature with an audible 'click" to ensure proper mating.  JST offers many fine pitch interconnect solutions. See JST for more information.

Many engineering and purchasing professionals think of JST as the fine pitch interconnect leader.  However, in addition to leading the industry in fine pitch connection systems, JST also offers high quality standard D-subs, memory card connectors, lugs and terminals, waterproof connectors, USB, mini USB and uUSB, DC power jacks and automotive rated connectors.  For complete details on the advanced connection system solutions offered from JST Corporation, please contact one of the TLCsolutions providers today at 651-558-2560 or tlcsales@gmail.com.

This is just a sampling of TLC Electronics' solutions for JST interconnect. To learn more about wire-to-wire, wire-to-board, board-to-board, I/O, communication interconnects, power connectors, and terminal blocks, click here.

Mr. Jon Crofford has accepted a position in the TLC Electronics’ sales department as an account manager responsible for sales and service of accounts and prospects in a portion of the Minneapolis/St. Paul area and in northeastern Minnesota and northwestern Wisconsin. In addition, Crofford is responsible for Madison and Milwaukee Wisconsin area accounts and prospects.

Crofford has a BA in Graphics Management from University of Wisconsin Stout and has been employed full time with TLC Electronics since November of 2005.  He has accepted progressive responsibilities within TLC over the last four and one half years including Process Improvement Team management, engineering and documentation control, and most recently, TLC’s Quick Response Manufacturing (QRM) program manager.   Crofford is a creative thinker, an excellent communicator and very excited to become a part of the sales team.  He is looking forward to working closely with our customers and prospects to provide solutions to their electromechanical component and assembly requirements.

Crofford will start in his new capacity beginning June 1, 2010.  Until that time, you may contact Steven Olson at s.olson@tlcelectronics.com or the TLC sales staff at tlcsales@gmail.com if you have questions, concerns or a requirement for TLC Electronics’ products or services.  Please see our web site at www.tlcelectronics.com.