Round mains connector (low power) - Page 1
Forum section: electronics / beginners

author: newbie666
author_rank: Regular Contributor
timestamp: March 20, 2018, 10:07:09 am
content: Hello,I've been going through mouser catalog for 2 days now and I can not seem to find what I need:I'm doing a lot of low power (5-30W) mains powered projects and I like to use those hammond extruded enclosures. The main pain point is cutting those square holes for IEC sockets.Is anyone aware of a power connector suitable to provide mains voltage that's round or at least has a round socket. That would make my life so much easier as I could just drill a hole in 30 seconds rather than spending an hour as I do now.I've only found PowerCon from Neutrik but the smallest one is rated 16A so definitely an overkill for my application.

author: RyanT
author_rank: Contributor
timestamp: March 20, 2018, 11:19:42 am
content: I once saw 240V going through a barrel plug. Still gives me the willies just thinking about all of the ways that could go horribly wrong.The IEC connectors are pretty well designed.My advice would be, since it seems you have the space for the IEC connector but the time drilling the hole is the bottleneck, to look at buying a punch for them. They're pricey ($100+) but worth it if you have to do a lot of connectors. You could also make yourself a jig to semi-automate the procedure yourself, if you can get a little mechanical advantage. My experience doing just a few at a time, drilling the biggest hole you can and then attacking the corners with a dremel (cut wheel) and/or a nibbler does the job just fine, though, you're right, it is a bit tedious.

author: tooki
author_rank: Super Contributor
timestamp: March 20, 2018, 04:23:25 pm
content: Is a fully-detachable cable an absolute requirement? Sounds like drilling a hole for a cable gland would be easy and quick.If partial detachability could work, what about using an IEC socket on a pigtail, and then mounting that on the device through a gland? Then the user plugs in their local IEC mains cable to the pigtail? Fugly, but functional.

author: fourtytwo42
author_rank: Super Contributor
timestamp: March 20, 2018, 04:33:29 pm
content: My way around may not be suitable for you but I use wall warts so the project box itself only needs a small round connector

author: Richard Crowley
author_rank: Super Contributor
timestamp: March 20, 2018, 04:43:26 pm
content: If you MUST have an IEC (presumably 60320 C14), there doesn't appear to be any available that fit into a round panel hole.OTOH, if you are looking for a modern round-hole mains connector, there is Neutrik Powercon. Same size as XLR connector:

author: mariush
author_rank: Super Contributor
timestamp: March 20, 2018, 08:56:34 pm
content: Digikey has something almost circular:https://www.digikey.com/product-detail/en/schurter-inc/4300.0096/486-2094-ND/639967If you don't need earth, then in theory you could drill two holes for the corners and then use some blade or file to create the straight holes... or if the back of your device is made out of circuit board maybe you can use vscoring or cut outs in combinations with holes.

author: newbie666
author_rank: Regular Contributor
timestamp: March 20, 2018, 09:44:19 pm
content: looks like PowerCon is the only viable option. They're a bit pricey but I think I'll go this way for now. Thanks for all the answers!

author: Nusa
author_rank: Super Contributor
timestamp: March 20, 2018, 09:48:51 pm
content: http://www.tubeampdoctor.com/product_info.php?products_id=318&url_node_name=Cables_Jacks_amp_Plugs_Connectors&language=en

author: mikeselectricstuff
author_rank: Super Contributor
timestamp: March 20, 2018, 10:07:21 pm
content: Quote from: newbie666 on March 20, 2018, 10:07:09 amIf it's taking an hour you're doing it wrong.Drill 2 holes and jigsaw. A few minutes max. The connector has a flange to hide a less-than-perfect edge.

author: Fludo
author_rank: Regular Contributor
timestamp: March 22, 2018, 12:27:41 pm
content: CPC from Amphenol and the other MILSPEC connectors will all fit into a round hole. The have multiple pieces you have to buy: Plug, receptacle, backshell and cable clamp. The crimp tools are cost prohibitive($600+), but there are solder cup variants.https://www.digikey.com/products/en/connectors-interconnects/circular-connectors/436?k=cpcThe plastic ones can have a 600V rating and the metal ones will do 3-4kV.

author: Jeroen3
author_rank: Super Contributor
timestamp: March 22, 2018, 01:12:42 pm
content: Buy a punch tool.Example:https://uk.rs-online.com/web/p/punch-die-combinations/0543614/

author: paulca
author_rank: Super Contributor
timestamp: March 22, 2018, 01:46:44 pm
content: If you can find an old vintage UK kettle, it will have a three pin round main plug and socket. It will be made of Bakelite or other prehistoric plastic though.

author: mikeselectricstuff
author_rank: Super Contributor
timestamp: March 22, 2018, 01:53:32 pm
content: Quote from: Jeroen3 on March 22, 2018, 01:12:42 pmIf you're doing a lot, then absoutely - these make a very clean hole quickly and easily

author: Ian.M
author_rank: Super Contributor
timestamp: March 22, 2018, 02:51:49 pm
content: *Way* back in the day, quite a lot of testgear used Bulgin PX06xx series 3A 250V circular power connectors for their main input. You aren't supposed to use them for mains if the connector is accessible without tools as the creepage distance from the trailing socket contacts to the end face of the socket 'plug' is a bit on the skimpy side, but as long as you don't let your kids or dog chew the end, or sell or lend out (other than to a competent person) any kit that has them, it really isn't a major issue.https://www.rapidonline.com/bulgin-miniature-3-pole-mains-connectors-63556There's also the 5A 250V XLR-LNE connector system - they are rather obsolete and aren't approved for domestic use but are still manufactured by Canford.Also considerhttps://www.rapidonline.com/bulgin-general-purpose-miniature-mains-connectors-63559

author: Nusa
author_rank: Super Contributor
timestamp: March 22, 2018, 03:56:37 pm
content: What I linked earlier in this thread is an IEC replacement for a Bulgin connector that goes in the same round hole.Quote from: Nusa on March 20, 2018, 09:48:51 pm

author: newbie666
author_rank: Regular Contributor
timestamp: March 22, 2018, 04:05:44 pm
content: Bulgin part may work! thanks for the tip.

author: MarkL
author_rank: Unknown
timestamp: March 23, 2018, 02:18:02 pm
content: Here's another connector for your consideration. The Hubbell midget twist lock series is round, and comes in 3-wire or 2-wire versions for grounded or not. It mounts in a 1+1/4" dia. hole (approx). It used to be very common on office equipment before IEC connectors.https://www.hubbell.com/hubbell/en/Products/Electrical-Electronic/Wiring-Devices/Locking-Devices/Midget-Twist-Lock/c/2027743

author: mikeselectricstuff
author_rank: Super Contributor
timestamp: March 23, 2018, 07:45:44 pm
content: If this is for anyone other than yourself, I think using anything other than one of the standard IEC types ( normal, clover-leaf or figure-8) will really piss off your customers.Especially the ones in other countries.

author: edavid
author_rank: Super Contributor
timestamp: March 23, 2018, 10:37:41 pm
content: There are also the round connectors used for rope lights:https://www.1000bulbs.com/product/114524/FT2-N120NA12CONKIT3W.html

author: stj
author_rank: Super Contributor
timestamp: March 24, 2018, 12:11:36 pm
content: there are many round connectors from people like bulgin,but they arent cheap.the simple method i use - also good for usb sockets.get a steel template, cut one from an old psu or something,drill the 2 mounting holes for your inlet and put the teplate on it with a couple of bolts.then mill around the rectangular hole with a dremel or similar tool and a milling drill bit - the steel will act as a guide to give a clean shape.