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Design Requirements for High-Voltage Connectors

January 13, 2017 AM Published by Gary Paul | Leave your thoughts

Special Orders Don’t Upset Us!
Hold the pickles, hold the lettuce … come on, you know the rest. That is, of course, if you grew up or were around in the 70s. Still used today, the “special orders …” tagline is Burger King’s most enduring one. The fast food giant wants everyone to know that even though the menu is set, they are more than willing to customize that Whopper to your liking. Why? Because not everyone likes pickles on their burger. All my life, I’ve never been tempted to throw a pickle or two on my burger. Onions? Not happening. But, to get even the most basic burger, you were subjected to getting both—along with a smear of mustard mixed in with the catsup. But the King knew not everyone wanted or needed the features they built into their standard product. 

No Two Are the Same

The beauty of working in the world of high voltage is that no two applications are the same. And that’s a fact. Sure, the basic principle of safely carrying potentially lethal levels of voltage from point A to point B is the underlying objective when specifying high-voltage connectors. However, the nuances associated with the individual applications can be as varied as the preferences we each have for that flame-broiled burger. 
Let me tell you about an inquiry we received recently.

A potential client submitted an inquiry through our website (www.caton.com). He was seeking a solution to his company’s high-voltage connector dilemma. Rules and regulations in their industry had taken a turn forcing the company to devise a more robust method of connecting its apparatus and meeting the new industry standards.

Someone at the company had discovered our products and services through a query of potential high-voltage connector suppliers. Like most, he reviewed the information provided throughout our website, read about the various high-voltage applications and products we have developed, and looked through our various product offerings. And like most, this person discovered a few potential solutions for the company that came close to what he thought it needed, but nothing that was an “off-the-shelf” solution. Once we began talking about his company’s needs and our ability to meet them by altering them to suit the new requirements, he knew he could get custom high-voltage cable connections

Cue the Jingle …
Special orders don’t upset us! In fact, it’s one of our defining qualities: our ability to assess a customer’s needs and meet the demands of their application in a safe, reliable, cost-effective manner. When approaching a project like this or any project, there are crucial details that must be gathered in advance to properly assess the application and determine the best course of action. The rule of thumb here is to provide as much design information as possible at the onset so we can (both) move forward with all available details and expectations at our disposal.

Details Needed when Submitting Design Requirements:

  • Application details—where and how the assembly will be used; environmental considerations
  • Electrical—operating voltage (DC or AC), amperage, frequency, and duration
  • Mechanical—connector type, cable requirements, size constraints
  • Test requirements
  • Usage

Contact us and find out how we can help meet the demands of your most challenging application. Have it your way … because special orders don’t upset us. 

Contact Us Now!



Categorized in: High Voltage Connectors, High Voltage Design

This post was written by Gary Paul

About Caton Connector

Since 1973 Caton has been the preferred souce for high voltage connectors and low voltage assembly solutions. Our products operate at voltages up to 100 kVDC and have partial discharge levels as low as 2 pC at voltages up to 40 kVRMS and 60 kVDC. Our high voltage connector insert configurations have up to 19 conductors, multi-shields and use single, double and triple extruded silicone cable and are built to lengths of up to 300 feet.

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