Amphenol Contents Star-Line(R) Series Overview...........................................................................................2 Star-Line EX(R) Series Overview.....................................................................................3 Environmental Highlights, Double Lead Acme Thread Features, Wire Limitation Guide....................................................................................................4 Contact Insert Features-Mod I, Mod II .........................................................................5 Connector Component Ordering Details................................................................. 6 - 9 Plug Hardware Assemblies................................................................................. 10 - 13 Receptacle Hardware Assemblies...................................................................... 14 - 22 Starline EX(R) Product Instructions........................................................................ 23 - 24 Starline EX(R) Ordering Details, EEx d Cable Types............................................. 25 - 27 Starline EX(R) Hardware....................................................................................... 28 - 30 Starline EX(R) Description of Equipment & Part Number Code Logic...........................31 Starline EX(R) Assembly and Termination Instructions.......................................... 32 - 40 Single Pole Power Connectors........................................................................... 41 - 45 Insert Configuration Listing, Electrical Ratings.................................................... 46 - 47 Spare Replacement Contacts for MOD II Inserts........................................................48 Termination Data.........................................................................................................49 Thermocouple Contacts..............................................................................................50 Insert Configuration Index................................................................................... 51 - 53 Insert Configurations........................................................................................... 54 - 81 V.F.D. Insert Configurations................................................................................ 82 - 83 Connector Components, Spare Parts, Cable Adapters and Accessories........... 84 - 89 Protection Covers and Caps Accessories........................................................... 90 - 91 Conduit System Accessories............................................................................... 92 - 93 Crimping, Insertion and Removal Tools.............................................................. 94 - 95 Connector Assembly and Termination Instructions.....................................................96 Connectors with RADSOK(R) High Amperage Contacts and Other Amphenol(R)/Pyle(R) Connectors.................................................................... 97 - 99 Sales Offices and Distributors Listing.......................................................................100 Catalog information for reference only. For more assistance, contact your local Amphenol field sales office or: Amphenol Industrial Operations 40-60 Delaware Avenue, Sidney, NY 13838-1395 Phone: 1-888-364-9011 Fax: 1-520-397-7169 Technical email: tech@amphenol-aio.com This catalog and most all Amphenol catalogs are available for viewing, printing and downloading on websites: www.amphenol-industrial.com www.amphenol-aerospace.com Amphenol INDUSTRIAL STAR-LINE(R) Series Star-Line Series "ZP/ZR" connectors are heavy duty environmentally sealed plugs and receptacles and have been successfully used in all types of Industrial and Aerospace applications. These compact environmental connectors have provided outstanding performance in complex ground support cable networks, automatic and process control systems and instrumentation systems. This family of connectors has made a major contribution to the successful interconnection of peak power generating systems as well as offshore petroleum production for power distribution and data acquisition. Ample margins of safety and reliability have been designed into the Star-Line connectors to maintain capability levels which make them ideally suited for the broad spectrum of demands placed on them by industry. The specific materials and design features incorporated in Star-Line connectors were originally selected to satisfy the stringent requirements of the Aerospace industry for heavy-duty connectors. These connectors combine electrical and mechanical capabilities that equal or exceed the performance parameters established by the Military Specification MIL-5015. * UL & CSA listed to UL1977/CSA C22.2 requirements * ENVIRONMENTAL RESISTANCE - Design and materials withstand the most challenging operating conditions. Series has an IP 68-8 rating. * SOLDER, CRIMP AND PRESSURE TERMINALS AVAILABLE * EASILY ACCESSIBLE WIRE TERMINALS - Conductors are readily terminated to contacts. Cable housings are slipped over conductors or leads after terminating. Cumbersome handling and seating of inserts with conductors attached is eliminated. * LARGE WIRING SPACE - Ample wiring space is provided in cable housings and conduit fitting bodies. Hub of body mounts in any of four positions (except FS & FD box assemblies). * REVERSIBLE INSERTS - A full range of contact inserts and application adapters are available. All are interchangeable and reversible to suit special needs. * DOUBLE-LEAD THREAD COUPLING - Modified Acme Thread does not clog under adverse conditions of ice, snow, sand or mud and provides the quick coupling feature. * HARD ANODIC COATING - All machine, aluminum parts finished with a hard, scratchresistant coating per MIL-A-8625, Type III. Dielectric strength 1800 volts. Heat resistance of 750 F. * HIGH TENSILE STRENGTH *ALUMINUM - Bar Stock Components precision machined. Points of impact designed for extra strength. * RADSOK(R) HIGH AMPERAGE CONTACTS - Special arrangements are available with RADSOK high amperage contacts. Standard Star-line inserts are not interchangeable with new RADSOK contact insert arrangements. Am HS Ro E U phe no l E /2 002 / 95 / C * RoHS COMPLIANT PRODUCT AVAILABLE - Consult Amphenol Industrial Operations. * Star-line Series Connectors are certified to UL 1977 specifications. Star-Line(R) EX series The Star-Line EX Series is a hybrid form of the parent Starline product line. The series is certified for use in a Zone 1-IIc haz ardous environment. Classified facilities such as petrochemical refineries, land and offshore drilling systems are but a few of the applications for this broad product series. * ATEX certified - for Zone 1-IIc hazardous environment. For certificate contact factory * IECEx CERTIFIED- For certificate contact factory * CENELEC IP68-8 RATED - Listed under EEx d IIc T6. Plugs and receptacles listed under EEx de IIc T6. * Hard anodic coating - All machined aluminum parts finished with a hard, scratch-resistant coating per MIL-A-8625, Type III. Dielectric strength 1800 volts. Heat resistance of 750 F. Star-Line EX Series connectors are certified for use in Zone 1-IIc hazardous environment * Solder, crimp and pressure terminalsavailable * Reversible inserts - A full range of contact inserts for power, signal and mixed applications are available. All are interchangeable and reversible to suit specific needs. * Easily accessible wire terminals - Conductors are readily terminated to contacts. Cable housings are slipped over conductors or leads after terminating. Cumbersome handling and seating of inserts with conductors attached is eliminated. * Large wiring space - Ample wiring space is provided in cable housings and hardware. * High tensile strength aluminum - Bar Stock Components precision machined. Points of impact designed for extra strength. * Cable Options - Starline EX Series can be terminated onto unarmored or armored and sheathed cables built to IEEE-45 / UL1309, IEC, BS, DIN and JIC standards. Flexible cables like SOOW-A, W, G-GC and DLO constructions can also be used with this Series. * EX CABLE GLANDS - Wide variety of glands are available for Star-Line EX connectors. For more information ask for new Amphenol Cable Glands and Cord Grips catalog 12-055. * insert variety - A broad range of inserts are offered ranging Star-Line EX Connector with EX gland (EX-13-3 style shown) from single-contact to 143 contacts. High amperage up to 1135 amps at 1000V / AC or DC. Contacts are high quality copper with silver plating. (Gold plating available as an option) Composite inserts for power, control and instrumentation service available. For Amphenol Star-Line product insert de-rating information per the National Electric Code, please consult the Amphenol Industrial website, www.amphenol-industrial.com. Chart is located under literature tab. * RADSOK(R) HIGH AMPERAGE CONTACTS - Special arrangements are available with RADSOK high amperage contacts. Standard Star-line EX inserts are not interchangeable with new RADSOK contact insert arrangements. Am phe no HS Ro E U l E /2 002 / 95 / C * RoHS COMPLIANT PRODUCT AVAILABLE - Consult Amphenol Industrial Operations STAR-LINE(R) Environmental Highlights Property MIL-5015 Requirements Classes A, B, E J&R Why the Double-Lead Acme Thread? Star-Line, Star-Lok Connectors TEMPERATURE -67 F to 225 F (-55 C to 107 C) Temperature Classes A, B, E, J and R can withstand 257 F continuously. For short duration high-temperature life, consult factory. PRESSURE No requirement 300 PSI external (coupled connectors) 200 PSI internal (with pin and socket inserts) AIR LEAKAGE 1 cubic inch/ hour maximum Exceeds Classes E and R specifications HUMIDITY AND MOISTURE RESISTANCE 1 1/2 times A.C. voltage rating after 14 days. Exposure to 95% relative humidity at 160 F. Exceeds Classes E and R. MIL-5015 Meets MIL-STD-202B, Method 106A CORROSION RESISTANCE 48 Hours - Method 1001 MIL-STD-1344 No exposure of base metal. Salt spray: 300 days - No exposure of base metal. CHEMICAL RESISTANCE No requirement Oil, most acids and alkalis. DUST RESISTANCE No requirement Meets MIL-STD-202B, Method 110, Condition B SHOCK RESISTANCE 50 G minimum Exceeds 60 G's Certain inserts available to 200 G. VIBRATION Method 2005 Method II MIL-STD-1344 Exceeds Method II & MIL-STD-167-1 (Ships). TEST PROBE ABUSE Contact size No. 16 and No. 18 Exceeds MIL-5015 on all contacts No. 18 through 4/0. The double-lead Acme thread is a moderate torque quick-coupling thread which permits complete coupling in approximately one turn of the coupling nut. In addition, there are actually two parallel threads having starting points 180 degrees apart. All of this ensures that plugs and receptacles are being mated or unmated axially. The thread contour makes it self-cleaning. One parallel thread removed to show actual thread angle. Standard double-lead Acme. Two parallel threads. Wire Limitation Guide There are restrictions to the maximum diameter of wire as they relate to the rear or wire side of the connector insert as follows. Mod I. When wires are passed through the rigid back insulation for ease of soldering: Wire size Maximum diameter #4/0 .747" #1/0 .555" #4 .400" #8 .262" #10 .201" #12 .150" #16 .107" #18 .086" Mod II & III #10 .248" #12 .193" #16 .130" #18 .110" Amphenol STAR-LINE(R) MOD I INDUSTRIAL Captive Contact Inserts Shell Seal Adapter Seal Double Lead Acme Thread Pressure Pad Adapter Washer Pressure Pad Cable Adapter Plug Shell Receptacle Shell Rigid Front Insulator Coupling Nut Resilient Contact Seal Laminant Rigid Rear Insulator The combined "sandwich" provides all the advantages of resilient mounting plus all the advantages of rigid mounting, with none of the shortcomings of either. Under pressure, between a shoulder and a thrust washer, the silicone reacts as a fluid and being non-compressible, flows against all surfaces to affect a reliable seal around the periphery of the insert and around all contacts where they penetrate the insulation. Contact cavities are clearly numbered on the front and rear insert face to facilitate identification during assembly, inspection and maintenance. Socket insulator contact cavities are of a bellmouth guided entry design. These chamfered leadins insure easy and positive mating of male contacts. Self-sealing Construction: all MOD I captive contact inserts are capable of being terminated after assembly in the basic barrel and are completely self-sealing when pressurized by any selected adapter. Water, gas, vapor, moisture or dust positively cannot pass in either direction through or around the insulation. The "sandwich" construction of MOD I inserts consists of a resilient silicone laminate between two rigid plastic insulators. The resilient laminate seals absorbs shock and vibration and allows the contacts to align themselves freely. The rigid faced plastic insulators impart just the right amount of restraint to retain the contacts in place. MOD II Insertable/Removable Crimp Contact Inserts Shell Seal Contact Seal Double Lead Acme Thread Insert Seal Adapter Seal Adapter Washer Pressure Sleeve Red Green Pressurizing Sleeve Plug Barrel Receptacle Barrel Cable Adapter Rigid Insulator Coupling Nut Resilient Insulator against leakage between the insert and shell, absorb shock and vibration, provide electrical insulation between contacts and retain the contacts in the connector. Contacts may be inserted and removed without degradation of the retention or environmental capability. The front rigid portion of the insert functions to stabilize and ensure positive alignment of the contacts. Contact cavities are clearly numbered on the front and rear insert face to facilitate identification during assembling, inspection and maintenance. Socket insulator contact cavities are of a bellmouth guided entry design. These chamfered leadins ensure easy and positive mating of male contacts. MOD II insulations have one less rigid disc than their MOD I counterparts. Individual unmounted contacts are crimped to their respective wires outside of the connector where ample working space is available. The crimping operation can be by hand or power operated tool. Contacts with crimped joint intact are inserted one by one, with a hand tool, into the insulation premounted within the connector barrel shell. The resilient portion of the insert functions to seal around the contacts and prevent leakage through contact cavities, seal STAR-LINE(R) Custom Build your own connectors Power Connectors - 20-30-60-100-200-325-700 Amperes, 1 thru 10 Contacts Control & Instrumentation Connectors - 3 thru 143 Contacts The following pages present connector sub-assemblies which are available and can be used in conjunction with the inserts listed. PIN INSERT CONFIGURATION PLUG CONFIGURATION RECEPTACLE CONFIGURATION SOCKET INSERT CONFIGURATION ordering information All plug and receptacle assemblies require two part numbers: A. The catalog number of the desired insert. B. The catalog number of the selected plug or receptacle hardware. To Order Complete Assemblies 1. Determine supply voltage, amperage and number of contacts desired. 2. Select insert configuration from pages 37-63. Write down Dash Number, Shell Size and MOD number of insert. Voltage and amperage information can be found on page 30. Example: 3#12 contacts - 27P (MALE) and 27S (FEMALE); MOD I; Shell Size 12 (page 37). 3. Select desired plug and receptacle hardware from pages 9-28. Make certain that the shell size of the hardware corresponds with the shell size of the desired insert. Determine outside diameter of cable. Example: Male Plug with Basket Weave. Cable is 3 conductor #12 (.635 outside diameter). ZPLK-1212-27P (page 15). Female Receptacle mounted to Junction Box with 45 Angle Adapter and 1" Conduit Hub. ZRLBB-312-27S (page 23). 4. Order tools from pages 76-77. To Order Assemblies Without The Insert (For large users stocking connector components in bulk) 1. If a MOD I insert will be used, order the hardware by the catalog number and eliminate the asterisk. Example: ZPLD-1212 (page 12). 2. If a MOD II insert will be used, order by the catalog number but substitute a 200 for the asterisk. Example: zpld-1212-200 3. MOD III inserts must be ordered assembled in their basic barrel (consult Amphenol Industrial Operations). Amphenol STAR-LINE(R) INDUSTRIAL please read carefully: 1. 2. 3.To insure proper coupling the following torque values should be used on the coupling nut: Hardware with a longer cable housing should be used if the insert has: A. Any pressure contact - line or ground. B. More than 10 contacts-any size. C. More than 4 #10 or larger contacts. Shell Size 12 16 20 C20 24 C24 28 C28 A jack coupling nut should be used if the insert has: A. A configuration with shorter relay contacts. B. A configuration of 37 or more contacts. A JACK COUPLING NUT SHOULD NOT BE USED ON ANY POWER INSERT CONNECTOR THAT IS TO BE DISCONNECTED UNDER LOAD Torque Setting (lb. ft.) 11.0 13.5 15.5 15.5 23.0 23.0 31.0 31.0 NOTE: The N.E.C. circuit breaking and non-circuit breaking ratings are based on test results of contacts and connectors. Consult the N.E.C. when selecting wire/cable for specific applications. Under certain conditions, a wire size may be rated higher or lower than our table indicates for a given contact size. Connector Assemblies typical mod I plug components MECHANICAL CLAMP NUT MALE INSERT GROMMET WASHER CABLE ADAPTER COUPLING NUT PIN CONTACTS ENVIRONMENTAL COVER - MALE MALE SKIRT typical mod I receptacle components FLANGE GASKET ENVIRONMENTAL COVER - FEMALE SQUARE FLANGE RECEPTACLE SOCKET CONTACTS FEMALE INSERT INSERT CLAMP NUT STAR-LINE(R) Connector Basic Components Typical Assemblies Amphenol STAR-LINE(R) INDUSTRIAL Code Logic Star-Line Series Cable Mounted Connectors Z P Environmental Cover / L for no cover Long cable adapter / Blank for standard length E L K Insert pattern (32 for solder / Grommet 332 for code number Mod 2 crimp / (cable dia.) J- 18 20- 332- Shell size Kellems of connector (Basket weave grip) / (physical size)/ M for C before Mechanical shell number nut clamp / Jack nut for 100 amp. D for (37 conductors & higher gland nut or more / Do not use for P for Plug / "C" power R for cable applications / mounted 100 amp or greater) Receptable (Inline) N for crimp contact / R for pressure / Blank for solder P N Optional Alternate Key Position K K for gold plated contact / Blank for standard Product Series Prefix Z- Star-Line P for Pin (male) / S for socket (female) Fixed Connectors Environmental Cover / L for no cover / C for flip cover Z R E Product Series Prefix Z- Star-Line P- 20- 332- Am phe no HS Ro l E /2 002 / 95 / C E U S N K N for crimp contact / R for pressure / Blank for Insert pattern solder (32 for solder / 332 for Mod 2 crimp) P for panel mount / BB for back box (see pg. 22) R for receptacle / P for plug RoHS COMPLIANT PRODUCT AVAILABLE - Consult Amphenol Industrial Operations. Shell size of connector K for gold plated contact / Blank for standard S for socket (female) / P for pin (male) -01 -01 Optional Alternate Key Position STAR-LINE(R) Straight Plug with standard compression nut To specify a complete plug, substitute the Dash No. of the contact insert selected, for the Asterisk (*) in the Catalog No. below. Types ZPLD ZPED Size Shell Cable Size Cat. No. With Standard Coupling Nut 12 ZPLD--12-* 16 ZPLD--16-* 20 ZPLD--20-* C20 ZPLD--C20-* 24 ZPLD--24-* Select C24 ZPLD--C24-* from 28 ZPLD--28-* Table Below C28 ZPLD--C28-* and Substitute 12 ZPLDL--12-* Symbol No. 16 ZPLDL--16-* for Delta 20 ZPLDL--20-* C20 ZPLDL--C20-* 24 ZPLDL--24-* C24 ZPLDL--C24-* 28 ZPLDL--28-* C28 ZPLDL--C28-* DIMENSIONS Catalog No. WITH STANDARD CABLE ADAPTER With Jack A B CCoupling Nut 5-3/8 1-13/16 5-31/32 5-5/8 2-5/16 5-7/32 6-1/8 2-13/16 6-23/32 6-5/8 2-13/16 7-7/32 6-5/8 3-5/16 7-7/32 7-1/8 3-5/16 7-23/32 7-1/8 3-13/16 7-23/32 7-5/8 3-13/16 8-7/32 WITH LONG CABLE ADAPTER 7-5/8 1-13/16 8-7/32 7-7/8 2-5/16 8-15/32 8-3/8 2-13/16 8-31/32 8-7/8 2-13/16 9-15/32 8-7/8 3-5/16 9-15/32 9-3/8 3-5/16 9-31/32 9-1/8 3-13/16 9-23/32 9-5/8 3-13/16 10-7/32 A ZPLDJ--12-* ZPLDJ--16-* ZPLDJ--20-* ZPLDJ--C20-* ZPLDJ--24-* ZPLDJ--C24-* ZPLDJ--28-* ZPLDJ--C28-* ZPLDLJ--12-* ZPLDLJ--16-* ZPLDLJ--20-* ZPLDLJ--C20-* ZPLDLJ--24-* ZPLDLJ--C24-* ZPLDLJ--28-* ZPLDLJ--C28-* B Safety wire holes (3) .062 DIA. C To specify plug with environmental cover, change third letter in Part No. "L' to "E'. Example: ZPLD changes to ZPED. OIL-RESISTANT RUBBER GROMMETS--SYMBOL NUMBERS OF SIZES AVAILABLE Substitute the symbol number for the Delta in the catalog number of plug. Example: ZPLD- -12-* for .500 to .625 Dia. Cable changes to ZPLD-10 12-* Shell 12 Shell 16 .062 to .125 .125 to .250 .250 to .375 .375 to .500 .500 to .625 02 04 06 08 10 - - 06 08 10 - - - - 10 - - - - - - - - - - .625 to .750 .750 to .875 .875 to .937 .937 to 1.000 1.000 to 1.125 12 14 15 - - 12 14 - 16 18 12 14 - 16 18 - - - 16 18 1.125 to 1.250 1.250 to 1.375 1.375 to 1.437 1.437 to 1.500 - - - - 20 22 23 - 20 22 - 24 20 22 - 24 Cable Dia. Shells Shells Shells 20 & C20 24 & C24 28 & C28 Cable Dia. Shell 12 Shell 16 1.500 to 1.625 1.625 to 1.750 1.750 to 1.875 1.875 to 1.937 1.937 to 2.000 - - - - - - - - - - 26 28 30 31 - 26 28 30 - 32 26 28 30 - 32 - - - - - 2.000 to 2.125 2.125 to 2.250 2.250 to 2.375 2.375 to 2.437 2.437 to 2.500 - - - - - - - - - - - - - - - 34 36 38 39 - 34 36 38 - 40 - - - 24 2.500 to 2.625 2.625 to 2.750 2.750 to 2.875 - - - - - - - - - - - - 42 44 46 10 Shell Shells Shells 20 & C20 24 & C24 28 & C28 Amphenol STAR-LINE(R) INDUSTRIAL Straight Plug with Mechanical Clamp Nut To specify a complete plug, substitute the Dash No. of the contact insert selected, for the Asterisk (*) in the Catalog No. below. Types ZPLM ZPEM Size Cable Shell Size Select from Table Below and Substitute Symbol No. for Delta Cat. No. With Standard Coupling Nut 12 16 20 C20 24 C24 28 C28 ZPLM--12-* ZPLM--16-* ZPLM--20-* ZPLM--C20-* ZPLM--24-* ZPLM--C24-* ZPLM--28-* ZPLM--C28-* 6-1/8 6-7/16 7 7-1/2 7-9/16 8-1/16 8-1/8 8-5/8 A DIMENSIONS WITH STANDARD CABLE ADAPTER B C D 12 16 20 C20 24 C24 28 C28 ZPLML--12-* ZPLML--16-* ZPLML--20-* ZPLML--C20-* ZPLML--24-* ZPLML--C24-* ZPLML--28-* ZPLML--C28-* 8-3/8 8-11/16 9-1/4 9-3/4 9-13/16 10-5/16 10-1/8 10-5/8 WITH LONG CABLE ADAPTER 1-13/16 8-31/32 2-3/8 2-5/16 9-9/32 3 2-13/16 9-27/32 3-3/4 2-13/16 10-11/32 3-3/4 3-5/16 10-13/32 4-1/2 3-5/16 10-29/32 4-1/2 3-13/16 10-23/32 5-1/8 3-13/16 11-7/32 5-1/8 1-13/16 2-5/16 2-13/16 2-13/16 3-5/16 3-5/16 3-13/16 3-13/16 6-23/32 7-1/32 7-19/32 8-3/32 8-5/32 8-21/32 8-23/32 9-7/32 Catalog No. With Jack Coupling Nut E 2-3/8 3 3-3/4 3-3/4 4-1/2 4-1/2 5-1/8 5-1/8 1-3/4 2-1/4 2-3/4 2-3/4 3-1/4 3-1/4 3-3/4 3-3/4 ZPLMJ--12-* ZPLMJ--16-* ZPLMJ--20-* ZPLMJ--C20-* ZPLMJ--24-* ZPLMJ--C24-* ZPLMJ--28-* ZPLMJ--C28-* 1-3/4 2-1/4 2-3/4 2-3/4 3-1/4 3-1/4 3-3/4 3-3/4 ZPLMLJ--12-* ZPLMLJ--16-* ZPLMLJ--20-* ZPLMLJ--C20-* ZPLMLJ--24-* ZPLMLJ--C24-* ZPLMLJ--28-* ZPLMLJ--C28-* B A E Reversible clamps for complete cable range D Max. Safety wire holes (3) .062 DIA. C To specify plug with environmental cover, change third letter in Part No. "L' to "E'. Example: ZPLM changes to ZPEM. OIL-RESISTANT RUBBER GROMMETS--SYMBOL NUMBERS OF SIZES AVAILABLE Substitute the symbol number for the Delta in the catalog number of plug. Example: ZPLM- -12-* for .500 to .625 Dia. Cable changes to ZPLM-10 12-* Shell 12 Shell 16 .062 to .125 .125 to .250 .250 to .375 .375 to .500 .500 to .625 02 04 06 08 10 - - 06 08 10 - - - - 10 - - - - - .625 to .750 .750 to .875 .875 to .937 .875 to 1.000 1.000 to 1.125 12 14 15 - - 12 14 - 16 18 12 14 - 16 18 1.125 to 1.250 1.250 to 1.375 1.375 to 1.437 1.375 to 1.500 - - - - 20 22 23 - 20 22 - 24 Cable Dia. Shells Shells Shells 20 & C20 24 & C24 28 & C28 Cable Dia. Shell 12 Shell 16 - - - - - 1.500 to 1.625 1.625 to 1.750 1.750 to 1.875 1.875 to 1.937 1.875 to 2.000 - - - - - - - - - - 26 28 30 31 - 26 28 30 - 32 26 28 30 - 32 - - - 16 18 - - - - - 2.000 to 2.125 2.125 to 2.250 2.250 to 2.375 2.375 to 2.437 2.375 to 2.500 - - - - - - - - - - - - - - - 34 36 38 39 - 34 36 38 - 40 20 22 - 24 - - - 24 2.500 to 2.625 2.625 to 2.750 2.750 to 2.875 - - - - - - - - - - - - 42 44 46 11 Shell Shells Shells 20 & C20 24 & C24 28 & C28 STAR-LINE(R) Straight Plug with conduit adapter (for flexible conduit fittings) To specify a complete plug, substitute the dash no. of the contact insert selected for the asterisk (*) In the catalog no. below. A PLUG WITH JACK COUPLING NUT SHOULD BE USED WITH INSERTS HAVING 37 OR MORE CONTACTS. Shell Size 12 16 20 C20 24 C24 28 C28 Size Conduit 3/4 1-1/4 1-1/2 1-1/2 2 2 2-1/2 2-1/2 Catalog No. With Standard Coupling Nut ZplT-2 12-* ZplT-4 16-* ZplT-5 20-* ZplT-5 C20-* ZplT-6 24-* ZplT-6 C24-* zplT-7 28-* zplT-7 C28-* DIMENSIONS B C 1-13/16 4-27-32 2-5/16 4-31/32 2-13/16 5-3/32 2-13/16 5-19/32 3-5/16 5-7/32 3-5/16 5-23/32 3-13/16 5-11/16 3-13/16 6-3/16 A 4-1/4 4-3/8 4-1/2 5 4-5/8 5-1/8 5-3/32 5-19/32 A D NPT Thread Size Types ZPLT ZPET Catalog No. With Jack Coupling Nut ZPLTJ-2 12-* ZPLTJ-4 16-* ZPLTJ-5 20-* ZPLTJ-5 C20-* ZPLTJ-6 24-* ZPLTJ-6 C24-* ZPLTJ-7 28-* ZPLTJ-7 C28-* D 3/4 1-1/4 1-1/2 1-1/2 2 2 2-1/2 2-1/2 B Safety Wire Holes (3) .062 DIA. C To specify plug with environmental cover, change third letter in Part No. "L" to "E". Example: ZPLT changes to ZPET. Straight Male Plug Panel Mount To specify a complete plug, substitute the dash no. of the contact insert selected for the asterisk (*) in the catalog no. below. A PLUG WITH JACK COUPLING NUT SHOULD BE USED WITH INSERTS HAVING 37 OR MORE CONTACTS. Shell Size 12 16 20 C20 24 C24 28 C28 Open Back Use with or without Potting Sleeve Catalog No. With Standard Coupling Nut ZplP-12-* ZplP-16-* ZplP-20-* ZplP-C20-* ZplP-24-* ZplP-C24-* ZplP-28-* zplP-C28-* A Types ZPLP ZPEP DIMENSIONS A 2-3/8 2-13/32 2-7/16 2-15/16 2-15/32 2-31/32 2-15/32 2-31/32 B 1-13/16 2-5/16 2-13/16 2-13/16 3-5/16 3-5/16 3-13/16 3-13/16 C C 2-31/32 3 3-1/32 3-17/32 3-1/16 3-9/16 3-1/16 3-9/16 J Hole Dia. G 1-17/64 1-11/16 2-3/32 2-3/32 2-17/32 2-17/32 3-1/32 3-1/32 H 1-5/8 2-1/8 2-5/8 2-5/8 3-1/8 3-1/8 3-3/4 3-3/4 B G SQ. H SQ. 12 Safety Wire Holes (3) .062 Dia. J 3/16 7/32 9/32 9/32 11/32 11/32 11/32 11/32 Catalog No. With Jack Coupling Nut ZPLPJ- 12-* ZPLPJ- 16-* ZPLPJ- 20-* ZPLPJ- C20-* ZPLPJ- 24-* ZPLPJ- C24-* ZPLPJ- 28-* ZPLPJ- C28-* To specify plug with environmental cover, change third letter in Part No. "L" to "E". Example: ZPLP changes to ZPEP. Amphenol STAR-LINE(R) INDUSTRIAL Straight Plug With Basketweave Cable Grip To specify a complete plug, substitute the Dash No. of the contact insert selected for the asterisk (*) in the catalog no. below. A PLUG WITH JACK COUPLING NUT SHOULD BE USED WITH INSERTS HAVING 37 OR MORE CONTACTS Size Cable Shell Size Catalog No. With Standard Coupling Nut Zplk--12-* Zplk--16-* Zplk--20-* Zplk--C20-* Zplk--24-* Zplk--C24-* zplk--28-* zplk--C28-* 12 16 20 C20 24 C24 28 C28 Select from Table Below and Substitute Symbol No. for Delta Types ZPLK ZPEK DIMENSIONS WITH STANDARD CABLE ADAPTER A B C 5-3/8 1-13/16 5-31/32 5-5/8 2-5/16 6-7/32 6-1/8 2-13/16 6-23/32 6-5/8 2-13/16 7-7/32 6-5/8 3-5/16 7-7/32 7-1/8 3-5/16 7-23/32 7-1/8 3-13/16 7-23/32 7-5/8 3-13/16 8-7/32 Catalog No. With Jack Coupling Nut ZPLKJ--12-* ZPLKJ--16-* ZPLKJ--20-* ZPLKJ--C20-* ZPLKJ--24-* ZPLKJ--C24-* ZPLKJ--28-* ZPLKJ--C28-* WITH LONG CABLE ADAPTER 12 16 20 C20 24 C24 28 C28 ZplkL--12-* ZplkL--16-* ZplkL--20-* ZplkL--C20-* ZplkL--24-* ZplkL--C24-* zplkL--28-* zplkL--C28-* 7-5/8 7-7/8 8-3/8 8-7/8 8-7/8 9-3/8 9-1/8 9-5/8 1-13/16 2-5/16 2-13/16 2-13/16 3-5/16 3-5/16 3-13/16 3-13/16 8-7/32 8-15/32 8-31/32 9-15/32 9-15/32 9-31/32 9-23/32 10-7/32 A See cable grip components page for basket weave grip lengths ZPLKJ--12-* ZPLKJ--16-* ZPLKJ--20-* ZPLKJ--C20-* ZPLKJ--24-* ZPLKJ--C24-* ZPLKJ--28-* ZPLKJ--C28-* B C Safety wire holes (3) .062 DIA. To specify plug with environmental cover, change third letter in Part No. "L" to "E". Example: ZPLK changes to ZPEK. OIL-RESISTANT RUBBER GROMMETS--SYMBOL NUMBERS OF SIZES AVAILABLE Substitute the symbol number for the Delta in the catalog number of plug. Example: ZPLK- -12-* for .500 to .625 Dia. Cable changes to ZPLK-10 12-* Cable Dia. Shell 12 Shell 16 Shells Shells Shells 20 & C20 24 & C24 28 & C28 Cable Dia. Shell 12 Shell 16 Shell 20 & C20 .062 to .125 .125 to .250 .250 to .375 .375 to .500 .500 to .625 02 04 06 08 10 - - 06 08 10 - - - - 10 - - - - - .625 to .750 .750 to .875 .875 to .937 .875 to 1.000 1.000 to 1.125 12 14 15 - - 12 14 - 16 18 12 14 - 16 18 1.125 to 1.250 1.250 to 1.375 1.375 to 1.437 1.375 to 1.500 - - - - 20 22 23 - 20 22 - 24 - - - - - 1.500 to 1.625 1.625 to 1.750 1.750 to 1.875 1.875 to 1.937 1.875 to 2.000 - - - - - - - - - - 26 28 30 31 - 26 28 30 - 32 26 28 30 - 32 - - - 16 18 - - - - - 2.000 to 2.125 2.125 to 2.250 2.250 to 2.375 2.375 to 2.437 2.437 to 2.500 - - - - - - - - - - - - - - - 34 36 38 39 - 34 36 38 - 40 20 22 - 24 - - - 24 2.500 to 2.625 2.625 to 2.750 2.750 to 2.875 - - - - - - - - - - - - 42 44 46 13 Shells Shells 24 & C24 28 & C28 STAR-LINE(R) In-Line Receptacle With Mechanical Clamp Nut To specify a complete receptacle, substitute the dash no. of the contact insert selected for the asterisk (*) in the catalog no. below. Size Cable Shell Size DIMENSIONS Cat. No. 12 16 20 C20 24 C24 28 C28 Types ZRLM ZREM ZRLM--12-* ZRLM--16-* ZRLM--20-* ZRLM--C20-* ZRLM--24-* ZRLM--C24-* ZRLM--28-* ZRLM--C28-* A C D E F G 6-1/8 6-7/16 7 7-1/2 7-9/16 8-1/16 8-1/8 8-5/8 6-3/4 7-1/16 7-5/8 8-1/8 8-3/16 8-11/16 8-3/4 9-1/4 1-3/4 2-1/4 2-3/4 2-3/4 3-1/4 3-1/4 3-3/4 3-3/4 1-61/64 2-31/64 3-1/32 3-1/32 3-9/16 3-9/16 4-1/16 4-1/16 1-3/4 2-1/4 2-3/4 2-3/4 3-1/4 3-1/4 3-3/4 3-3/4 2-3/8 3 3-3/4 3-3/4 4-1/2 4-1/2 5-1/8 5-1/8 1-61/64 2-31/64 3-1/32 3-1/32 3-9/16 3-9/16 4-1/16 4-1/16 1-3/4 2-1/4 2-3/4 2-3/4 3-1/4 3-1/4 3-3/4 3-3/4 2-3/8 3 3-3/4 3-3/4 4-1/2 4-1/2 5-1/8 5-1/8 Select from Table Below and Substitute Symbol No. WITH LONG CABLEADAPTER for Delta 12 ZRLML--12-* 8-3/8 9 1-3/4 16 ZRLML--16-* 8-11/16 9-5/16 2-1/4 20 ZRLML--20-* 9-1/4 9-7/8 2-3/4 C20 ZRLML--C20-* 9-3/4 10-3/8 2-3/4 24 ZRLML--24-* 9-13/16 10-7/16 3-1/4 C24 ZRLML--C24-* 10-5/16 10-15/16 3-1/4 28 ZRLML--28-* 10-1/8 10-3/4 3-3/4 C28 ZRLML--C28-* 10-5/8 11-1/4 3-3/4 A To specify receptacle with threaded environmental cover, change third letter in Part No. "L" to "E". Example: ZRLM changes to Zrem. OIL-RESISTANT RUBBER GROMMETS--SYMBOL NUMBERS OF SIZES AVAILABLE Substitute the symbol number for the Delta in the catalog number of plug. Example: ZRLM--12-* for .500 to .625 Dia. cable changes to ZRLM-10 12-* Cable Dia. Shell 12 Shell 16 Shells Shells Shells 20 & C20 24 & C24 28 & C28 Cable Dia. Shell 12 Shell 16 .062 to .125 .125 to .250 .250 to .375 .375 to .500 .500 to .625 02 04 06 08 10 - - 06 08 10 - - - - 10 - - - - - .625 to .750 .750 to .875 .875 to .937 .875 to 1.000 1.000 to 1.125 12 14 15 - - 12 14 - 16 18 12 14 - 16 18 1.125 to 1.250 1.250 to 1.375 1.375 to 1.437 1.375 to 1.500 - - - - 20 22 23 - 20 22 - 24 - - - - - 1.500 to 1.625 1.625 to 1.750 1.750 to 1.875 1.875 to 1.937 1.875 to 2.000 - - - - - - - - - - 26 28 30 31 - 26 28 30 - 32 26 28 30 - 32 - - - 16 18 - - - - - 2.000 to 2.125 2.125 to 2.250 2.250 to 2.375 2.375 to 2.437 2.437 to 2.500 - - - - - - - - - - - - - - - 34 36 38 39 - 34 36 38 - 40 20 22 - 24 - - - 24 2.500 to 2.625 2.625 to 2.750 2.750 to 2.875 - - - - - - - - - - - - 42 44 46 14 Shell Shells 20 & C20 24 & C24 Shells 28 & C28 Amphenol STAR-LINE(R) INDUSTRIAL In-Line Receptacle with standard compression nut To specify a complete receptacle, substitute the dash no. of the contact insert selected for the asterisk (*) in the catalog no. below. Size Cable Shell Size Types ZRLD ZRED Dimensions Cat. No. A C 12 ZRLD-- 12-* 5-3/8 6 16 ZRLD-- 16-* 5-5/8 6-1/4 20 ZRLD-- 20-* 6-1/8 6-3/4 C20 ZRLD-- C20-* 6-5/8 7-1/4 24 ZRLD-- 24-* 6-5/8 7-1/4 C24 ZRLD-- C24-* 7-1/8 7-3/4 Select 28 ZRLD-- 28-* 7-1/8 7-3/4 from C28 ZRLD-- C28-* 7-5/8 8-1/4 Table Below With Long Cable Adapter and Substitute 12 ZRLDL--12-* 7-5/8 8-1/4 Symbol No. 16 ZRLDL--16-* 7-7/8 8-1/2 for Delta 20 ZRLDL--20-* 8-3/8 9 C20 ZRLDL--C20-* 8-7/8 9-1/2 24 ZRLDL--24-* 8-7/8 9-1/2 C24 ZRLDL--C24-* 9-3/8 10 28 ZRLDL--28-* 9-1/8 9-3/4 C28 ZRLDL--C28-* 9-5/8 10-1/4 D E 1-3/4 2-1/4 2-3/4 2-3/4 3-1/4 3-1/4 3-3/4 3-3/4 1-61/64 2-31/64 3-1/32 3-1/32 3-9/16 3-9/16 4-1/16 4-1/16 1-3/4 2-1/4 2-3/4 2-3/4 3-1/4 3-1/4 3-3/4 3-3/4 1-61/64 2-31/64 3-1/32 3-1/32 3-9/16 3-9/16 4-1/16 4-1/16 A D E Safety Wire Holes (3).062 Dia. C To specify receptacle with threaded environmental cover, change third letter in Part No. "L" to "E". Example: ZRLD changes to ZreD. OIL-RESISTANT RUBBER GROMMETS--SYMBOL NUMBERS OF SIZES AVAILABLE Substitute the symbol number for the Delta in the catalog number of plug. Example: ZRLD--12-* for .500 to .625 Dia. cable changes to ZRLD-10 12-* Cable Dia. Shell 12 Shell 16 Shells Shells Shells 20 & C20 24 & C24 28 & C28 Cable Dia. Shell 12 Shell 16 Shell 20 & C20 .062 to .125 .125 to .250 .250 to .375 .375 to .500 .500 to .625 02 04 06 08 10 - - 06 08 10 - - - - 10 - - - - - .625 to .750 .750 to .875 .875 to .937 .875 to 1.000 1.000 to 1.125 12 14 15 - - 12 14 - 16 18 12 14 - 16 18 1.125 to 1.250 1.250 to 1.375 1.375 to 1.437 1.375 to 1.500 - - - - 20 22 23 - 20 22 - 24 - - - - - 1.500 to 1.625 1.625 to 1.750 1.750 to 1.875 1.875 to 1.937 1.875 to 2.000 - - - - - - - - - - 26 28 30 31 - 26 28 30 - 32 26 28 30 - 32 - - - 16 18 - - - - - 2.000 to 2.125 2.125 to 2.250 2.250 to 2.375 2.375 to 2.437 2.437 to 2.500 - - - - - - - - - - - - - - - 34 36 38 39 - 34 36 38 - 40 20 22 - 24 - - - 24 2.500 to 2.625 2.625 to 2.750 2.750 to 2.875 - - - - - - - - - - - - 42 44 46 15 Shells Shells 24 & C24 28 & C28 STAR-LINE(R) In-Line Receptacle with Basketweave Cable Grip To specify a complete receptacle, substitute the dash no. of the contact insert selected for the asterisk (*) in the catalog no. below. Size Cable Shell Size Types ZRLK ZREK Dimensions Cat. No. A C 12 ZRLK-- 12-* 5-3/8 6 16 ZRLK-- 16-* 5-5/8 6-1/4 6-1/8 6-3/4 20 ZRLK-- 20-* C20 ZRLK-- C20-* 6-5/8 7-1/4 24 ZRLK-- 24-* 6-5/8 7-1/4 C24 ZRLK-- C24-* 7-1/8 7-3/4 Select 7-1/8 7-3/4 28 ZRLK-- 28-* from C28 ZRLK-- C28-* 7-5/8 8-1/4 Table Below With Long Cable Adapter and Substitute 12 ZRLKL--12-* 7-5/8 8-1/4 Symbol No. 7-7/8 8-1/2 16 ZRLKL--16-* for Delta 8-3/8 9 20 ZRLKL--20-* C20 ZRLKL--C20-* 8-7/8 9-1/2 24 ZRLKL--24-* 8-7/8 9-1/2 9-3/8 10 C24 ZRLKL--C24-* 28 ZRLKL--28-* 9-1/8 9-3/4 9-5/8 10-1/4 C28 ZRLKL--C28-* D E 1-3/4 2-1/4 2-3/4 2-3/4 3-1/4 3-1/4 3-3/4 3-3/4 1-61/64 2-31/64 3-1/32 3-1/32 3-9/16 3-9/16 4-1/16 4-1/16 1-3/4 2-1/4 2-3/4 2-3/4 3-1/4 3-1/4 3-3/4 3-3/4 1-61/64 2-31/64 3-1/32 3-1/32 3-9/16 3-9/16 4-1/16 4-1/16 A See cable grip components page for basket weave grip lengths D E Safety Wire Holes (3).062 Dia. C To specify receptacle with threaded environmental cover, change third letter in Part No. "L" to "E". Example: ZRLK changes to ZreK. OIL-RESISTANT RUBBER GROMMETS--SYMBOL NUMBERS OF SIZES AVAILABLE Substitute the symbol number for the Delta in the catalog number of plug. Example: ZRLK--12-* for .500 to .625 Dia. cable changes to ZRLK-10 12-* Cable Dia. Shell 12 Shell 16 Shells Shells Shells 20 & C20 24 & C24 28 & C28 Cable Dia. Shell 12 Shell 16 Shell 20 & C20 .062 to .125 .125 to .250 .250 to .375 .375 to .500 .500 to .625 02 04 06 08 10 - - 06 08 10 - - - - 10 - - - - - .625 to .750 .750 to .875 .875 to .937 .875 to 1.000 1.000 to 1.125 12 14 15 - - 12 14 - 16 18 12 14 - 16 18 1.125 to 1.250 1.250 to 1.375 1.375 to 1.437 1.375 to 1.500 - - - - 20 22 23 - 20 22 - 24 - - - - - 1.500 to 1.625 1.625 to 1.750 1.750 to 1.875 1.875 to 1.937 1.875 to 2.000 - - - - - - - - - - 26 28 30 31 - 26 28 30 - 32 26 28 30 - 32 - - - 16 18 - - - - - 2.000 to 2.125 2.125 to 2.250 2.250 to 2.375 2.375 to 2.437 2.437 to 2.500 - - - - - - - - - - - - - - - 34 36 38 39 - 34 36 38 - 40 20 22 - 24 - - - 24 2.500 to 2.625 2.625 to 2.750 2.750 to 2.875 - - - - - - - - - - - - 42 44 46 16 Shells Shells 24 & C24 28 & C28 Amphenol STAR-LINE(R) INDUSTRIAL In-Line Receptacle with conduit adapter (for flexible conduit fittings) To specify a complete receptacle, substitute the dash no. of the contact insert selected, for the asterisk (*) in the catalog no. below. To specify receptacle with threaded environmental cover, change third letter in part no. "L" to "E"". Shell Size 12 16 20 C20 24 C24 28 C28 Size Conduit 3/4 1-1/4 1-1/2 1-1/2 2 2 2-1/2 2-1/2 Types ZRLT ZRET Dimensions Cat. No. ZRLT-2 12-* ZRLT-4 16-* ZRLT-5 20-* ZRLT-5 C20-* ZRLT-6 24-* ZRLT-6 C24 ZRLT-7 28-* ZRLT-7 C28-* A B C D E 4-1/4 4-3/8 4-1/2 5 4-5/8 5-1/8 5-3/32 5-19/32 3/4 1-1/4 1-1/2 1-1/2 2 2 2-1/2 2-1/2 4-7/8 5 5-1/8 5-5/8 5-1/4 5-3/4 5-23-32 6-7/32 1-3/8 2-1/4 2-3/4 2-3/4 3-1/4 3-1/4 3-3/4 3-3/4 1-61/64 2-15/32 3-1/32 3-1/32 3-9/16 3-9/16 4-1/16 4-1/16 D A B NPT Thread E Safety Wire Holes (3) .062 Dia. C B NPT Thread To specify receptacle with threaded environmental cover, change third letter in Part No. "L" to "E". Example: ZRLT changes to ZRET. 17 STAR-LINE(R) Square Flange Receptacle To specify a complete receptacle, substitute the dash no. of the contact insert selected, for the asterisk (*) in the catalog no. below. Types ZRLP ZRCP ZREP Shell Size 12 16 20 C20 24 C24 28 C28 Open Back Use with or without Potting Sleeves Catalog No. ZRLP- 12-* ZRLP- 16-* ZRLP- 20-* ZRLP- C20-* ZRLP- 24-* ZRLP- C24-* ZRLP- 28-* ZRLP- C28* A 1-3/4 2-1/4 2-3/4 2-3/4 3-1/4 3-1/4 3-3/4 3-3/4 B 1-3/8 1-11/16 2-3/32 2-3/32 2-17/32 2-17/32 3-1/32 3-1/32 C* 1-1/12 2 2-1/2 2-1/2 3 3 3-1/2 3-1/2 DIMENSIONS WITH STANDARD CABLE ADAPTER E F G J K 11/64 2-15/16 2-1/8 1 1-11/32 13/64 2-15/16 2-1/8 1 1-27/32 7/32 2-15/16 2-3/16 1 2-11/32 7/32 3-7/16 2-11/16 1-1/2 2-11/32 9/32 2-15/16 2-3/16 1 2-27/32 9/32 3-7/16 2-11/16 1-1/2 2-27/32 11/32 2-15/16 2-3/16 1 3-11/32 11/32 3-7/16 2-11/16 1-1/2 3-11/32 L 2-21/64 2-21/64 2-21/64 2-53/64 2-21/64 2-53/64 2-21/64 2-53/64 N 1/4 1/4 1/4 3/4 1/4 3/4 1/4 3/4 L A Sq. B Sq. J 3/16 C k Modified Acme thread E hole Dia. WITH THREADED ENVIRONMENTAL COVER AND SASH CHAIN WITH HINGED SPRING COVER G N F 5/8 Max panel thickness when back mounted using jack nut plugs.** E Hole Dia. 1/16" Gasket Fits front or back of flange. To specify receptacle with threaded environmental cover, change third letter in part number from "L" to "E". Example: ZRLP changes to ZREP. To specify receptacle with spring door cover, change third letter in part number from "L" to "C". Example: ZRLP changes to ZRCP. Drill hole in panel 1/64" larger than Dimension "K" for front mounting or dimension "C" for back mounting **Maximum panel thickness may be increased 1/8" when using Standard Coupling Nut Plugs. 18 Amphenol STAR-LINE(R) INDUSTRIAL Square Flange Receptacle with Mechanical Clamp Nut Type ZRLPM ZRCPM ZREPM To specify a complete receptacle, substitute the dash no. of the contact insert selected, for the asterisk (*) in the catalog no. below. Size Cable Shell Size Select from Table Below and Substitute Symbol No. for Delta Dimensions Catalog Number A 12 16 20 C20 24 C24 28 C28 ZRLPM-- 12-* 6-1/8 ZRLPM-- 16-* 6-7/16 ZRLPM-- 20-* 7 ZRLPM-- C20-* 7-1/2 ZRLPM-- 24-* 7-9/16 ZRLPM-- C24-* 8-1/16 ZRLPM-- 28-* 8-1/8 ZRLPM-- C28-* 8-5/8 12 16 20 C20 24 C24 28 C28 ZRLPML--12-* 8-3/8 ZRLPML--16-* 8-11/16 ZRLPML--20-* 9-1/4 ZRLPML--C20-* 9-3/4 ZRLPML--24-* 9-13/16 ZRLPML--C24-* 10-5/16 ZRLPML--28-* 10-1/8 ZRLPML--C28-* 10-5/8 B C D E 1-3/4 6-3/4 1-3/8 11/64 2-1/4 7-1/16 1-11/16 13/64 2-3/4 7-5/8 2-3/32 7/32 2-3/4 8-1/8 2-3/32 7/32 3-1/4 8-3/16 2-17/32 9/32 3-1/4 8-11/16 2-17/32 9/32 3-3/4 8-3/4 3-1/32 11/32 3-3/4 9-1/4 3-1/32 11/32 With Long Cable Adapter 1-3/4 9 1-3/8 11/64 2-1/4 9-5/16 1-11/16 13/64 2-3/4 9-7/8 2-3/32 7/32 2-3/4 10-3/8 2-3/32 7/32 3-1/4 10-7/16 2-17/32 9/32 3-1/4 10-15/16 2-17/32 9/32 3-3/4 10-3/4 3-1/32 11/32 3-3/4 11-1/4 3-1/32 11/32 F N 2-3/8 3 3-3/4 3-3/4 4-1/2 4-1/2 5-1/8 5-1/8 G 1-1/2 2 2-1/2 2-1/2 3 3 3-1/2 3-1/2 1/4 1/4 1/4 3/4 1/4 3/4 1/4 3/4 1-3/4 2-1/4 2-3/4 2-3/4 3-1/4 3-1/4 3-3/4 3-3/4 2-3/8 3 3-3/4 3-3/4 4-1/2 4-1/2 5-1/8 5-1/8 1-1/2 2 2-1/2 2-1/2 3 3 3-1/2 3-1/2 1/4 1/4 1/4 3/4 1/4 3/4 1/4 3/4 B Sq. D Sq. A Drill hole in panel 1/64" larger than Dimension "H" for back mounting.. H F Reversible clamps for complete cable range G Max. H 1-3/4 2-1/4 2-3/4 2-3/4 3-1/4 3-1/4 3-3/4 3-3/4 1/16" Gasket fits front or back of flange E hole Dia. E Hole Dia. C To specify receptacle with threaded environmental cover, change third letter in Part No. "L" to "E". Example: ZRLPM changes to ZrePm. N To specify receptacle with spring door cover, change third letter in Part No. "L" to "C". Example: ZRLPM changes to ZrCPm. OIL-RESISTANT RUBBER GROMMETS--SYMBOL NUMBERS OF SIZES AVAILABLE Substitute the symbol number for the Delta in the catalog number of plug. Example: ZRLK--12-* for .500 to .625 Dia. cable changes to ZREK-10 12-* Cable Dia. Shell 12 Shell 16 Shells Shells Shells 20 & C20 24 & C24 28 & C28 Cable Dia. Shell 12 Shell 16 Shell 20 & C20 .062 to .125 .125 to .250 .250 to .375 .375 to .500 .500 to .625 02 04 06 08 10 - - 06 08 10 - - - - 10 - - - - - .625 to .750 .750 to .875 .875 to .937 .875 to 1.000 1.000 to 1.125 12 14 15 - - 12 14 - 16 18 12 14 - 16 18 1.125 to 1.250 1.250 to 1.375 1.375 to 1.437 1.375 to 1.500 - - - - 20 22 23 - 20 22 - 24 - - - - - 1.500 to 1.625 1.625 to 1.750 1.750 to 1.875 1.875 to 1.937 1.875 to 2.000 - - - - - - - - - - 26 28 30 31 - 26 28 30 - 32 26 28 30 - 32 - - - 16 18 - - - - - 2.000 to 2.125 2.125 to 2.250 2.250 to 2.375 2.375 to 2.437 2.437 to 2.500 - - - - - - - - - - - - - - - 34 36 38 39 - 34 36 38 - 40 20 22 - 24 - - - 24 2.500 to 2.625 2.625 to 2.750 2.750 to 2.875 - - - - - - - - - - - - 42 44 46 19 Shells Shells 24 & C24 28 & C28 STAR-LINE(R) Square Flange Receptacle with Basketweave Cable Grip To specify a complete receptacle, substitute the dash no. of the contact insert selected for the asterisk (*) in the catalog no. below. Size Cable Select from Table Below and Substitute Symbol No. for Delta ZRLPK, ZRCPK, ZREPK Dimensions Shell Size Catalog Number A 12 16 20 C20 24 C24 28 C28 ZRLPK-- 12-* ZRLPK-- 16-* ZRLPK-- 20-* ZRLPK-- C20-* ZRLPK-- 24-* ZRLPK-- C24-* ZRLPK-- 28-* ZRLPK-- C28-* 5-3/8 5-5/8 6-1/8 6-5/8 6-5/8 7-1/8 7-1/8 7-5/8 12 16 20 C20 24 C24 28 C28 ZRLPKL--12-* ZRLPKL--16-* ZRLPKL--20-* ZRLPKL--C20-* ZRLPKL--24-* ZRLPKL--C24-* ZRLPKL--28-* ZRLPKL--C28-* 7-5/8 7-7/8 8-3/8 8-7/8 8-7/8 9-3/8 9-1/8 9-5/8 B C D 1-3/4 6 1-3/8 2-1/4 6-1/4 1-11/16 2-3/4 6-3/4 2-3/32 2-3/4 7-1/4 2-3/32 3-1/4 7-1/4 2-17/32 3-1/4 7-3/4 2-17/32 3-3/4 7-3/4 3-1/32 3-3/4 8-1/4 3-1/32 With Long CableAdapter 1-3/4 8-1/4 1-3/8 2-1/4 8-1/2 1-11/16 2-3/4 9 2-3/32 2-3/4 9-1/2 2-3/32 3-1/4 9-1/2 2-17/32 3-1/4 10 2-17/32 3-3/4 9-3/4 3-1/32 3-3/4 10-1/4 3-1/32 E F G 11/64 13/64 7/32 7/32 9/32 9/3 11/32 11/32 1-1/2 2 2-1/2 2-1/2 3 3 3-1/2 3-1/2 1/4 1/4 1/4 3/4 1/4 3/4 1/4 3/4 11/64 13/64 7/32 7/32 9/32 9/32 11/32 11/32 1-1/2 2 2-1/2 2-1/2 3 3 3-1/2 3-1/2 1/4 1/4 1/4 3/4 1/4 3/4 1/4 1/4 A Drill hole in panel 1/64" larger than Dimension "H" for back mounting.. F C E Hole Dia. To specify receptacle with threaded environmental cover, change third letter in Part No. "L" to "E". Example: ZRLPK changes to ZrePR. G To specify receptacle with spring door cover, change third letter in Part No. "L" to "C". Example: ZRLPM changes to ZrCPR. OIL-RESISTANT RUBBER GROMMETS--SYMBOL NUMBERS OF SIZES AVAILABLE Substitute the symbol number for the Delta in the catalog number of plug. Example: ZRLK--12-* for .500 to .625 Dia. cable changes to ZREK-10 12-* Cable Dia. Shell 12 Shell 16 Shells Shells Shells 20 & C20 24 & C24 28 & C28 Cable Dia. Shell 12 Shell 16 Shell 20 & C20 .062 to .125 .125 to .250 .250 to .375 .375 to .500 .500 to .625 02 04 06 08 10 - - 06 08 10 - - - - 10 - - - - - .625 to .750 .750 to .875 .875 to .937 .875 to 1.000 1.000 to 1.125 12 14 15 - - 12 14 - 16 18 12 14 - 16 18 1.125 to 1.250 1.250 to 1.375 1.375 to 1.437 1.375 to 1.500 - - - - 20 22 23 - 20 22 - 24 - - - - - 1.500 to 1.625 1.625 to 1.750 1.750 to 1.875 1.875 to 1.937 1.875 to 2.000 - - - - - - - - - - 26 28 30 31 - 26 28 30 - 32 26 28 30 - 32 - - - 16 18 - - - - - 2.000 to 2.125 2.125 to 2.250 2.250 to 2.375 2.375 to 2.437 2.437 to 2.500 - - - - - - - - - - - - - - - 34 36 38 39 - 34 36 38 - 40 20 22 - 24 - - - 24 2.500 to 2.625 2.625 to 2.750 2.750 to 2.875 - - - - - - - - - - - - 42 44 46 20 Shells Shells 24 & C24 28 & C28 Amphenol STAR-LINE(R) INDUSTRIAL Receptacle Mounted to Junction Box with angle adapter To specify a complete receptacle, substitute the dash no. of the contact insert selected, for the asterisk (*) in the catalog no. below. Shell Size Hub Size 3/4 1 1 1-1/4 1-1/2 1-1/4 1-1/2 2 1-1/4 1-1/2 2 2-1/2 3 2-1/2 3 2-1/2 3 2-1/2 3 12 16 20 C20 24 C24 28 C28 Cat. No. ZRLBB- 2 12-* ZRLBB-3 12-* ZRLBB-3 16-* ZRLBB-4 16-* ZRLBB-5 16-* ZRLBB-4 20-* ZRLBB-5 20-* ZRLBB-6 20-* ZRLBB-4 C20-* ZRLBB-5 C20-* ZRLBB-6 C20-* ZRLBB-7 24-* ZRLBB-8 24-* ZRLBB-7 C24-* ZRLBB-8 C24-* ZRLBB-7 28-* ZRLBB-8 28-* ZRLBB-7 C28-* ZRLBB-8 C28-* A 5-1/4 5-1/4 5-1/4 5-1/4 5-1/4 6 6 6 6 6 6 B 4-5/8 4-5/8 4-5/8 4-5/8 4-5/8 5-1/4 5-1/4 5-1/4 5-1/4 5-1/4 5-1/4 C 4-3/16 4-3/16 4-3/16 4-3/16 4-3/16 4-1/2 4-1/2 4-1/2 4-1/2 4-1/2 4-1/2 8 8 8 8 8 8 8 8 See Drawing Below Types ZRLBB ZRCBB ZREBB Dimensions D 3-9/16 3-9/16 3-9/16 3-9/16 3-9/16 3-7/8 3-7/8 3-7/8 3-7/8 3-7/8 3-7/8 7 7 7 7 7 7 7 7 E 2-3/8 2-3/8 2-3/8 2-5/8 2-5/8 3-3/4 3-3/4 3-3/4 3-3/4 3-3/4 3-3/4 3-3/4 4-1/2 3-3/4 4-1/2 3-3/4 4-1/2 3-3/4 4-1/2 F 2-13/16 2-13/16 2-15/16 2-15/16 2-15/16 3-39/64 3-39/64 3-39/64 3-39/64 3-39/64 3-39/64 3-33/64 3-33/64 3-33/64 3-33-64 3-1/2 3-1/2 3-1/2 3-1/2 G 2-7/16 2-7/16 2-17/32 2-17/32 2-17/32 3 3 3 3-3/8 3-3/8 3-3/8 2-19/64 2-19/64 2-21-32 2-21-32 2-7/64 2-7/64 2-15/32 2-15/32 H 9/32 9/32 9/32 9/32 9/32 9/32 9/32 9/32 9/32 9/32 9/32 7/16 7/16 7/16 7/16 7/16 7/16 7/16 7/16 Other hub sizes are available. Consult Amphenol Industrial Operations. SHELL SIZES 12 - 16 - 20 - C20 HUB SIZE A B SHELL SIZES 24 - C24 - 28 - C28 E 6-3/4 HUB SIZE 5/8 F CD 9-1/2 7 5-3/8 8 G D C B A H 5/8 8 H WITH HINGED SPRING COVER WITH THREADED ENVIRONMENTAL COVER AND SASH CHAIN To specify receptacle with spring door cover, change third letter in part number from "L" to "C". Example: ZRLBB changes to ZRCBB To specify receptacle with threaded environmental cover, change third letter in part number from "L" to "E". Example: ZRLBB changes to ZREBB 21 STAR-LINE(R) Receptacle Mounted to Junction Box with straight adapter To specify a complete receptacle, substitute the dash no. of the contact insert selected, for the asterisk (*) in the catalog no. below. Shell Size 12 16 20 C20 24 C24 28 C28 Hub Size 3/4 1 1 1-1/4 1-1/2 1-1/4 1-1/2 2 1-1/4 1-1/2 2 2-1/2 3 2-1/2 3 2-1/2 3 2-1/2 3 Cat. No. ZRLA- 2 12-* ZRLA-3 12-* ZRLA-3 16-* ZRLA-4 16-* ZRLA-5 16-* ZRLA-4 20-* ZRLA-5 20-* ZRLA-6-20-* ZRLA-4 C20-* ZRLA-5 C20-* ZRLA-6 C20-* ZRLA-7 24-* ZRLA-8 24-* ZRLA-7 C24-* ZRLA-8 C24-* ZRLA-7 28-* ZRLA-8 28-* ZRLA-7 C28-* ZRLA-8 C28-* A 5-1/4 5-1/4 5-1/4 5-1/4 5-1/4 6 6 6 6 6 6 B 4-5/8 4-5/8 4-5/8 4-5/8 4-5/8 5-1/4 5-1/4 5-1/4 5-1/4 5-1/4 5-1/4 C 4-3/16 4-3/16 4-3/16 4-3/16 4-3/16 4-1/2 4-1/2 4-1/2 4-1/2 4-1/2 4-1/2 8 8 8 8 8 8 8 8 See Drawing Below Types ZRLA ZRCA ZREA Dimensions D 3-9/16 3-9/16 3-9/16 3-9/16 3-9/16 3-7/8 3-7/8 3-7/8 3-7/8 3-7/8 3-7/8 7 7 7 7 7 7 7 7 E 2-3/8 2-3/8 2-3/8 2-5/8 2-5/8 3-3/4 3-3/4 3-3/4 3-3/4 3-3/4 3-3/4 3-3/4 4-1/2 3-3/4 4-1/2 3-3/4 4-1/2 3-3/4 4-1/2 F 1-27/32 1-27/32 1-27/32 1-27/32 1-27/32 3-1/16 3-1/16 3-1/16 2-9/16 2-9/16 2-9/16 2-11/32 2-11/32 2-27/32 3-33-64 2-27/32 2-9/32 2-25/32 2-25/32 G 1 1 1 1 1 1-7/32 1-7/32 1-7/32 1-7/32 1-7/32 1-7/32 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 H 9/32 9/32 9/32 9/32 9/32 9/32 9/32 9/32 9/32 9/32 9/32 7/16 7/16 7/16 7/16 7/16 7/16 7/16 7/16 Other hub sizes are available. Consult Amphenol Industrial Operations. SHELL SIZES 12 - 16 - 20 - C20 HUB SIZE A B E SHELL SIZES 24 - C24 - 28 - C28 5/8 F CD D C B A H 6-3/4 HUB SIZE 9-1/2 5-3/8 7 8 G 5/8 WITH HINGED SPRING COVER 8 H WITH THREADED ENVIRONMENTAL COVER AND SASH CHAIN To specify receptacle with spring door cover, change third letter in part number from "L" to "C". Example: ZRLA changes to ZRCA. To specify receptacle with threaded environmental cover, change third letter in part number from "L" to "E". Example: ZRLA changes to ZREA. 22 Amphenol STAR-LINE EX(R) Amphenol(R) Star-Line EX(R) Product Instructions Sections Contents: * Hazardous Location Page * Part Number Guide * EX Gland Code Guide * EX-13 Plug * EX-15 Inline Receptacle * EX-17 Panel Mount Receptacle * Familiarization & Assembly Information * Assembly & Termination * Mixing Instructions * Potting Instructions 23 INDUSTRIAL STAR-LINE EX(R) Star-Line EX(R) Hazardous Certification Information Hazardous Area Equipment Mark Markings for IEC/EN (ATEX) IEC/ATEX (76/117/EEC) Explosion protection Protection method Gas Group Temperature Class Equipment Protection Level Ex d IIC T6 Gb European (EU) ATEX Directive (94/9/EC) CE marking Ingress Protection (IP) Ratings ID# of Notified Body for the QA System EU Explosive Atmosphere symbol Above ground Category Gas, Dust First Number Second Number Protection against solid bodies Protection against Liquids 0 No Protection 0 No Protection 1 Objects greater than 50mm 1 Vertically dripping water 0518 2 Objects greater than 12mm 2 75 to 90 dripping water 3 Objects greater than 2.5mm 3 Sprayed water II 2 GD 4 Objects greater than 1mm 4 Splashed water * 5 Dust-protected 5 Water jets 6 Dust-tight 6 Dust-tight 6 Heavy Seas 7 Temporary immersion * 8 Indefinite immersion HazLoc Hand Chart Temperature Ratings Protection Method IEC/EN (ATEX) ATEX Ex Code Gas Ex Code Dust Category UEC, EU (Europe) Surface USA (NEC 505) Temperature Canada * * 450 C (842 F) T1 300 C (572 F) T2 200 C (392 F) T3 135 C (275 F) T4 100 C (212 F) T5 85 C (185 F) T6 * * Intrinsic Safety ia ib ic 60079-11 60079-11 60079-11 Zone 0 Zone 1 Zone 2 Flameproof d d 60079-1 Zone 1 Enclosure Enclosure Purge & Pressurization px py pz 60079-2 60079-2 60079-2 Note: Star-Line Ex products certification denoted with a *. * * * * 61241-11 61241-11 Zone 20 Zone 21 tD tD 61241-1 61241-1 Zone Zone20, 20,21 21,,22 22 1 2 3 2 2 Zone 1 Zone 1 Zone2 Pressurized (R) iaD ibD 2 2 3 pD 612441-4 Zone 21, 22 maD mbD 61241-18 61241-18 Zone 20 Zone 21 Increased Safety e e 60079-7 60079-7 Zone 1 Encapsulation ma mb 60079-18 60079-18 Zone 0 Zone 1 Oil Immersion o 60079-6 Zone 1 2 Powder Filled q 60079-5 Zone 1 2 Non Incendive nA, nC, nL, nR 60079-15 Zone 2 3 Rooms (draft) p 60079-13 Zone 1 2 Optical Radiation op.. 60079-28 Zone 0 General Requirements 60079-0 Class. of Hazardous Areas 60079-1 Electrical Installations 60079-14 Inspection & Maintenance 60079-17 24 22 1 2 1 61241-0 Amphenol STAR-LINE EX(R) INDUSTRIAL Code Logic Star-Line EX Termination Method "##" code for grommets N for crimp contact / used w/ type "2" or "4" R for pressure / hardware styles(See page 67)/ Letter code designation for Blank for solder Cable Type EEx d gland sizes Omit if unarmored. (see chart below) Blank Aluminum -BS or -BSR S = Stainless Steel Insert (see cable type B = Brass Configuration in charts on next page) EX S Product Series Prefix Example: 13 3 Hardware Style (see pgs. 25-28) C 20 332 Connector Shell Size (12, 16, 20, 24, 28, C20, C24, C28) 13 for Male Plug / 15 for Female Inline/ 17 for Female Panel Mount 18 for Panel Mount Circular Flange 19 for Thru Bulkhead-Dual Mate Receptacle P N -01 -BS Optional Alternate Key Positions Contact Gender P for Male Pin / S for Female Socket A376 Callout to designate T5 temperature rating -20o C to 55o C EX-13-3-C-20-332PN Male Plug with EEX gland for a cable with 0.95" 24.1mm O.D., 20ea #12awg/4mm2 male contacts. EX-15-4-1620-332SN Female Inline with basket weave grip for a cable with 0.95" 24.1mm O.D., 20ea #12awg/4mm2 female contacts. EX-17-1-20-332SN Female Panel Mount, 20ea #12awg/4mm2 female contacts. EX-13-3-C-16-22PR-BS Male Plug with EEX gland for an armored cable with 1.25"/31.75mm O.D., 4ea #4awg/25mm2 male contacts. EX-17-3-C-16-22SR-BS Female Panel Mount with cable adapter with and EEX gland for an armored and sheathed cable. For Amphenol Star-Line product insert de-rating information per the National Electric Code, please consult the Amphenol Industrial website, www.amphenol-industrial.com. Chart is located under literature tab. 25 STAR-LINE EX(R) PRODUCT CERTIFICATIONS Certificate Number: SIRA 03ATEX1101X Cert. No.: IECEx SIR 10.0064X The Starline product family carries all of the industry standard approvals ranging from ATEX and IECEx to UL and CSA. AEx North American Hazloc Listing Consult Factory for Listing No GOST-R Cert. No. MX.96.00012 (TUV) Brasil Cert. No. TUV 11.0147X U (R)L Starline EX offers a full range of hardware styles including the use of EX rated cable glands, mechanical clamps and gland nuts. File Number: E184393 CSA Listed Member: International Association of Drilling Contractors 26 Amphenol STAR-LINE EX(R) INDUSTRIAL EEx d Cable Types EEx d Cable Gland Size Code Unarmored Cable No deviation if Unarmored Min Max A1 .1575 (4.0) A2 A Min UA Armored & Sheathed Cable -BS Standard Max Min Max .3307 (8.4) .3543 (9.0) .5315 (13.5) Armored & Sheathed with reduced bore -BSR OD-Reduced Min Max .3307 (8.4) .1339 (3.4) .2638 (6.7) .4055 (10.3) .2835 (7.2) .4606 (11.7) .2835 (7.2) .4606 (11.7) .4528 (11.5) .6299 (16.0) .3701 (9.4) .4921 (12.5) .3780 (9.6) .5512 (14.0) .3701 (9.4) .5512 (14.0) .6102 (15.5) .8307 (21.1) .4724 (12.0) .6929 (17.6) B .5315 (13.5) .7874 (20.0) .5315 (13.5) .7874 (20.0) .7992 (20.3) 1.079 (27.4) .6614 (16.8) .9409 (23.9) C .7677 (19.5) 1.035 (26.3) .7677 (19.5) 1.035 (26.3) 1.051 (26.7) 1.339 (34.0) .9134 (23.2) 1.201 (30.5) C2 .9055 (23.0) 1.268 (32.2) .9055 (23.0) 1.268 (32.2) 1.299 (33.0) 1.598 (40.6) 1.126 (28.6) 1.425 (36.2) D 1.110 (28.2) 1.504 (38.2) 1.106 (28.1) 1.504 (38.2) 1.551 (39.4) 1.839 (46.7) 1.370 (34.8) 1.669 (42.4) D2 1.307 (33.2) 1.736 (44.1) 1.303 (33.1) 1.736 (44.1) 1.799 (45.7) 2.094 (53.2) 1.618 (41.1) 1.909 (48.5) E 1.547 (39.3) 1.972 (50.1) 1.543 (39.2) 1.969 (50.0) 2.051 (52.1) 2.343 (59.5) 1.870 (47.5) 2.157 (54.8) E2 1.839 (46.7) 2.205 (56.0) 1.839 (46.7) 2.205 (56.0) 2.299 (58.4) 2.591 (65.8) 2.118 (53.8) 2.409 (61.2) F 2.059 (52.3) 2.441 (62.0) 2.051 (52.1) 2.441 (62.0) 2.551 (64.8) 2.843 (72.2) 2.370 (60.2) 2.677 (68.0) F2 2.287 (58.1) 2.677 (68.0) 2.283 (58.0) 2.677 (68.0) 2.799 (71.1) 3.071 (78.0) 2.618 (66.5) 2.890 (73.4) G 2.453 (62.3) 2.835 (72.0) 2.449 (62.2) 2.835 (72.0) 3.031 (77.0) 3.307 (84.0) - Star-Line EX Plug with EX Gland Amphenol offers an extensive line of explosion proof and general duty cable glands. Consult Amphenol Industrial Operations and ask for new catalog 12-055, Amphenol Cable Glands and Cord Grips. 27 Cables can be designed with a custom overmold to any Amphenol cylindrical connector for any industrial application. Consult Amphenol Industrial Operations for further information. STAR-LINE EX(R) Hardware *Notes: For "C" length inserts, add 1/2" to both dimensions "A" & "B". Plug with mechanical clamp Dimension Shell 12 16 20 24 28 EX-13-2 Style (POTTING REQUIRED) A* B* C D E F 7-7/16 (189) 9-1/2 (241) 9-9/16 (243) 9-5/8 (245) 9-11/16 (246) 3-9/16 (91) 3-9/16 (91) 3-9/16 (91) 3-9/16 (91) 3-9/16 (91) 2-1/8 (54) 2-5/8 (67) 3-1/8 (79) 3-5/8 (92) 4-1/8 (105) 2 (51) 2-1/16 (52) 2-1/8 (54) 2-3/16 (56) 2 1/4 (57) 15/16 (24) 1-7/16 (37) 1-15/16 (49) 2-7/16 (62) 2-7/8 (73) 2-3/8 (60) 3 (76) 3-3/4 (95) 4-1/2 (114) 5-1/8 (130) A B D C (MAX) (MAX) E F Plug with EEx d Gland (POTTING IS NOT REQUIRED) EX-13-3 Style Note: `D' Dimension varies according to cable gland. Detailed cable dimensions and type required. Gland is included with the connector. Dimension Shell 12 16 20 24 28 A* B* C 6-1/16 (154) 8-1/16 (205) 8-1/16 (205) 8-1/16 (205) 8-1/16 (205) 3-9/16 (91) 3-9/16 (91) 3-9/16 (91) 3-9/16 (91) 3-9/16 (91) 2-1/8 (54) 2-5/8 (67) 3-1/8 (79) 3-5/8 (92) 4-1/8 (105) Gland Thread M25 M40 M50 M63 M75 D A (NOM) B C (MAX) Plug with Basketweave Cable Grip Dimension Shell 12 16 20 24 28 (POTTING REQUIRED) EX-13-4 Style A* B* C D E F G 6-1/16 (154) 8-1/16 (205) 8-1/16 (205) 8-1/16 (205) 8-1/16 (205) 3-9/16 (91) 3-9/16 (91) 3-9/16 (91) 3-9/16 (91) 3-9/16 (91) 2-1/8 (54) 2-5/8 (67) 3-1/8 (79) 3-5/8 (92) 4-1/8 (105) 1-1/4 (32) 1-1/4 (32) 1-1/4 (32) 1-1/4 (32) 1-1/4 (32) 15/16 (24) 1-7/16 (37) 1-15/16 (49) 2-7/16 (62) 2-7/8 (73) 1-9/32 (33) 1-25/32 (45) 2-9/32 (58) 2-25/32 (71) 3-9/32 (83) 8 (203) 10-1/2 (267) 14-1/2 (368) 17-1/2 (445) 19 (483) A G (MAX) D B C (MAX) E (MAX) 28 F (MAX) Amphenol STAR-LINE EX(R) *Notes: INDUSTRIAL For "C" length inserts, add 1/2" to both dimensions "A" & "B". In-line Receptacle with Mechanical Clamp Dimension Shell 12 16 20 24 28 EX-15-2 Style (POTTING REQUIRED) A* B* C D E F 7 (178) 9-1/16 (230) 9-1/8 (232) 9-3/16 (233) 9-1/4 (235) 1-7/16 (37) 1-7/16 (37) 1-7/16 (37) 1-7/16 (37) 1-7/16 (37) 1-1/2 (38) 2 (51) 2-1/2 (64) 3 (76) 3-1/2 (89) 2 (51) 2-1/16 (52) 2-1/8 (54) 2-3/16 (56) 2-1/4 (57) 15/16 (24) 1-7/16 (37) 1-15/16 (49) 2-7/16 (62) 2-7/8 (73) 2-3/8 (60) 3 (76) 3-3/4 (95) 4-1/2 (114) 5-1/8 (130) A B F (MAX) D C In-line Receptacle with EEx d Gland (POTTING IS NOT REQUIRED) Note: `D' Dimension varies according to cable gland. Detailed cable dimensions and type required. Gland is included with the connector. Dimension Shell 12 16 20 24 28 A* B* 5-5/8 (143) 7-5/8 (194) 7-5/8 (194) 7-5/8 (194) 7-5/8 (194) E (MAX) EX-15-3 Style C 1-7/16 (37) 1-7/16 (37) 1-7/16 (37) 1-7/16 (37) 1-7/16 (37) Gland Thread 1-1/2 (38) M25 2 (51) M40 2-1/2 (64) M50 3 (76) M63 3-1/2 (89) M75 A B D C In-line Receptacle with Basketweave Cable Grip Dimension Shell 12 16 20 24 28 A* B* 6-1/4 (159) 8-1/4 (210) 8-1/4 (210) 8-1/4 (210) 8-1/4 (210) 1-7/16 (37) 1-7/16 (37) 1-7/16 (37) 1-7/16 (37) 1-7/16 (37) C 1-1/2 (38) 2 (51) 2-1/2 (64) 3 (76) 3-1/2 (89) (POTTING REQUIRED) EX-15-4 Style D E F G 1-1/4 (32) 1-1/4 (32) 1-1/4 (32) 1-1/4 (32) 1-1/4 (32) 15/16 (24) 1-7/16 (37) 1-15/16 (49) 2-7/16 (62) 2-7/8 (73) 1-9/32 (33) 1-25/32 (45) 2-9/32 (58) 2-25/32 (71) 3-9/32 (83) 8 (203) 10-1/2 (267) 14-1/2 (368) 17-1/2 (445) 19 (483) A B D G (MAX) F (MAX) E C 29 (MAX) STAR-LINE EX(R) *Notes: For "C" length inserts, add 1/2" to both dimensions "A" & "B". Panel Mount Receptacle Dimension Shell 12 16 20 24 28 (POTTING REQUIRED) EX-17-1 Style A* B* C D 4 7/16 4 7/16 4 7/16 4 7/16 4 7/16 1.765 1.765 1.765 1.765 1.765 1-1/2 (38) 2 (51) 2-1/2 (64) 3 (76) 3-1/2 (89) E 1.654 (42) 2.047 (52) 2.441 (62) 2.835 (72) 3.228 (82) F 2-1/4 (57) 2-5/8 (67) 3 (76) 3-1/2 (89) 4 (102) M40 M50 M63 M75 M90 A B #10 (M5) F (THREAD) C D Square 23/32 (MIN. FULL THREAD) E Square Fixed In-Line Receptacle with Mechanical Clamp Dimension Shell 12 16 20 24 28 EX-17-2 Style (POTTING REQUIRED) A* B* C D E F 7 (178) 9-1/16 (230) 9-1/8 (229) 9-3/16 (233) 9-1/4 (235) 1-7/16 (27) 1-7/16 (27) 1-7/16 (27) 1-7/16 (27) 1-7/16 (27) 1-1/2 (38) 2 (51) 2-1/2 (64) 3 (76) 3-1/2 (89) 2 (51) 2-1/16 (52) 2-1/8 (54) 2-3/16 (56) 2-1/4 (57) 5/16 (24) 1-7/16 (37) 1-15/16 (49) 2-7/16 (62) 2-7/8 (73) 2-3/8 (60) 3 (76) 3-3/4 (95) 4-1/2 (114) 5-1/8 (130) A B F (MAX) D C E (MAX) Fixed In-Line Receptacle with EEx d Gland (POTTING IS NOT REQUIRED) Note: `D' Dimension varies according to cable gland. Detailed cable dimensions and type required. Gland is included with the connector. Dimension Shell 12 16 20 24 28 A* B* C Gland Thread 5-5/8 (143) 7-7/8 (194) 7-7/8 (194) 7-7/8 (194) 7-7/8 (194) 1-7/16 (37) 1-7/16 (37) 1-7/16 (37) 1-7/16 (37) 1-7/16 (37) 1-1/2 (38) 2 (51) 1-/12 (64) 3 (76) 3-1/2 (89) M25 M40 M50 M63 M75 EX-17-3 Style A B D C Fixed In-Line Receptacle with Basketweave Cable Grip (POTTING REQUIRED) EX-17-4 Style Dimension Shell 12 16 20 24 28 A* B* C D E F G 6-1/4 (159) 8-1/4 (210) 8-1/4 (210) 8-1/4 (210) 8-1/4 (210) 1-7/16 (27) 1-7/16 (27) 1-7/16 (27) 1-7/16 (27) 1-7/16 (27) 1-1/2 (38) 2 (51) 2-1/2 (64) 3 (76) 3-1/2 (89) 1-1/4 (32) 1-1/4 (32) 1-1/4 (32) 1-1/4 (32) 1-1/4 (32) 15/16 (24) 1-7/16 (37) 1-15/16 (49) 2-7/16 (62) 2-7/8 (73) 1-9/32 (33) 1-25/32 (45) 2-9/32 (58) 2-25/32 (71) 3-9/32 (83) 8 (203) 10-1/2 (267) 14-1/2 (368) 17-1/2 (445) 19 (483) A B D G (MAX) F (MAX) E 30 C (MAX) Amphenol STAR-LINE EX(R) INDUSTRIAL Description of equipment The Star-line EX series of connectors is comprised of metallic bodied plug and receptacle shells, to form inline cable connections. Externally the main bodies are fitted with suitably certified cable glands. Internally the main bodies each contain an insulator insert fitted with solder or pressure type contacts of either a pin or socket variety. The plug and receptacle shells together form an in-line connector. When connected together they form a spigotted flamepath and are mechanically interlocked by means of a threaded nut retained by a grub screw. Additionally, the receptacle connector is available in a bulkhead mounted version that contains an externally threaded flamepath for mounting to certified EX enclosures with suitable internal mating thread. This variety of bulkhead mount connector, must be internally potted, as described within this document. The range is comprised of seven body (forms) sizes, each with a number of pin/socket size combinations between 1 and 143 contacts. The connector shell size, pin configuration and rating are reflected in the individual type designations. Design Option are described below and include, alternative keying options, and pin or sleeve contacts in either the plug or receptacle bodies. Part Number Code Logic: EX(a) - (b) - (c) - (d)- (e) - (f)(g)(h)(j) - (k) Connector series type designation EX Shell material (a) Aluminium (default, omit code) B-Brass S-Stainless steel Shell configuration (b) 13- Inline Receptacle, w/ accompanying blanking cap 15- Inline Plug, w/ accompanying blanking cap. 17 - Flange Mount Receptacle, w/ accompanying blanking cap. 18 - Circular Bulkhead Mount Receptacle, w/ cap. Cable Adapter style (c) 1- 2- 3- 4- Grommet ID (d) See catalog for available sizes and codes Shell Size (e) 12, 16, 20, C20, 24, C24, 28, C28 Contact Insulation (f) See catalog for configurations Contact Gender (g) P - Pin, Termination Style (h) N - Crimp, R - Pressure Insert Rotation (j) Normal (default, omit code) For alternates, refer to catalog Planned Additions (k) Certified Variations Bulkhead Mount (w/ potting adapter; requires potting) Mechanical Clamp (requires potting) Threaded for use with EX certified Gland Basketweave Grip (requires potting) S - Socket 31 STAR-LINE EX(R) Star-Line EX(R) Familiarization & Assembly Information 1. 2. 3. 4. Read manufacturer's assembly instructions before actually starting to assemble connectors. Besides the matter of instruction on correct procedures, there are two important reasons for this preliminary step: To identify the various component parts, and to check for any missing parts. Cut cable jackets and sheathing squarely and to correct length, using only wire strippers that have been approved for the operation. In preparing the individual wires in cables and harnesses for assembly, make allowances in length for reaching the outermost circle of contact cavities in the conductors. The insulation should be cut progressively longer as they extend out from the center of the cable or harness to assure sufficient length. Follow chart on page 34 covering maximum cable stripping lengths for effective cable gland or grommet sealing. All conductors should be fit into contact wire wells correctly. A practice layout should be done so that the assembler can oversee what the finished will look like when finished. Some cables that will be used will have a `basket weave' type of armor under the outer jacket (sheath) and over the inner jacket. Since many regulatory entities require that the armor be grounded at least at the source end, it is beneficial to ground the armor via a spare contact within the connector. Following the removal of sufficient amount of outer jacket (see chart on page 34) ample amount of the armor can be clipped away, but not all. An adequate amount should remain in order that a small cross-section conductor, short in length, be woven into the remaining armor weave and either soldered or covered with mastic impregnated heat shrink, creating an intimate bond to the armor. At the opposite end of the short piece of wire a contact should be crimped and inserted into the insert. 5. Use only correctly sized and ingress protected certified glands or sealing grommets to assure resistance to moisture and other contaminants. 6. Use only the proper crimping tools that have been set or calibrated with precision gages. 7. Make certain that all contacts are the correct size before attempting to assemble in insert cavities. This point is particularly important when both power and control types of contacts are used in the same connector. 8. Be sure that ground contacts (when applicable) are correctly located. 9. Seat all contacts properly so that they will not be damaged or become disengaged during connector mating operations 10. Use only the proper insertion tools and be sure that they are aligned axially when pushing contact into their fully seated position. 11. When inserts have more cavities than conductors, plug unused cavities with furnished contacts. 12. After all terminated contacts are inserted in their respective cavities and inspected (detailed on page 34), the cable adapter or insert clamp nut should be tightened with a wrench. (detailed on page 37). 13. When handling cables, use adequate support to prevent damage to the internal wires. Exd glands are intended for sealing purposes and should not be used as a cable grip. 14. If for any reason terminated conductors have to be removed from an insert because of an assembly error or change in circuitry, be sure to remove the cable gland or cable adapter first before extracting the contact and reinserting it. 15. If one of the connector poles is a ground wire, make sure that it is grounded properly before the connector actually is engaged. 16. When connectors having the same configuration are to be mounted close together, different or alternate keying arrangements should be used to prevent mismatching and possible damage to the electrical system. 17. Always inspect all aspects of connector assembly operations before putting connectors into actual operation. 18. Crimping and terminating of conductors to contacts must be done carefully. Make certain that wire strands are fully bottomed in contact-wells by checking through inspection hole provided (Detailed on page 34). 19. Never try to straighten bent contacts. Straightening cannot be done properly and the plating on contacts very likely will be marred. This will result in a high resistance connection and will expose the base material to possible corrosion. 20. Each assembly operator should be his own inspector. Worn, damaged, or defective tools should be reported immediately to foreman and supervisors. Assembly operators should be indoctrinated with this attitude and made to understand the importance of always guarding quality. Assembly workmanship is a significant factor in terminating the quality of multiple contact connectors. Quality cannot be "inspected" into connectors; it must be "built-in" during each and every assembly operation. 32 Amphenol STAR-LINE EX(R) INDUSTRIAL Star-Line EX(R) Cable Types It is the responsibility of the specifier/user to select the appropriate cable to be used with the EX Star-Line connector system. The specifier/user should favor the use of cables constructed with flexible conductors (IEC class 5 or higher/ICEA type H or higher) as well as a flexible armor type (basket weave) if required. Armor systems such as those identified in IEC 92-3 or IEEE455 or UL1309 are recommended. An impervious jacket should always be furnished over the armor. IEC/ BS cables such as armored with SWA (X), tape(Z), and NEC style cables such as `interlocked' or MC are not recommended with the EX connector system. The armor system should be grounded at the source point. Periodically the specifier/user should investigate the need for armor grounding (earthing) within the plug or in-line connector itself. In addition to the weaving of the armor grounding conductor, soldering and/or heat shrink and/or strong adhesive electrical takes, and/or `tension banding' should be applied on the armor and conductor to insure a permanent bond. The armor grounding wire should be terminated (solder or crimp) to an appropriate sized contact, and inserted into the connector insert. Since there is no armor grounding contact path provided within the connector assembly, a suitable external method must be employed. It is recommended that a small strip of outer jacket be cut away a reasonable distance from the entrance to the cable gland of the connector. A durable insulated conductor with a cross section not smaller than #14awg/4mm should be bonded to the exposed armor. Protective tapes or heat or cold shrink (3M PST) should be applied to protect this bonding point. The opposite end of this grounding conductor should be terminated at the corresponding receptacles' panel via one of the receptacles' fastening screws or a dedicated grounding lug or bar. In an `in-line' configuration, a mirror image of the above should be used with a simple mating point in close proximity to the connector set. In summary the specifier/user should be versed in acceptable applications that are allowed by the regulatory/certifying bodies having jurisdiction. Periodic inspection of this grounding arrangement should be implemented. All connectors are furnished with a protective cover. In actuality this cover is viewed as a critical part of the connector. The cover is compared to a cover on a flameproof (Eexd) encloThe armor system should not be confused or associated with sure. Absence of the cover voids the Ex certification. The shielding which is employed with instrumentation/ telecommunication cables. Shielding for pairs/triads have their covers should not be viewed as an incidental protection to the external elements, but a required component of a hazardous own individual drain wires which should be terminated onto certified device. When the connectors are plugged together dedicated contacts. These drain wires should be insulated with heat shrink within the connector body to prevent contact the covers can be screwed into each other to protect the threads from damage. When the connectors are not mated, it with other drain wires or pair/triad shield faces. is required that the covers be installed and the set screws on The above procedure does not apply to single conductor cathe covers be fully driven into the body of the connector. bles, i.e., 444-1111mcm (150mm-500mm), or multiconductor Replacement covers and `NYLOK' set screws are available on power or control cables. request. Single conductor Cables Periodically single conductor cables will be required in an armored and sheathed construction. SIRA Product Labeling Information Information below must be attached to connectors via non-removable label. Amphenol Sidney NY 13838 USA Marking for all connectors used in standard (+40C max.) ambient: Star-Line, Size Ref Ex Ex Ex Ex Work Order Number; Date Code; Facility Code 0518 II 2 GD d IIC T6 Gb (Inline Plugs and Receptacles) tb IIIC T80C Db IP68 (Inline Plugs and Receptacles) de IIC T6 Gb (Panel mount receptacle filled w/ cement) tb IIIC T80C Db IP68 (Panel mount receptacle filled w/ cement) -20C Tamb +40C IP68-8 Marking for inline connectors, used in +55C max. ambient: (INCREASED TEMP RANGE ONLY ALLOWABLE FOR CONNECTORS Sira 03ATEX1101X & IECEx SIR 10.0064X (EX-13-3, EX-15-3, EX-17-3) EMPLOYING SUITABLE EX CERTIFIED GLANDS. THIS MARKING IS NOT APPLICABLE FOR CE"Max volts, Max amp, Current rating per pin" MENTED CONFIGURATIONS) Ex d IIC T5 Gb (Inline Plugs and Receptacles) DO NOT SEPARATE WHEN ENERGIZED Ex tb IIIC T95C Db IP68 (Inline Plugs and Receptacles) -20C Tamb +55C 33 Page 4 STAR-LINE EX(R) The following instructions apply to equipment covered by certificate numbers: Sira 03ATEX1101X & IECEx SIR 10.0064X The equipment may be used with flammable gases and vapours with apparatus group(s) IIA, IIB, & IIC and with temperature classes T6, T5, T4, T3, T2 & T1. The equipment is only certified for use in ambient temperatures in the range -20C to +40oC and should not be used outside this range. The product complies with the following standards: Installation shall be carried out by suitably-trained personnel in accordance with the applicable code of practice e.g. EN 60079-0:2006 (IEC 60079-0:2007 5th Ed) General requirements for electrical apparatus for explosive gas atmospheres EN 60079-1:2007 (IEC 60079-1:2007 6th Ed) Electrical apparatus for explosive gas atmospheres Part 1: Flameproof enclosures "d EN 60079-7:2007 (IEC 60079-7:2006 4th Ed) Electrical apparatus for explosive gas atmospheres - Part 7: Increased safety "e" EN 61241-0:2006 (IEC 61241-1:2004 1st Ed + Corr Nov 05) General requirements for electrical apparatus for use in the presence of combustible dust EN 61241-1:2004 (IEC 61241-1:2004 1st Ed) Electrical apparatus for use in the presence of combustible dust. Protection by enclosures "tD" EN/IEC 60079-14 or EN/IEC 61241-14. It is the end user's responsibility to ensure that the product, as specified and confirmed by the product label, is suitable for it intended application. Inspection and maintenance of this equipment shall be carried out by suitably trained personnel in accordance with the applicable code of practice e.g. EN/IEC 60079-17 or EN/IEC 61241-17. Repair of this equipment shall be carried out by suitably trained personnel in accordance with the applicable code of practice e.g. EN/IEC 60079-19. Components to be incorporated into or used as replacement parts of the equipment shall be fitted by suitably trained personnel, using only components purchased from Amphenol or an Amphenol approved distributor. Any use of nonapproved components/suppliers will invalidate the certification for that product. The certification of this equipment relies upon the following materials used in its construction: 1. 2. Connector Materials: x (Standard Base Material) ASTM B211 or B221 Alloy 6061-T6, Aluminum (<7%Mg, <7%Ti), x (Optional Base Material) ASTM 5640, Alloy 303, Stainless Steel, x (Optional Base Material) ASTM B455, Alloy C38500, Brass. Seal Materials: x Buna Rubber w/ Durometer of 70 SHORE A. If the equipment is likely to come into contact with aggressive substances, then it is the responsibility of the user to take suitable precautions that prevent it from being adversely affected, thus ensuring that the type of protection provided by the equipment is not compromised. Aggressive substances: e.g. acidic liquids or gases that may attack metals, or solvents that may affect polymeric materials. Suitable precautions: e.g. regular checks as part of routine inspections or establishing from the material's data sheets that it is resistant to specific chemicals. 34 Amphenol STAR-LINE EX(R) INDUSTRIAL SPECIAL CONDITIONS FOR SAFE USE/CONDITIONS OF CERTIFICATION The following must be adhered to in full for safety and as to not invalidate product certification. 1. The panel mounted variants may be installed in suitably certified and dimensioned flameproof equipment providing that the certification of this flameproof equipment will allow such installation. 2. The panel mounted variants may be fitted in an increased safety enclosure when the free internal space is filled with epoxy resin and providing the certification of the enclosure will allow such installation. An electric strength test in accordance with EN 60079-7:2007 and IEC 60079-7:2007 Clause 7.1 will be performed on each unit after instal-lation of the epoxy resin. 3. The Ex-18 range of panel-mounted variants may be installed in a suitably certified and dimensioned flameproof equipment providing that the certification of this flameproof equipment will allow such installation. They have the following dimensioned spigot joints and are suitable for Group IIA, IIB or IIC, dependent upon the associated appa-ratus entry dimensions. Shell Size Spigot diameter (mm) Spigot length (mm) 12 39.90/39.85 46 (+/-1) 16 49.90/49.85 46 (+/-1) 20 62.90/62.85 46 (+/-1) 24 74.90/74.85 46 (+/-1) 28 89.90/89.85 46 (+/-1) 1. The Ex-18 range of receptacles shall only be used where the temperature at the point of entry in service on the associated enclosure is between -20C to +70.2C. 2. The Ex-18 range connector does not incorporate an external earth facility. It is the responsibility of the user or installer to ensure adequate earth continuity by means of guidance given within the manufac-turer's installation instructions. (R) Star-Line EX Connector Mating, Securement and Certification Compliance The Starline EX series utilizes a traditional threaded (ACME) coupling scheme, with an additional enhancement. The coupling sleeve is part of an actual assembly. The assembly is comprised of a coupling sleeve, and two (2) grub screws (set screws). These set screws and their proper implementation, are a requirement of the Certificate of Conformity. Once the connectors are mated, and the coupling nut has been tightened, it is a requirement that the Grub Screws both be tightened using a proper tool (allen key; supplied with connector). This prevents the coupling nut from backing off, and minimizes "unauthorized decoupling" of the mated connector pair. The Grub Screws would have to be intentionally loosened, in order for the coupling nut to be retracted, and the connectors unmated. WARNING: Compliance with the Certificate of Conformity is satisfied when: 1) the male and female connectors are completely mated, and 2) the coupling sleeve is fully engaged, and 3) the grub screws are fully engaged, and 4) all the above are established before the circuit is energized. WARNING: When circuits are de-energized, and the connectors, all plugs and receptacles, are un- mated, the respective flameproof blanking caps must be installed, and all grub screws secured. Flame- proof blanking caps are a part of the certification, and their use is required, to maintain flameproof wor- thiness of the connector halves independently, should the circuit be re-energized. 35 STAR-LINE EX(R) Star-Line EX(R) Assembly & Terminating Instructions Cable Jacket & Wire Stripping Shell Size Contact Size AWG(mm) 12 18 (0.75mm) 16 (1.5mm) 12 (4.0mm) 10 (6.0mm) 18 (0.75mm) 16 (1.5mm) 12 (4.0mm) 10 (6.0mm) 8 (10.0mm) 4 (25.0mm) 18 (0.75mm) 16 (1.5mm) 12 (4.0mm) 10 (6.0mm) 8 (10.0mm) 4 (25.0mm) 1/0 (50.0mm) 535MCM (240mm) 18 (0.75mm) 16 (1.5mm) 12 (4.0mm) 10 (6.0mm) 8 (10.0mm) 4 (25.0mm) 1/0 (50mm) 4/0 (120mm) 535 MCM (240mm) 777 MCM (400mm) 18 (0.75mm) 16 (1.5mm) 12 (4.0mm) 10 (6.0mm) 8 (10.0mm) 4 (25.0mm) 1/0 (50mm) 4/0 (120mm) 16 20 24/C24 28/C28 350 MCM (185mm) Mod 1 (Solder Contact) Strip Lengths (mm) Conductor Jacket Mod 1 (Pressure Contact) Strip Lengths (mm) Conductor Jacket Mod 2 & 3 (Crimp Contact) Strip Lengths (mm) Conductor Jacket 7.2mm 7.2mm 8.7mm 11.9mm 7.2mm 7.2mm 8.7mm 11.9mm 15.1mm 16.7mm 7.2mm 7.2mm 8.7mm 11.9mm 15.1mm 16.7mm 18.3mm 99.2mm 99.2mm 99.2mm 99.2mm 105.5mm 105.5mm 105.5mm 105.5mm 105.5mm 105.5mm 118.2mm 118.2mm 118.2mm 118.2mm 118.2mm 118.2mm 118.2mm 17.5mm 14.3mm 17.5mm 17.5mm 19.1mm 90.5mm 90.5mm 90.5mm 84.1mm 96.8mm 96.8mm 96.8mm 90.5mm 88.9mm 87.3mm 109.5mm 109.5mm 109.5mm 103.2mm 101.6mm 101.6mm 98.4mm 11.5mm 14.6mm 15.5mm 17.1mm 11.5mm 14.6mm 15.5mm 17.1mm 21.0mm 23.0mm 11.5mm 14.6mm 15.5mm 17.1mm 21.0mm 23.0mm 31.0mm 90.5mm 90.5mm 90.5mm 92.1mm 96.8mm 96.8mm 96.8mm 98.4mm 98.4mm 101.6mm 109.6mm 109.6mm 109.6mm 111.12mm 111.12mm 113.9mm 115.2mm 50.0mm 118.2mm - 90.0mm - - 7.2mm 7.2mm 8.7mm 11.9mm 15.1mm 16.7mm 18.3mm 18.3mm 130.9mm 130.9mm 130.9mm 130.9mm 130.9mm 130.9mm 130.9mm 130.9mm 17.5mm 19.1mm 19.1mm 122.2mm 122.2mm 122.2mm 115.9mm 114.3mm 100.0mm 117.5mm 127.0mm 11.5mm 14.6mm 15.5mm 17.1mm 21.0mm 23.0mm 31.0mm 31.6mm - 50.0mm 130.9mm - 90.0mm - - 50.0mm 130.9mm - 90.0mm - - 17.5mm 19.1mm 19.1mm 125.6mm 125.6mm 125.6mm 122.2mm 120.7mm 106.4mm 123.8mm 133.4mm 11.5mm 14.6mm 15.5mm 17.1mm 21.0mm 23.0mm 31.0mm 31.6mm - - 130.1mm 33.5mm - 7.2mm 7.2mm 8.7mm 11.9mm 15.1mm 16.7mm 18.3mm 18.3mm 21.4mm 137.3mm 137.3mm 137.3mm 137.3mm 137.3mm 137.3mm 137.3mm 137.3mm 137.3mm 36 Amphenol STAR-LINE EX(R) INDUSTRIAL Star-Line EX Assembly & Terminating Instructions (R) Electrical Connectors with MOD I Inserts The following table gives the wire sizes and cord/cable types to be used with the Star-line plugs, receptacles and cable connectors. The plugs and cable connectors are intended for connection to 3, 4 or 5 conductor cords/ cables depending on the contact insert configuration. Amperes Rating of Device Conductor Size AWG 20 #14 60 #6, #4 30 The cord sealing grips range for plugs and cord connectors is 1/8". For instance, if inside dia. of grommet is 3/4" it will seal and grip a cord dia. in the range of .750 dia. max. to .625 dia min. Inside diameter of grommets are in sixteenth of an inch increments. Type Cord/Cable S, SO #12, #10 100 S, SO W #0, #1, #2 200 W #3/0, #4/0 W There are two types of contacts used in Mod I style inserts, one is solder, the other is pressure. The pressure contacts apply termination force via a set screw, and require being torque to values provided in the table below: Lb-in N-M 20 amp. #12 contact 30 amp. #10 contact 40 amp. #8 contact 60 amp. #4 contact 100 amp. #1/0 contact 200 amp. #4/0 contact N/A 15 25 20 50 100 N/A 1.7 2.8 2.3 5.7 11.3 A. Prepare end of cable by stripping jacket and insulation per tables shown on previous page. Remove any ridges or grooves by scarfing the edges to provide a smooth surface on the cable to insure good grommet sealing. Tin conductors to be soldered to within 1/16" of insulation. Use only resin flux for all soldering. B. Slide the EX gland nut, cable grip, or anti-friction washer, grommet and cable adapter, over the cable in the order named. Be sure the right size EX gland or grommet has been selected to obtain a proper seal. See photo "YY". C. Solder conductors in contacts, if solder type. TO ENSURE ENVIRONMENTAL SEALING, ALL CONTACTS MUST REMAIN IN PLACE EVEN IF EVERY ONE IS NOT BEING USED. The silicone insulation is heat resistant, but reasonable care must be exercised to prevent unnecessary heating. It is recommended that a DC induction soldering unit be used if possible. Do not use open flame soldering. It is recommended that heat shrink be applied over finished termination point. YY D. Support the barrel assembly in a vise having smooth-faced jaws; with female receptacle have flange secured in vice for holding steady. The plug and receptacle keyways/keys are designed to withstand the assembly torque. See photo "MM". MM E. Apply cable adaptor or insulation clamp nut by strap wrench, turning counterclockwise (left hand thread) until hand-tight. APPLY STRAP WRENCH TO CABLE ADAPTER OR INSULATION CLAMP AND TIGHTEN UNTIL IT SHOULDERS FULLY ON BARREL. Substantial resistance should be felt by assembler as he rotates adapter on final revolution. See photo "PP". F. Slide Ex gland or grommet into cable adapter and engage either cable grip, or gland washer and gland nut. DRAW UP TIGHT WITH WRENCH. If mechanical clamp nut is used, tighten clamp screws as final step. NOTE 1. Photo "YY" is an example of EX-13-3 Series Plug using Exd gland. 37 PP STAR-LINE EX(R) Star-Line EX(R) Assembly & Terminating Instructions Electrical Connectors with MOD II Inserts Individual contacts are crimped to their respective conductors outside of the connector where ample working space is available. The crimping operation can be done by hand or power operated tools. Reference page 86 of this catalog for proper tool information. Terminated contacts are individually inserted into the insulation with a contact insertion tool. See photo "JJ". Contacts may be inserted and removed without degrading contact retention or environmental capability. The front rigid portion of the insert functions to stabilize and ensure positive alignment of the contacts. Contact cavities are clearly numbered on the front and rear insert face to facilitate identification during assembly, inspection, and maintenance. All contact cavities, whether used or not, must be populated in order to maintain certification and proper environmental sealing. JJ For Electrical Connectors with MOD III Inserts Mod III connectors contain insulations that are factory installed and locked into position with a non-removable retaining ring. Each insulator assembly contains a resilient seal interposed between two rigid plastic insulators. Mod III contacts are rear insert-able and rear release-able for quick and easy circuit changes. Mod III contacts are retained in their respective cavities by means of collapsible metal collets. The main advantage of collet style retention are lower insertion forces, eliminating need for insertion tools, and higher retention forces. Contact cavities are clearly numbered on the front and rear insert face to facilitate identification during assembly, inspection, and maintenance. All contact cavities, whether used or not, must be populated in order to maintain certification and proper environmental sealing. All connectors are shipped with the inserts factory installed in the barrel shell, and in the specified key position. CRIMPING CONTACTS: Contacts are crimped outside of the connector with a proper tool. Check through the inspection hole in contact to make certain wires are fully bottomed in well before crimping. Panel Mounting a Receptacle Panel Gasket Sealing Washer Brass Locknut 1.The panel receptacle is comprised of two basic pieces. The first is the actual panel receptacle assembly, where the mating plug enters, and the second is the panel adapter/potting chamber. 2. Following the termination and/or insertion of the contacts into their representative cavities, the panel adapter is the firmly tightened all the way until travel ceases. 3. The potting step can then be completed. After the potting compound has hardened, the completed receptacle assembly can be installed into the enclosure. 4. The square panel gasket is furnished for installation on the outer surface of the enclosure behind the square flange. The sealing washer and brass locknut should be fully tightened with proper tools. Following this step four proper length 10mm screws should be installed into holes in corner of front flange. (Brass locknut is not required when threading receptacle assembly into a flameproof enclosure. 5. For all increased safety panel mount receptacles: In accordance with EN50019:2000, Clause 7.1, the increased safety enclosure certificate must include the use of the device as well as an electric strength test on the finished assembly. 6. The panel mount variant shall be installed in a suitably certified and dimensioned flameproof equipment when it's certificate allows such installation. 38 Amphenol STAR-LINE EX(R) INDUSTRIAL Star-Line EX Potting Instructions (R) All cable adapters, other than ones suited for mating with an EX-certified gland, must be filled with encapsulant (potted). The material certified for use in filling this connector line is to be supplied by Amphenol Industrial part number 10- 838535. The user or installer shall consider the performance of these materials with regard to attack by aggressive substances that may be present in the hazardous area. This material is a two-component casting system with a 1:1 volumetric mix ratio. It has low exothermic qualities, peaking at only 102F during cure. The material starts to harden in under 2 hours and fully cures at room temperature in 24. It can be quick cured in 2 hours at 140F. The product is available in easy "mix & dispense" cartridges. More informa tion is available by contacting: Amphenol Industrial Operations, Technical Support Phone: (520) 285-5130 Filling Depths Mixing Instructions The Cable Adapter should be filled with the encapsulant to the following levels: 1. CAUTION: Wear goggles or other eye protection during all operations. 2. Remove the tape band from the mid-section of the cartridge. 3. Squeeze cartridge slightly in area of the removed tape band to deform foil barrier. 4. Push the threaded end of the mixing rod into small and fully threaded into it's mating thread within the tube. 5. Push the mixing rod to the bottom of cartridge and begin plunging the mixing rod, the full length of the cartridge, while rotating the mixing rod approximately 90 with each stroke. Mix for the total number of 50 strokes. A stroke is one complete in and out cycle. On the last stroke, mixing rod should be fully extended outward. 6. Grasp the cartridge firmly at the neck of the tube, and unscrew the mixing rod by turning counterclock-wise approximately 3 turns. Remove mixing rod. 7. Install nozzle and remove bottom cap. 8. Load tube into a standard painters caulk gun. 9. Pot connectors in mated condition to assure contact alignment. 1-3/4" Empty Filled With Compound Cable Adapter * In-line cable adapters are filled to within one & three quarter inches (13/4") of the end of the adapter. The goal is to have all the volume filled without interrupting the cable grommet from seating when the strain relief nut is installed. 10. Potting not required when using Exd/Exe gland option for plugs and in-line receptacles. Panel Adapter (shown above) * Bulkhead adapters should be filled to within 1/16" of the top. 39 STAR-LINE EX(R) Star-Line EX(R) Potting Instructions Volume Chart The following chart illustrates how much potting compound is needed per connector. This is based on fill lengths of 3-7/8" (in-line adapters) and 1-3/4" (Panel mount adapters) and the smallest allowable cable diameter included for each particular shell. * Note: These volumes are estimated. Necessary volumes may vary depending on conductor count, insulation, and jacket thickness. Shell Size Approx. Cement usage in a 6" cable adapter* (Fluid Ounces) Approx. Cement usage in a bulkhead adapter* (Fluid Ounces) 12 1.6 .5 16 3.5 1.1 20 6.1 2.1 24 9.0 3.3 28 11.1 4.5 Recommendations It is recommended where possible, that when mated sets of connectors are potted that the connector with the female insert be potted first, allowed to set and then the male be potted while it is mated to the previously potted female connector. This will ensure that the male contacts will be seated or `aimed' properly at the female socket contact opposite it. The male contacts have a given amount of movement while not engaged, and if during initial potting procedures the male contacts are positioned beyond this movement range, they will not properly make contact with the socket contact. Mixing Rod Cartridge Foil Barrier Plunger Catalyst Tape Band Base Compound Bottom Cap 40 Amphenol (R) STAR-LINE Single Pole Power INDUSTRIAL Rig-Power(R) Connectors (1000v AC/DC) Connector Style Insert Gender Plug w/ Mech. Clamp Plug w/ Mech. Clamp Cable Receptacle w/ Mech. Clamp Cable Receptacle w/ Mech. Clamp Fixed CableReceptacle w/ Mech. Clamp Fixed Cable Receptacle w/ Mech. Clamp Panel Mount Receptacle (Bus Bar) Panel Mount Receptacle (Bus Bar) Panel Mount Receptacle (Direct Cable Entry) Panel Mount Receptacle (Direct Cable Entry) Dead Front Pin (Line side) Socket Contact (Load Side) Dead Front Pin (Line side) Socket Contact (Load Side) Dead Front Pin (Line side) Socket Contact (Load Side) Dead Front Pin (Line side) Socket Contact (Load Side) Dead Front Pin (Line side) Socket Contact (Load Side) RIG-10P-XX-M- RIG-10S-XX-M- RIG-15P-XX-M- RIG-15S-XX-M- RIG-17P-XX-M- RIG-17S-XX-M- RIG-17PR- RIG-17SR- RIG-17PN- RIG-17SN- RIG-Power Grommet Selection Guide (XX) Cable Size & Amperage Selection Guide (p) RIG-Radsok(R) Amperage Standard Amperage 2 = 313 kcmil 3 = 373 kcmil 4 = 444 kcmil 5 = 535 kcmil 6 = 646 kcmil 7 = 777 kcmil 625 700 800 900 1000 1135 RIG-R10P-XX-M- RIG-R10S-XX-M- RIG-R15P-XX-M- RIG-R15S-XX-M- RIG-R17P-XX-M- RIG-R17S-XX-M- RIG-R17PR- RIG-R17SR- RIG-R17PN- RIG-R17SN- NOTE: Radsok(R) version not backward compatible with original contact design * Select Cable Size. See Cable Size & Amperage Guide below. XX - Select Cable Diameter Code #. See Grommet Selection Guide below. M designates Mechanical Clamp (For basketweave grip substitute K for M). Select standard color code from Color Code options below. Use Crimp Tool: T&B #TBM15 Cable Size RIG-Radsok(R) Part Number* Standard Part Number* TBM 15 Die Code No. 925 1000 1200 1350 1500 1500 Cable Diameter 1.000-1.125 1.125-1.250 1.250-1.375 1.375-1.500 1.500-1.625 1.625-1.750 1.750-1.875 76 87 107 107 107 115 Code No. (XX) 18 20 22 24 26 28 30 Color Code Options (t) Current Type Standard Color Code Part Number Suffix DC Blue -BL Orange -OR AC Yellow -Y Brown -BR Red -R White -W Black -BK Green -G NOTE: It is the responsibility of the user to ensure other components of their system have equal/greater amperage carrying capacity. 41 Single Pole Power RIG-R17SR-R RIG-Power(R) Receptacle w/Radsok (R) Busbar Socket (Color Code Red) RIG-R10P7-22-M-R RIG-Power(R) Plug w/Radsok(R) Pin (Color Code Red) Mated Pair Starline EX Rig-Power w/Radsok(R) EX-17-1-C24-R386SR Starline EX Receptacle w/Radsok(R) Socket EX-13-3-D2-C24-R386PN StarLine EX Plug w/Radsok(R) Pin 8.703 8.734 PLUG RIG-10X -XX-M NOTE: See page 20, shell size C24 for full mounting dimensions. .297 DIA. 4 HOLES 2.531 SQ. 3.250 SQ. 42 PANEL MOUNT RECEPTACLE RIG-17X Amphenol Single Pole Power INDUSTRIAL Single Pole Power Connectors P-500TM / PD-501 POWER Connectors Wire Size Ampacity 900* 900* 900* 325 Type of Termination Gender - 535MCM 535MCM 313MCM Stud Solder Crimp Solder Socket Pin Pin Pin Part Number Boot Part # (See Color Code) Cable Sealing Range P-500126-BS- PD-501-L P-500126-P PD-501-S - TMPC-10- TMPC-10- TMPC-10- - 1.125 - 1.500 1.125 - 1.500 1.125 - 1.500 Note: Connectors are rated at 1000 Volts AC/DC when mounted on 5" centers. Copper alloy, silver plated contacts for maximum conductivity. Crimp tool required for P-500126-P is Thomas & Betts hex crimp using Tool # TBM15 & die catalog #15505 or BURNDY "YA" * When used with 125 C rated cable. 6.813 5.969 2.750 3.625 1.875 .547 MIN. PANEL THICKNESS .750 2.250 TMPC-10-R 1.375 BOOT 2.656 D .750 D 1.375 D 1.062 D PIN 1.066 DIA. OVER KNURL 1.062 MOUNTING HOLE DIA. 1.052 PIN PD-501-L PANEL BOARD SOCKET P-500126-BS 6.813 3.625 1.875 6.813 1.375 3.625 1.875 BOOT 2.656 D .750 D 1.375 2.656 D .750 D 1.250 D .955 D BOOT 1.187 D .875 D PIN PIN PIN P-500126-P PIN PD-501-S TMPCTM Connectors With StandardWith Radsok Contacts Contacts Cable Type of Part Current Part Current Wire Boot Sealing Gender Termination Number Range Number Range Size Part No. Range Socket Socket Pin Pin 7/8" Stud/Panel Board 2 Hole Bus Bar Crimp Crimp TMPC-41777-L- TMPC-41777-24L TMPC-40535-L TMPC-40777-L 900-1135 amps 900-1135 amps 900 amps 900-1135 amps TMPC-41777-RL- TMPC-41777-R24L TMPC-40535-RL TMPC-40777-RL 1500 1500 1500 1500 N/A N/A 444-535 kcmil 646-777 kcmil N/A N/A TMPC-10- TMPC-10- Note: TMPC Connectors are rated at 1000 Volts AC/DC when mounted on 5" centers. Material is copper alloy, silver plated for maximum conductivity and corrosion resistance. Recommended crimping tools are as follows: Anderson (Square D) Versa Crimp VC8 (four indent). COLOR CODE DOT 1-1/8 DIA. .547 MIN.PANEL THICKNESS 3.500 4-1/16 REF. 6.000 CLEVIS PIN 6.000 2.250 1.062 1.052 1.750 1.066 DIA. OVER KNURL DIA. MOUNTING HOLE .656 DIA. 2 HOLES MOTOR BUS BAR MOUNT SOCKET TMPC-41777-24L PANEL BOARD SOCKET TMPC-41777-L 43 N/A N/A 1.125-1.500 1.125-1.500 STAR-LINE(R) TMPC POWER MOUNT Amphenol(R) TMPC POWER MOUNT Flange Mounted Traction Motor Power Connector series featuring RADSOK(R) Contacts. Amphenol Industrial Operations introduces the addition of our "NEW" TMPC Power Mount flange mounted connector series. The New TMPC Power Mount series is an addition to our time tested TMPC Single Pin power connector line. The TMPC Power Mount incorporates our existing TMPC connectors with RADSOK(R) contacts into our new thermoplastic molded receptacle flange. Available in color codes per the NEC AC/DC Electrical requirements, the TMPC Power Mount series is designed to work with current IEEE Type P drilling cables (sizes range from 313 MCM through 777 MCM). The RADSOK(R) contacts allow for higher amperages and reduced insertion/removal forces when compared to similar products in the market. Features & Benefits: * RADSOK contact provide increased amperages than competition * Contacts rated at 1500 amp for 777 MCM cables * Contacts machined from high grade aluminum to offer longer life, more mating cycles * Lower insertion/removal forces is a byproduct of our RADSOK contacts * Molded flange base mounts directly to Stainless or Aluminum panels, thus eliminating the need for added secondary mounting fixtures * Color coded mounting bases and cable side boots available to help prevent cross mating, while allowing easier electrical phase identification * Connector series comes complete with molded Hypalon caps and insulation boots * Patent Pending 44 Amphenol STAR-LINE(R) INDUSTRIAL PLUG KIT PART NUMBER COLOR BLACK 313 MCM 444 MCM TMPC-SP3-BK 535 MCM TMPC-SP4-BK TMPC-SP5-BK 646 MCM 777 MCM TMPC-SP6-BK TMPC-SP7-BK COLOR OPTIONS AVAILABLE: Black, Blue, Brown, Green, Gray, Orange, Purple, Red, White, Yellow Plug Kit Consist of: - Pin Contact - Boot (color designation) - Rubber Cover RECEPTACLE KIT PART NUMBER COLOR Black FLANGE KIT W/ CONTACT TMPC-SR-BK FLANGE KIT LESS CONTACT TMPC-SRLC-BK BOOT PART TMPC-10-BK COLOR OPTIONS AVAILABLE: Black, Blue, Brown, Green, Gray, Orange, Purple, Red, White, Yellow Receptacle Kit Consist of: - Socket Contact (affixed into the flange) - Flange (color designation) - Rubber Cover ACCESSORIES CONTACTS ONLY (FOR PIN RETENTION RING ADD -RR) CABLE SIZE 313-777 MCM CABLE SIZE BUSBAR CONTACT 313-535 MCM 646-777 MCM TMPC-40535-RL TMPC-40777-RL DESCRIPTION RECEPTACLE CAP BOOT CAP MOUNTING GASKET BOOT RING 313 MCM BOOT RING 444 MCM BOOT RING 535 MCM BOOT RING 646 MCM BOOT RING 777 MCM TMPC-1 PIN CONTACT 45 PART NUMBER TMPC-SR-CAP TMPC-SP-CAP TMPC-SR-G SR1-313R SR1-444R SR1-535R SR1-646R SR1-777R STAR-LINE(R) Insert Configuration Listing For Amphenol(R)/ Pyle(R) Star-Line, Star-Lok and Star-Line EX Connectors introduction The Amphenol/Pyle Star-Line Insert Configuration Listing is issued primarily to identify various contact insert arrangements. For the engineer, it provides visual selection of the insert configuration needed to satisfy his requirements. For the end user, the list provides general information useful in the termination of plugs and receptacles. To aid the reader, the insert configurations are presented in numerical order, based on the number of contacts in each. The male insert illustration shown left (and those on the following pages) is shown as it appears when viewed from the front. Contacts are shown by both physical position within the configuration and by contact number. The contact number corresponds to the contact position shown on the rear face of the insert illustrated as well as to both the front and rear faces of the mating insert. The symbol used to show contact location is indicative of contact size. For example, the contact symbol in this illustration represents a #8 contact. An explanation of contact symbols is presented on each page of the listing. Each drawing also provides data on normal and alternate key positions. Drawings are reduced from actual size of the insert configuration. Note: Alternate keying or insert polarization is intended to resist improper intermating of plugs and receptacles of like shell sizes and like insert arrangements. Contact Insert Ordering Plug and receptacle contact inserts are selected according to requirements for Service Voltage Rating, Number of Contacts, Wire Size and Ampere Rating. Mod I and II inserts may be purchased separately for assembly into the basic barrel. The Catalog Number for each is shown on the chart accompanying each drawing. Pin or socket inserts are interchangeable in male and female barrels. Mod III inserts, as a unit, cannot be purchased separately because contact inserts are factory assembled to, and sealed in, the basic barrel. The Dash Number given with each Mod Ill configuration must be shown as a suffix to the basic barrel Catalog Number to identify the insert desired. Arrangements are available with high amperage RADSOK(R) contacts specifically designed for Star-Line inserts. These are designated with an `R' in the part number. For example: ZP-C28-R42PR would designate an insert with size 4/0 RADSOK pin contacts. ZP-C28-R42SR would designate an insert with size 4/0 socket contacts. 46 Amphenol STAR-LINE(R) ELECTRICAL Ratings Service Voltage Ratings The voltage to which contact inserts are limited is a function of the dielectric separation between adjacent contacts and between contacts and shell. The voltage rating is designated by a service voltage rating letter which is shown in the service voltage rating table with each contact configuration listing. INDUSTRIAL MIlitaryN.E.C. Ratings Ratings MIL-5015 Non- Circuit Over Specifications Circuit Breaking Surface Thru-Air Non-Circuit Distance Spacing Breaking Inches Inches Service Nominal Nominal D.C. A.C. D.C. A.C. Voltage Volts Volts RMS RMS RMS RMS Instrument A D E B C 250 700 1250 1750 2450 4200 200 500 900 1250 1750 3000 - 250 600 600 600 600 - 240 600 600 600 600 1/16 1/8 3/16 1/4 5/16 1 - 1/16 1/8 3/16 1/4 5/16 Three Classifications of Ampere Ratings MS Ampere Ratings: (MIL-C-39029) Based on the combination of the following: The amount of current which an individual pin and socket contact may carry is a function of contact material and design efficiency of the pin and socket system as well as the ability of the primary conductor insulation to resist temperature rises due to inherent copper losses and bundling factors. Total current carrying capacity of the connector is a function of the insert temperature which is rated at 225 F (107 C) for continuous operation. The total operating temperature is the summation of the ambient temperature plus the temperature rise resulting from the thermal losses of each contact. MIL-W-5088 specifications may be used as a general reference on the subject inasmuch as pertinent cable derating data is included. N.E.C. Non-Circuit-Breaking or Disconnect Ampere Ratings The non-interrupting current ratings, shown in the table, are based on the temperature of the contacts being within the range specified by Underwriter's Laboratories, Inc. when wire sizes are selected in accordance with the National Electrical Code. When multiple conductors are used, the load factor and temperature rise based on ambient and total insert temperature must be taken into consideration.. NOTE: The N.E.C. circuit breaking and non-circuit breaking ratings are based on test results of contacts and connectors. Consult the N.E.C. when selecting wire/cable for specific applications. Under certain conditions, a wire size may be rated higher or lower than the table indicates for a given contact size. Non-Circuit Breaking MV Drop ContactAmpere Rating Size AWG/ MS N.E.C. Solder Crimp MCM *** Contacts Contacts #18 #16 #12 #10 #8 #4 #1/0 #4/0 350 MCM 500 MCM 535 MCM 646 MCM 777 MCM - 13 23 33 46 80 150 225 - - - - - 9 16 30 40 50 90 155 225 325 750 839 937 1048 22 21 20 16 12 10 10 8 8 - - - - Measurements made at extreme ends of mated contacts with probe touching contact and wire (MIL-5015 specifications). ** Based on temperature rise (National Electrical Code Requirement). *** Based on Arcing Control (National Electrical Code Requirement). 30 29 27 26 23 22 22 22 - 30 - - - For Amphenol Star-Line product insert de-rating information per the National Electric Code, please consult the Amphenol Industrial website, www.amphenol-industrial.com. Chart is located under literature tab. 47 STAR-LINE(R) spare/replacement contacts for mod II and mod III inserts Contacts are machined copper alloy ranging in size (AWG) from #18 to 500 MCM. Standard line contacts are silver plated but can also be furnished with gold over silver, gold over nickel, and other combinations of plating systems available upon request. Pin contacts are of blended geometry to provide extra strength and protection against damage. Socket contacts are the closed entry type. Contacts for MOD I inserts are not listed because these inserts are factory assembled and damage may be done to the resilient center insulation if contacts are inserted or removed by inexperienced personnel in the field. MOD II Size Awg/MCM "W" Length "C" Length "W" Ground Polarizing Standard 18 Pin 18 Socket ZP-4018-36L ZP-4118-36L 16 Pin 16 Socket ZP-4016-36L ZP-4016-37L ZP-4116-36L 12 Pin 12 Socket ZP-4012-36L ZP-4112-36L ZP-4012-37L3 10 Pin 10 Socket ZP-4010-36L ZP-4110-36L ZP-4010-37L2 8 Pin 8 Socket ZP-4008-66L ZP-4108-66L 4 Pin 4 Socket ZP-4004-66L ZP-4104-66L Polarizing "C" ZP-4804-66L ZP-4904-66L 1/0 Pin ZP-4000-66LB 1/0 Socket ZP-4100-66L ZP-4900-66LK ZP-4800-66LKB 4/0 Pin ZP-4041-76LB 4/0 Socket ZP-4141-76L 500 MCM Pin 500 MCM Socket P-206053-CP P-206053-CS 535 MCM Pin 535 MCM Socket RIG-C24-535PN RIG-C24-535SN 646-777 MCM Pin 646-777 MCM Socket RIG-C24-386PN RIG-C24-386SN "W" length represents standard insert length for sizes 12, 16, 20 24 and 28. "C" length represents longer insert length for sizes C20, C24 and C28. Contacts in "C" length inserts are 1/2" longer than standard. Ground contacts are 1/8" longer than standard. Ground clips are part of inserts. "C' length ground contacts are 1/8" longer than "C" length line contacts. For Amphenol Star-Line product insert de-rating information per the National Electric Code, please consult the Amphenol Industrial website, www.amphenol-industrial.com. Chart is located under literature tab. 48 Amphenol STAR-LINE(R) INDUSTRIAL Termination Data Amphenol - Pyle Connectors Corporation's tools for contact crimping, insertion and removal are required for terminating and assembling contacts. Contact Dimensions Contact WIRE WELL DIMENSIONS Crimp* Mod III Size Solder Mod I Crimp* Mod II AWG (mm) Diameter Depth Diameter Depth Diameter Depth #18 (0.75) .060" (1.52) 13/64" (5.15) .059" (1.49) 3/8" (9.52) .058" (1.47) 3/8" (9.52) #16 (1.5) .079" (2.00) 13/64" (5.15) .079" (2.00) 1/2" (12.70) .079" (2.00) 1/2" (12.70) #12 (4.0) .117" (2.97) 17/64" (6.47) .113" (2.87) 17/32" (6.74) .113" (2.87) 17/32" (13.49) #10 (6.0) .142" (3.61) 25/64" (9.92) .142" (3.60) 19/32" (15.09) .142" (3.60) 19/32" (15.08) #8 (10.0) .210" (5.33) 33/64" (9.12) .189" (4.80) 3/4" (19.05) .188" (4.77) 3/4" (19.05) #4 (25.0) .333" (8.45) 37/64" (14.63) .289" (7.34) 53/64" (21.03) .278" (7.06) 53/64" (21.03) 1/0 (50.0) .470" (11.94) 41/64" (16.27) .445" (11.30) 1-1/8" (28.58) .455" (11.56) 15/16" (23.81) 4/0 (120.00) .656" (16.7) 57/64" (22.62) .656" (16.7) 15/16" (23.81) 350MCM (185.00) .798" (20.27) 1-1/8" (28.58) 500 MCM (240.00) 1.00" (25.40) 1-3/8" (34.93) * Crimp contacts have inspection hole. Crimp Data Contact Size Conductor Wire Size (AWG) Crimped Crimp Retention Min. Force Lbs. (N) #18 (0.75) #18 #20 #22 38 (169.0) 19 (84.5) 15 (66.7) #16 (1.5) #16 #18 #20 50 (222.4) 38 (169.0) 19 (84.5) #12 (4.0) #12 #14 #16 110 (489.3) 70 (311.4) 50 (222.4) #10 (6.0) #10 #12 #14 180** (800.7) 110 (489.3) 70 (311.4) #8 (10.0) #8 225 (1000) to #10 180 (800) #4 (25.0) #4 to #6 400 (1779) 1/0 (50.0) #2 to 1/0 550 (2447) 4/0 (120.00) 4/0 3/0 2/0 875 (3892) 825 (3670) 750 (3336) 500 MCM 2500 (11120) 500(240.00) 535 646 777 Torque Data for Pressure Contacts MOD I Contact/Conductor Size/Awg (mm) Torque Req. Retention Force In./Lbs. (N*m) Lbs. (N) 4/0 (120.00) 100 (11.3) 1/0 (50.0) 50 (5.7) 4/0 3/0 2/0 1/0 #1 #2 450 (2001.7) 350 (1556.9) 300 (1334.5) 250 (1112.0) 200 (889.6) 180 (800.7) #4 (25.0) 20 (2.3) #4 #6 #8 140 (622.8) 100 (444.8) 90 (400.3) #8 75 (333.6) #10 #12 #14 80 (355.9) 70 (311.4) 60 (266.9) #8 (10.0) 25 (2.8) #10 (6.0) 15 (1.7) 300 (1334) 700 (3114) Recommend using Thomas & Betts TBM 15 crimp tool with appropriate sized dies. ** Stranded wire 49 STAR-LINE(R) thermocouple contacts Thermocouple contacts are available for use in all insert configurations. Contact can be either purchased separately or included in the insert/connector-please coordinate with the factory on this latter option. For crimp terminations-see tools shown on page 76. When soldering, please adhere to the following procedures: (1) clean wire and solder well with stainless scratch brush. (2) Use Handy and Harman Silver Solder Flux. (3) Use Handy and Harman AMS 2665 Silver Solder with flame torch. IMPORTANT-Use extreme care to prevent overheating the female contact, otherwise tension will be lost and result in poor contact. (4) Clean flux from all surfaces using boiling water or steam. MOD I & II Color Code Size Gender Cat. No. Pin ZP-4016-10MF #16 Socket ZP-4116-10MF Thermocouple Material* Black Pin ZP-4016-10NF #16 Yellow Socket ZP-4116-10NF Pin ZP-4016-10PO #16 Socket ZP-4116-10PO Pin ZP-4016-10RO #16 Socket ZP-4116-10RO * Iron/Constantan Chromel/Alumel Copper/Constantan Chromel/Constantan Copper/Copper Alloy #11 Green Alumel Red Copper White Yellow Blue Purple Black Temperature Range Material* Degrees Short Time Continuous Constantan Chromel ISA Symbol Nomenclature* (+) J K T E B S Iron White Pin ZP-4016-10CF #16 Socket ZP-4116-10CF Table Temperature Range of Thermocouple Material Electrolytic Copper 190-350C & Constantan Chromel & Constantan 0-900C Iron & Constantan 0-1100C Chromel & Alumel 0-1100C ISA Color Military Color Coding Coding (-) Jacket (+) (-) Red Red Red Red White Black Yellow Blue Purple Black Black White Red White Red Yellow Green Yellow Yellow Red to 600C to 1100C to 1100C to 1350C Conductor Identification Positive (+) Negative (-) Magnetic Non-Magnetic Copper Color Non-Magnetic Copper Color Non-Magnetic Magnetic Non-Magnetic Silver Color Non-Magnetic Non-Magnetic Chromel and Alumel are registered trademarks of Hoskins Manufacturing Company. For Amphenol Star-Line product insert de-rating information per the National Electric Code, please consult the Amphenol Industrial website, www.amphenol-industrial.com. Chart is located under literature tab. 50 Amphenol STAR-LINE(R) INDUSTRIAL Insert Configuration Index For drawings and further information of insert arrangements listed see the referenced page numbers. Arrangements with RADSOK contacts are designated with an `R' in front of the dash number in the part number. For availability of other arrangements, consult Amphenol Industrial Operations. Insert Arrangement Number MOD MOD MOD Radsok I II III Contacts Total 18 Number (0.75) of Contacts 16 (1.5) 12 10 8 4 1/0 4/0 313MCM 350 MCM 373 MCM 444 MCM 535 MCM 646-777 Page (4.0) (6.0) (10.0) (250) (50.0) (120.0) (185.0) (240.0) (300-400) No. RIG-C24-386 X 1 RIG-C24-R386 X X 1 RIG-C24-535 X 1 RIG-C24-R535 X X 1 RIG-C24-313 X 1 RIG-C24-R313 X X 1 RIG-C24-373 X 1 RIG-C24-R373 X X 1 RIG-C24-444 X 1 RIG-C24-R444 X X 1 ZP-12-310 X(G) X 7 7 ZP-12-14 X 4 4 ZP-12-314 X 4 4 ZP-12-316 X 4 4 ZP-12-22 X(G) 4 4 ZP-12-322 X(G) 4 4 ZP-12-323 X 17 17 ZP-12-24 X 5 5 ZP-12-324 X X 5 5 ZP-12-326 X 5 3 2 ZP-12-27 X 3 3 ZP-12-327 X X 3 3 ZP-12-330 X(G) X 3 3 ZP-12-33 X 4 4 ZP-12-333 X 4 4 ZP-12-334 X(G) 10 10 ZP-12-348 X 7 7 ZP-12-53 X(G) 5 5 ZP-12-653 X(G) 5 5 ZP-12-354 X X 7 7 ZP-12-355 X 10 10 ZP-12-56 X(G) 3 3 ZP-C-16-341 X 1 ZP-16-312 X(G) X 19 19 ZP-16-16 X 5 5 ZP-16-316 X 5 5 ZP-16-321 X 37 37 ZP-16-22 X 4 4 ZP-16-322 X 4 4 ZP-16-324 X 18 16 2 ZP-16-325 X 16 16 ZP-16-28 X 4 4 ZP-16-328 X 4 4 ZP-16-29 X 9 8 1 ZP-16-333 X 61 61 ZP-16-335 X 27 24 3 ZP-16-37 X 26 18 4 4 ZP-16-38 X(G) 4 4 ZP-16-638 X(G) 4 4 ZP-16-640 X 55 55 ZP-16-344 X 21 11 10 ZP-16-346 X 9 6 3 ZP-16-349 X 14 12 2 ZP-16-355 X 19 19 (G) depicts arrangement with grounded contact 51 1 1 1 1 1 1 1 1 1 1 54 54 54 54 54 54 54 54 54 54 64 56 56 56 56 56 70 59 59 61 55 55 55 56 56 67 64 59 59 65 67 55 54 71 59 59 74 57 57 70 69 57 57 66 79 73 73 57 57 77 72 66 68 71 STAR-LINE(R) Insert Configuration Index For drawings and further information of insert arrangements listed see the referenced page numbers. Arrangements with RADSOK contacts are designated with an `R' in front of the dash number in the part number. For availability of other arrangements, consult Amphenol Industrial Operations. Insert Arrangement Number MOD I MOD II MOD III ZP-16-70 X ZP-16-371 X ZP-16-373 ZP-16-74 ZP-16-75 Radsok Contacts Total Number of Contacts 3 45 46 X(G) 3 X(G) 5 X(G) ZP-16-377 X ZP-16-378 45 27 X(G) ZP-16-376 18 (0.75) 16 (1.5) 12 (4.0) 10 (6.0) 24 7 7 ZP-16-381 X 10 6 ZP-20-313 X 68 68 ZP-20-323 X 38 35 3 ZP-20-329 X 64 62 2 ZP-20-331 X 22 20 X X 55 76 55 59 4 67 70 65 4 67 75 79 2 73 20 20 72 20 20 16 60 646-777 Page (300-400) No. 79 20 X 500MCM (240.0) 5 X(G) ZP-20-334 350 MCM (185.0) 73 6 ZP-20-332 4/0 (120.0) 3 19 X 1/0 (50.0) 3 10 ZP-20-32 4 (250) 3 1 19 X 8 (10.0) 72 4 72 ZP-20-35 X 60 ZP-20-38 X(G) 5 ZP-C20-40 X(G) 4 4 57 4 4 57 4 ZP-C20-640 X(G) ZP-C20-42 X 4 ZP-20-43 X(G) 6 ZP-20-643 X(G) 6 ZP-20-344 X 81 70 ZP-20-345 X 90 90 ZP-20-46 X ZP-20-646 ZP-20-48 X X ZP-20-648 ZP-20-49 X X ZP-20-649 X ZP-20-350 X(G) ZP-20-354 X ZP-20-55 78 5 X 58 2 4 62 & 82 2 4 62 11 80 80 6 4 2 6 4 2 62 62 6 3 3 62 6 3 3 62 5 3 2 61 5 3 2 61 37 37 47 X 60 75 45 2 10 76 8 2 68 ZP-20-358 X 16 16 70 ZP-20-359 X 7 7 65 ZP-20-673 X 50 ZP-20-374 X 27 ZP-20-375 X 12 ZP-20-376 X ZP-C20-379 X ZP-20-84 X 46 4 25 77 2 74 12 19 68 19 71 1 X 1 54 5 5 60 5 5 60 ZP-20-384 X ZP-20-386 X X 37 37 74 ZP-20-387 X(G) X 20 20 72 ZP-20-388 X(G) 19 19 71 ZP-24-313 X 100 ZP-C24-26 X(G) (G) depicts arrangement with grounded contact 100 81 4 4 52 58 Amphenol STAR-LINE(R) INDUSTRIAL Insert Configuration Index For drawings and further information of insert arrangements listed see the referenced page numbers. Arrangements with RADSOK contacts are designated with an `R' in front of the dash number in the part number. For availability of other arrangements, consult Amphenol Industrial Operations. Insert Arrangement Number MOD I ZP-24-331 MOD II MOD III Radsok Contacts X Total Number of Contacts 60 18 (0.75) 16 (1.5) 12 (4.0) 53 X 37 ZP-C24-38 ZP-24-40 ZP-C24-47 X X 4 15 X 15 10 ZP-C24-48 X 5 2 ZP-C24-49 X(G) 5 X 8 X 75 61 ZP-24-362 X 62 62 ZP-24-371 X 37 37 X 58 500MCM (240.0) 646-777 Page (300-400) No. 78 75 58 69 5 5 69 3 61 60 58 78 4 4 11 65 3 80 79 75 6 3 3 5 X(G) 350 MCM (185.0) 5 ZP-24-354 ZP-C24-680 4/0 (120.0) 4 ZP-C24-353 ZP-C24-79 1/0 (50.0) 2 10 X(G) X 4 (250) 35 ZP-24-352 ZP-C24-72 8 (10.0) 7 ZP-C24-36 X 10 (6.0) 63 5 60 10 6 4 68 10 5 69 4 58 ZP-C24-81 X(G) 15 ZP-24-83 X 4 ZP-24-84 X 58 58 77 58 58 77 ZP-24-384 X X ZP-24-385 X 100 100 81 ZP-24-388 X 72 72 80 ZP-24-389 X 60 60 ZP-28-314 X 100 83 78 17 81 ZP-C28-15 X 47 43 ZP-C28-18 X 6 2 4 63 & 82 ZP-C28-R18 X 6 2 4 82 ZP-C28-21 X 8 4 4 66 ZP-28-322 ZP-C28-23 X 143 X(G) 1 81 5 5 X 55 ZP-C28-327 X 6 ZP-C28-328 X 29 23 ZP-28-339 X 42 42 X ZP-C28-42 X(G) 6 ZP-C28-43 X(G) 8 X X 76 143 ZP-28-324 ZP-C28-R44 3 41 5 3 6 77 6 2 2 74 4 4 1 ZPC28-R44 63 4 76 4 7 61 3 4 64 & 83 66 64 & 83 83 (G) depicts arrangement with grounded contact 53 STAR-LINE(R) Insert Configurations front face of pin insert shown 1 Contact (Dead Front Male Contact/Line Side) Style Wire Terminal Shell Type Size N Mod II Crimp C24 Insert Type Pin Socket Dash Number Catalog Qty. Size Current Number AWG (mm) Rating Voltage 386PN 386SN RIG-C24-386PN 1 RIG-C24-386SN 646-777 (300-400) 1135A 1000V Mod II Radsok C24 Crimp Pin Socket R386PN R386SN RIG-C24-R386PN 1 RIG-C24-R386SN 646-777 (300-400) 1135A 1000V Mod II Radsok C24 Busbar Pin Socket R386PR R386SR RIG-C24-R386PR 1 RIG-C24-R386SR 646-777 (300-400) 1135A 1000V Mod II Crimp C24 Mod II Radsok C24 Crimp Crimp C24 Mod II Mod II Radsock C24 Crimp Mod II Crimp C24 Mod II Radsock C24 Crimp Mod II Crimp C24 Mod II Radsock C24 Crimp Pin Socket Pin Socket Pin Socket Pin Socket Pin Socket Pin Socket Pin Socket Pin Socket 535PN 535SN R535PN R535SN R444PN R444SN R444PN R444SN R373PN R373SN R373PN R373SN R313PN R313SN R313PN R313SN RIG-C24-535PN 1 RIG-C24-535SN RIG-C24-R535PN 1 RIG-C24-R535SN RIG-C24-444PN 1 RIG-C24-444SN RIG-C24-R444PN 1 RIG-C24-R444SN RIG-C24-373PN 1 RIG-C24-373SN RIG-C24-R373PN 1 RIG-C24-R373SN RIG-C24-313PN 1 RIG-C24-313SN RIG-C24-R313PN 1 RIG-C24-R313SN 535 (240) 535 (240) 444 (185) 444 (185) 373 (150) 373 (150) 313 (120) 313 (120) 900A 1000V 900A 1000V 800A 1000V 800A 1000V 700A 1000V 700A 1000V 625A 1000V 625A 1000V N 535 MCM, 444 MCM 373 MCM, 313 MCM N 1 Contact Style 777 MCM Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod II Crimp C20 Pin Socket 379PN 379SN Service Voltage Rating ZP-C20-379PN 1 500MCM D ZP-C20-379SN NOTE: Will accept 535 standard stranding 500 MCM extra flexible cable. N 1 Contact Style Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod II Crimp C16 Pin Socket Grounding Contact Termination Symbol Solder Well Pressure Crimp 341PN 341SN Service Voltage Rating ZP-C16-341PN 1 4/0 D ZP-C16-341SN 341 MCM Contact Symbols Wire Size AWG 18 16 12 10 8 4 1/0 4/0 Metric 0.75 1.5 4.0 6.0 10.0 25.0 50.0 120.00 Pre-assembled insert should be ordered mounted in barrel. 350 MCM 500 MCM 646-777 185.00 240.00 300-400 SERVICE VOLTAGE RATING A = 240V, D = 600V 54 Amphenol STAR-LINE(R) INDUSTRIAL Insert Configurations front face of pin insert shown 3 Contacts Style Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod I Solder 12 Pin Socket 27P 27S ZP-12-27P ZP-12-27S Mod II Pin Socket 327PN 327SN ZP-12-327PN ZP-12-327SN Radsok 12 Crimp 3 N Service Voltage Rating 12 1 03 Mod II Crimp 12 Radsok Pin Socket 330PN 330SN ZP-12-330PN ZP-12-330SN 3 05 144 N Service Voltage Rating 12 36 3 05 3 Contacts 03 o 108o 04 144o N Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod I Solder 12 Pin Socket 56P 56S ZP-12-56P ZP-12-56S 3 Service Voltage Rating 8 Pin Socket 74P 74S ZP-16-74P ZP-16-74S Mod I Pressure 16 Pin Socket 74PR 74SR ZP-16-74PR ZP-16-74SR 04 3 o 2 02 03 180 140o o Service Voltage Rating 4 80o 01 3 220 Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod I Solder 16 1 A 3 Contacts Style 72 2 02 D o o 01 1 180o Style o 108 04 180o Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG 72 02 3 3 Contacts Style 01 2 D U (R)L 36o 01 D 02 3 Contacts Style Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod I Solder 16 Pin Socket 70P 70S ZP-16-70P ZP-16-70S Mod I Pressure 16 Pin Socket 70PR 70SR ZP-16-70PR ZP-16-70SR Grounding Contact Termination Symbol Solder Well Pressure Crimp 3 Service Voltage Rating 4 01 D Contact Symbols Wire Size AWG 18 16 12 10 8 4 1/0 4/0 Metric 0.75 1.5 4.0 6.0 10.0 25.0 50.0 120.00 Pre-assembled insert should be ordered mounted in barrel. 350 MCM 500 MCM 646-777 185.00 240.00 300-400 SERVICE VOLTAGE RATING A = 240V, D = 600V 55 o STAR-LINE(R) Insert Configurations 4 Contacts Style front face of pin insert shown Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod I Solder 12 Pin Socket 33P 33S ZP-12-33P ZP-12-33S 4 Mod II Crimp 12 Pin Socket 333PN 333SN ZP-12-333PN ZP-12-333SN Service Voltage Rating 16 D 4 Contacts Wire Style Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod I Solder 12 Pin 14P ZP-12-14P 4 10 Socket 14S ZP-12-14S Mod I Pressure 12 Pin Socket 14PR 14SR ZP-12-14PR ZP-12-14SR Mod II Crimp 12 Pin Socket 314PN 314SN ZP-12-314PN ZP-12-314SN Service Voltage Rating D U (R)L 4 Contacts Style Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod II Crimp 12 Pin Socket 316PN 316SN ZP-12-316PN ZP-12-316SN 4 Service Voltage Rating 10 04 D 252 U (R)L 4 Contacts Style Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod I Solder 12 Pin Socket 22P 22S ZP-12-22P ZP-12-22S Mod I Pressure 12 Pin Socket 22PR 22SR ZP-12-22PR ZP-12-22SR Mod II Crimp 12 Pin Socket 322PN 322SN ZP-12-322PN ZP-12-322SN Grounding Contact Termination Symbol Solder Well Pressure Crimp 4 N 324o 1 03 4 o 36 01 o 2 3 02 108 o Service Voltage Rating 10 D U (R)L Contact Symbols Wire Size AWG 18 16 12 10 8 4 1/0 4/0 Metric 0.75 1.5 4.0 6.0 10.0 25.0 50.0 120.00 Pre-assembled insert should be ordered mounted in barrel. 350 MCM 500 MCM 646-777 185.00 240.00 300-400 SERVICE VOLTAGE RATING A = 240V, D = 600V 56 Amphenol STAR-LINE(R) INDUSTRIAL Insert Configurations front face of pin insert shown 4 Contacts Style Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod I Solder 16 Pin Socket 28P 28S ZP-16-28P ZP-16-28S 4 Mod II Crimp 16 Pin Socket 328PN 328SN ZP-16-328PN ZP-16-328SN Service Voltage Rating 8 N 01 1 D o 2 4 U (R)L 45 02 3 o 112 30' NOTE: Cannot be used with short cable adapter 4 Contacts Style Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod I Solder 16 Pin Socket 22P 22S ZP-16-22P ZP-16-22S 4 Mod I Pressure 16 Pin Socket 22PR 22SR ZP-16-22PR ZP-16-22SR Mod II Crimp 16 Pin Socket 322PN 322SN ZP-16-322PN ZP-16-322SN Service Voltage Rating 4 U (R)L 255 Pin Socket 38P 38S ZP-16-38P ZP-16-38S Mod I Pressure 16 Pin Socket 38PR 38SR ZP-16-38PR ZP-16-38SR Mod III Crimp 16 Pin Socket 638PN 638SN 4 04 03 o 02 345o N 330o 05 315o 04 03 1 Service Voltage Rating 4 D 4G Insert Type Pin Socket Dash Number 40P 40S Catalog Qty. Number ZP-C20-40P 4 ZP-C20-40S Mod I Pressure C20 Pin Socket 40PR 40SR ZP-C20-40PR ZP-C20-40SR Mod III Crimp C20 Pin Socket 640PN 640SN Solder Well Pressure Crimp Size AWG 1/0 N Current Rating D 135 01 02 3 U (R)L Wire Style Terminal Shell Type Size Mod I Solder C20 105o o 2 4 Contacts Grounding Contact Termination Symbol 01 2 3 240o Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod I Solder 16 1 4 D 4 Contacts Style N 15 105o 120o o 01 1 2 4G U (R)L 3 02 165o Contact Symbols Wire Size AWG 18 16 12 10 8 4 1/0 4/0 Metric 0.75 1.5 4.0 6.0 10.0 25.0 50.0 120.00 Pre-assembled insert should be ordered mounted in barrel. 350 MCM 500 MCM 646-777 185.00 240.00 300-400 SERVICE VOLTAGE RATING A = 240V, D = 600V 57 STAR-LINE(R) Insert Configurations 4 Contacts front face of pin insert shown Wire Style Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod I Solder C20 Pin 42P ZP-C20-42P 4 1/0 Socket 42S ZP-C20-42S Mod I Pressure C20 Pin Socket 42PR 42SR Service Voltage Rating D 01 key position not available in pressure termination 4 Contacts Style Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod I Solder 24 Pin Socket 83P 83S ZP-24-83P ZP-24-83S 4 01 4 2 1 02 225 o N Service Voltage Rating 4/0 o 3 U (R)L ZP-C20-42PR ZP-C20-42SR 15 N 45o 01 2 3 D 1 4 4 Contacts Style N Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod I Solder C24 Pin Socket 26P 26S ZP-C24-26P ZP-C24-26S 4 Mod I Pressure C24 Pin Socket 26PR 26SR ZP-C24-26PR ZP-C24-26SR Service Voltage Rating 4/0 15o 01 1 D 2 4G U (R)L 3 02 165o 4 Contacts Style Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod I Solder C24 Pin Socket 38P 38S ZP-C24-38P ZP-C24-38S Mod II Pressure C24 Pin Socket 38PR 38SR ZP-C24-38PR ZP-C24-38SR Grounding Contact Termination Symbol Solder Well Pressure Crimp 4 Service Voltage Rating 4/0 N 15 o 01 3 D U (R)L 240 o 03 225 o 2 02 4 1 Contact Symbols Wire Size AWG 18 16 12 10 8 4 1/0 4/0 Metric 0.75 1.5 4.0 6.0 10.0 25.0 50.0 120.00 Pre-assembled insert should be ordered mounted in barrel. 350 MCM 500 MCM 646-777 185.00 240.00 300-400 SERVICE VOLTAGE RATING A = 240V, D = 600V 58 Amphenol STAR-LINE(R) INDUSTRIAL Insert Configurations 5 Contacts Style front face of pin insert shown Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod I Solder 12 Pin Socket 53P 53S Mod III Crimp 12 Pin Socket 653PN 653SN ZP-12-53P ZP-12-53S 5 Service Voltage Rating 12 N 2 1 D 3 4G 5 01 key position not available in presssure termination 5 Contacts Style Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG ModI Solder 12 Pin Socket 24P 24S ZP-12-24P ZP-12-24S Mod II Pin Socket 324PN 324SN ZP-12-324PN ZP-12-324SN Radsok 12 Crimp 5 Service Voltage Rating 12 N 48o 1 5 D 01 2 02 4 97o30' 3 U (R)L 5 Contacts Style Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod I Solder 16 Pin Socket 16P 16S ZP-16-16P ZP-16-16S 5 Mod II Crimp 16 Pin Socket 316PN 316SN ZP-16-316PN ZP-16-316SN Service Voltage Rating 8 N 36 o 01 5 D 1 2 4 U (R)L 3 5 Contacts Wire Style Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod I Solder 16 Pin 75P ZP-16-75P 5 8 Socket 75S ZP-16-75S Service Voltage Rating D N 2 1 U (R)L Grounding Contact Termination Symbol Solder Well Pressure Crimp 3 5 4G Contact Symbols Wire Size AWG 18 16 12 10 8 4 1/0 4/0 Metric 0.75 1.5 4.0 6.0 10.0 25.0 50.0 120.00 Pre-assembled insert should be ordered mounted in barrel. 350 MCM 500 MCM 646-777 185.00 240.00 300-400 SERVICE VOLTAGE RATING A = 240V, D = 600V 59 STAR-LINE(R) Insert Configurations front face of pin insert shown 5 Contacts Style Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod I Solder 20 Pin Socket 84P 84S ZP-20-84P ZP-20-84S 5 Mod I Pressure 20 Pin Socket 84PR 84SR ZP-20-84PR ZP-20-84SR Mod II Crimp 20 Pin Socket 384PN 384SN ZP-20-384PN ZP-20-384SN Service Voltage Rating 4 N D 3 4 2 U (R)L 1 5 5 Contacts Style Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod I Solder 20 Pin Socket 38P 38S ZP-20-38P ZP-20-38S Mod I Pressure 20 Pin Socket 38PR 38SR ZP-20-38PR ZP-20-38SR 5 Service Voltage Rating 4 15o N 01 1 D 5 2 U (R)L 4G 3 5 Contacts Style Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod I Solder C24 Pin Socket 79P 79S ZP-C24-79P ZP-C24-79S 5 Mod I Pressure C24 Pin Socket 79PR 79SR ZP-C24-79PR ZP-C24-79SR N Service Voltage Rating 1/0 2 1 E 3 U (R)L 01 5 108o 4 5 Contacts Style Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod I Solder C24 Pin Socket 49P 49S ZP-C24-49P ZP-C24-49S 5 Mod I Pressure C24 Pin Socket 49PR 49SR ZP-C24-49PR ZP-C24-49SR Service Voltage Rating 1/0 N 5 E 36 o 01 1 4G U (R)L 2 3 Grounding Contact Termination Symbol Solder Well Pressure Crimp Contact Symbols Wire Size AWG 18 16 12 10 8 4 1/0 4/0 Metric 0.75 1.5 4.0 6.0 10.0 25.0 50.0 120.00 Pre-assembled insert should be ordered mounted in barrel. 350 MCM 500 MCM 646-777 185.00 240.00 300-400 SERVICE VOLTAGE RATING A = 240V, D = 600V 60 Amphenol STAR-LINE(R) INDUSTRIAL Insert Configurations front face of pin insert shown 5 Contacts Style Mod I Mod I Wire Terminal Shell Type Size Solder C28 Pressure C28 Insert Type Pin Socket Pin Socket Dash Number 23P 23S 23PR 23SR Catalog Number Qty. ZP-C28-23P ZP-C28-23S ZP-C28-23PR ZP-C28-23SR Service Voltage Rating Size AWG 5 4/0 N 1 D 5 02 Wire Terminal Shell Type Size Crimp 12 Insert Type Pin Socket Dash Number 326PN 326SN Catalog Number Qty. ZP-12-326PN ZP-12-326SN Service Voltage Rating Size AWG 2 3 8 16 N Mod III Wire Terminal Shell Type Size Insert Type Dash Number 49P 49S Catalog Number Solder 20 Pin Socket Crimp 20 Pin Socket 649PN 649SN Insert Type Dash Number Catalog Number Qty. ZP-20-49P ZP-20-49S 270 o 05 4 3 2 04 E E 90o 02 03 115 o o Service Voltage Rating 1/0 12 o 01 1 180 Size AWG 2 3 45 5 A A 5 Contacts Mod I N A 280 o 04 250 o E B 80o 01 02 03 D 110o C 5 Contacts Style Mod I Wire Terminal Shell Type Size Solder C24 Pin Socket 48P 48S Qty. ZP-C24-48P ZP-C24-48S Service Voltage Rating Size AWG 3 2 4/0 12 N 45 D A 292o 03 o 01 1 5 2 4 3 02 157o30' Grounding Contact Termination Symbol Solder Well o 180o (R) Style 126 03 5 Contacts Mod II o 4G 3 Style 90 2 01 U (R)L Pressure Crimp Contact Symbols Wire Size AWG 18 16 12 10 8 4 1/0 4/0 Metric 0.75 1.5 4.0 6.0 10.0 25.0 50.0 120.00 Pre-assembled insert should be ordered mounted in barrel. 350 MCM 500 MCM 646-777 185.00 240.00 300-400 SERVICE VOLTAGE RATING A = 240V, D = 600V 61 STAR-LINE(R) Insert Configurations front face of pin insert shown 6 Contacts Style Mod I Mod III Wire Terminal Shell Type Size Pressure Crimp 20 20 Insert Type Pin Socket Pin Socket Dash Number Catalog Number 43PR 43SR ZP-20-43PR ZP-20-43SR 643PN 643SN Qty. Service Voltage Rating Size AWG 4 2 4 10 D D 30o N 01 1 4G 3 270 o 05 (R) 240 6 04 o 5 2 02 120o 03 180 6 Contacts Style Mod I Mod III Wire Terminal Shell Type Size Insert Type Solder 20 Pin Socket Crimp 20 Pin Socket Dash Number 46PR 46SR Catalog Number Qty. ZP-20-46P ZP-20-46S 646PN 646SN Service Voltage Rating Size AWG 2 4 1/0 4 334 A A 270 Style Mod I Mod III Insert Type Solder 20 Pin Socket Crimp 20 Pin Socket Dash Number 48P 48S Catalog Number Qty. ZP-20-48P ZP-20-48S 648PN 648SN Size AWG 3 3 1/0 12 A B 03 02 244 Service Voltage Rating 01 F C E D 6 Contacts Wire Terminal Shell Type Size 26 N 04 N 290 D D F A 01 04 B E D 03 C 02 145 215 Grounding Contact Termination Symbol Solder Well Pressure Crimp 70 Contact Symbols Wire Size AWG 18 16 12 10 8 4 1/0 4/0 Metric 0.75 1.5 4.0 6.0 10.0 25.0 50.0 120.00 Pre-assembled insert should be ordered mounted in barrel. 350 MCM 500 MCM 646-777 185.00 240.00 300-400 SERVICE VOLTAGE RATING A = 240V, D = 600V 62 Amphenol STAR-LINE(R) INDUSTRIAL Insert Configurations front face of pin insert shown 6 Contacts Style Mod I N Wire Terminal Shell Type Size Solder C24 Insert Type Pin Socket Dash Number 72P 72S Catalog Number Qty. ZP-C24-72P ZP-C24-72S Service Voltage 290o Rating 04 D D Size AWG 3 3 4/0 12 6 1 70o 01 5 2 4 3 02 03 145o 215o 6 Contacts Style Mod II Wire Terminal Shell Type Size Crimp C28 Insert Type Pin Socket Dash Number 327PN 327SN Catalog Number Qty. ZP-C28-327PN ZP-C28-327SN Service Voltage Rating Size AWG 6 1/0 N 30 o 01 1 D 60 02 2 5 o 03 90 o 6 4 04 3 120 05 230 o o 6 Contacts Style Mod I Wire Terminal Shell Type Size Solder C28 Insert Type Pin Socket Dash Number 18P 18S Catalog Number Qty. ZP-C28-18P ZP-C28-18S 4 2 Size AWG 350 MCM 12 Service Voltage Rating N 1 5 D E 01 60 o 4 2 3 6 02 120 03 195 Grounding Contact Termination Symbol Solder Well Pressure Crimp o Contact Symbols Wire Size AWG 18 16 12 10 8 4 1/0 4/0 Metric 0.75 1.5 4.0 6.0 10.0 25.0 50.0 120.00 Pre-assembled insert should be ordered mounted in barrel. 350 MCM 500 MCM 646-777 185.00 240.00 300-400 SERVICE VOLTAGE RATING A = 240V, D = 600V 63 o STAR-LINE(R) Insert Configurations front face of pin insert shown 6 Contacts Style Mod I Wire Terminal Shell Type Size Solder C28 Mod I Pressure C28 Mod I Radsok C28 Pressure Insert Type Pin Socket Pin Socket Pin Socket Dash Number Catalog Number Qty. 42P 42S 42PR 42SR ZP-C28-42P ZP-C28-42S ZP-C28-42PR ZP-C28-42SR R42PR R42SR ZP-C28-R42PR ZP-C28-R42SR Service Voltage Rating Size AWG 4 2 4/0 10 N 5 D D 1 6 4G U (R)L 01 90 2 02 3 126 03 180 7 Contacts Style Mod I Wire Terminal Shell Type Size Radsok C28 Pressure Insert Type Pin Socket Dash Number R44PR R44SR Insert Type Dash Number Catalog Number ZP-C28-R44PR ZP-C28-R44SR Qty. 3 3 1 Size AWG 4/0 8 10 Service Voltage Rating D D D Size AWG Service Voltage Rating o N 7 Contacts Style Mod II Wire Terminal Shell Type Size Crimp 12 Pin Socket 348PN 348SN Catalog Number Qty. ZP-12-348PN ZP-12-348SN 7 16 330o 300 A 270 (R) 10 o 240 11 o 210 Style Mod II Radsok Crimp 12 Insert Type Pin Socket Dash Number 310PN 310SN Catalog Number Qty. 4 ZP-12-310PN ZP-12-310SN 7 12 o 6 A 5 Solder Well Pressure Crimp 180 03 90 04 150 o 60 02 o 120o o 1 7 4 2 3 Ground terminal method same as corresponding line contacts (R) Grounding Contact Termination Symbol 05 o N Service Voltage Rating Size AWG 3 07 06 7 Contacts Wire Terminal Shell Type Size 2 7 5 08 o 01 1 6 09 30 N Contact Symbols Wire Size AWG 18 16 12 10 8 4 1/0 4/0 Metric 0.75 1.5 4.0 6.0 10.0 25.0 50.0 120.00 Pre-assembled insert should be ordered mounted in barrel. 350 MCM 500 MCM 646-777 185.00 240.00 300-400 SERVICE VOLTAGE RATING A = 240V, D = 600V 64 o o Amphenol STAR-LINE(R) INDUSTRIAL Insert Configurations front face of pin insert shown 7 Contacts Style Mod II Wire Terminal Shell Type Size Radsok Crimp 12 Insert Type Pin Socket Dash Number 354PN 354SN Catalog Number Qty. ZP-12-354PN ZP-12-354SN Service Voltage Rating Size AWG 7 12 N 1 A 2 7 3 4 6 5 (R) N 7 Contacts Style Mod II Wire Terminal Shell Type Size Crimp 16 Insert Type Pin Socket Dash Number 378PN 378SN Catalog Number Qty. ZP-16-378PN ZP-16-378SN Size AWG 7 1 Service Voltage Rating 12 280 o 04 03 Mod II Wire Terminal Shell Type Size Crimp 20 Insert Type Pin Socket Dash Number 359PN 359SN Catalog Number Qty. ZP-20-359PN ZP-20-359SN Service Voltage Rating Size AWG 7 8 288 252 N 08 Mod II Crimp 01 1 2 7 4 06 C24 Insert Type Pin Socket Dash Number 353PN 353SN Catalog Number Qty. ZP-C24-353PN ZP-C24-353SN Size AWG 4 4 1/0 12 1 7 02 2 3 6 5 71o 03 108o 4 04 222o Grounding Contact Termination Symbol Solder Well Pressure Crimp Contact Symbols Wire Size AWG 18 16 12 10 8 4 1/0 4/0 Metric 0.75 1.5 4.0 6.0 10.0 25.0 50.0 120.00 Pre-assembled insert should be ordered mounted in barrel. 350 MCM 500 MCM 646-777 185.00 240.00 300-400 SERVICE VOLTAGE RATING A = 240V, D = 600V 65 o 30o 01 8 B A 108 144o o N Service Voltage Rating 03 o 04 05 180 72 02 3 5 07 8 Contacts Style 36o 6 216o Wire Terminal Shell Type Size 228o 180o E o 01 02 o 09 o 4 5 324o 7 Contacts Style 3 6 D 140 2 7 STAR-LINE(R) Insert Configurations front face of pin insert shown 8 Contacts Style Mod I N Wire Terminal Shell Type Size Solder C28 Insert Type Pin Socket Dash Number 21P 21S Catalog Number Qty. ZP-C28-21P ZP-C28-21S 4 4 Size AWG 350 MCM 12 Relay Service Voltage Rating 1 5 D E 7 4 60 01 o 2 8 6 3 8 Contacts Style Mod I Wire Terminal Shell Type Size Solder C28 Insert Type Pin Socket Dash Number 43P 43S Catalog Number Qty. ZP-C28-43P ZP-C28-43S 4 4 Size AWG 350 MCM 12 Relay N Service Voltage Rating 2 6 7 D E 01 3 1 8 5 4G 9 Contacts Style Mod I Wire Terminal Shell Type Size Solder 16 Insert Type Pin Socket Dash Number 29P 29S Catalog Number Qty. ZP-16-29P ZP-16-29S Size AWG 1 8 N Service Voltage Rating 4 16 300 o 05 D D 8 7 240 6 04 o 1 9 Mod II Crimp 16 Insert Type Pin Socket Dash Number 346PN 346SN Catalog Number Qty. ZP-16-346PN ZP-16-346SN 6 3 12 8 8 7 A A 6 230 (R) Grounding Contact Termination Symbol Solder Well Pressure Crimp 02 o 1 9 5 05 60 o 120 o o 30 N Service Voltage Rating Size AWG 4 03 9 Contacts Wire Terminal Shell Type Size 01 3 5 180 Style 2 o 01 2 02 3 4 60 o 03 90o 04 120o Contact Symbols Wire Size AWG 18 16 12 10 8 4 1/0 4/0 Metric 0.75 1.5 4.0 6.0 10.0 25.0 50.0 120.00 Pre-assembled insert should be ordered mounted in barrel. 350 MCM 500 MCM 646-777 185.00 240.00 300-400 SERVICE VOLTAGE RATING A = 240V, D = 600V 66 75o Amphenol STAR-LINE(R) INDUSTRIAL Insert Configurations front face of pin insert shown 10 Contacts Style Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod II Crimp 12 Pin Socket 355PN 355SN ZP-12-355PN ZP-12-355SN 10 N Service Voltage Rating 16 5 4 3 A 10 9 6 1 2 7 75o 01 8 (R) N 10 Contacts Style Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod II Crimp 12 Pin Socket 334PN 334SN ZP-12-334PN ZP-12-334SN 10 16 1 9 8 Service Voltage Rating 7 6 10 4 5 A 2 3 70o 02 03 145o (R) 10 Contacts Style Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod II Crimp 16 Pin Socket 381PN 381SN ZP-16-381PN ZP-16-381SN 4 6 N Service Voltage Rating 10 12 5 4 8 D D 10 9 30 01 o 02 45 o 1 6 2 3 7 (R) 10 Contacts Style Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod II Crimp 16 Pin Socket Grounding Contact Termination Symbol Solder Well 35o N Pressure Crimp 376PN 376SN ZP-16-376PN ZP-16-376SN 4 6 Service Voltage Rating 10 12 1 6 9 01 2 7 5 D D 4G 10 8 3 Contact Symbols Wire Size AWG 18 16 12 10 8 4 1/0 4/0 Metric 0.75 1.5 4.0 6.0 10.0 25.0 50.0 120.00 Pre-assembled insert should be ordered mounted in barrel. 350 MCM 500 MCM 646-777 185.00 240.00 300-400 SERVICE VOLTAGE RATING A = 240V, D = 600V 67 STAR-LINE(R) Insert Configurations front face of pin insert shown 10 Contacts Style N Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod I Solder 20 Pin Socket 55P 55S ZP-20-55P ZP-20-55S 2 8 Service Voltage Rating 1/0 12 D D o 01 1 8 7 30 2 10 9 6 60o 02 90o 03 3 5 04 4 120 (R) 10 Contacts Style N Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod III Crimp C24 Pin Socket 680PN 680SN 4 6 Service Voltage Rating 1/0 12 Pin Socket 375PN 375SN ZP-20-375PN ZP-20-375SN 12 27o 9 D 8 01 1 2 10 12 214 5 Pin Socket 349PN 349SN ZP-16-349PN ZP-16-349SN 2 12 o 173 8 D A 7 12 6 30 1 14 Solder Well Pressure Crimp o 02 2 60 10 3 03 4 06 o 90 o 04 112o 05 157 Grounding Contact Termination Symbol 133o 01 9 13 11 5 107o o N Service Voltage Rating 4 16 04 05 14 Contacts Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG 03 4 06 67o 3 7 (R) Mod II Crimp 16 02 11 6 Style 3 8 N Service Voltage Rating 10 7 10 12 Contacts Mod II Crimp 20 2 9 5 4G Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG 01 1 (R) Style 35o 6 D D 135 o o Contact Symbols Wire Size AWG 18 16 12 10 8 4 1/0 4/0 Metric 0.75 1.5 4.0 6.0 10.0 25.0 50.0 120.00 Pre-assembled insert should be ordered mounted in barrel. 350 MCM 500 MCM 646-777 185.00 240.00 300-400 SERVICE VOLTAGE RATING A = 240V, D = 600V 68 o Amphenol STAR-LINE(R) INDUSTRIAL Insert Configurations front face of pin insert shown 15 Contacts Style N Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod I Solder 24 Pin Socket 40P 40S ZP-24-40P ZP-24-40S 5 10 Service Voltage Rating 1/0 16 9 8 13 Mod I Solder C24 Pin Socket 47P 47S ZP-C24-47P ZP-C24-47S 5 10 N Service Voltage Rating 1/0 12 D A Mod I Solder C24 5 6 Pin Socket 81P 81S ZP-C24-81P ZP-C24-81S 5 10 Service Voltage Rating 1/0 12 4 3 D A 5 1 6 13 12 2 14 11 15 10 9 16 Contacts 7 8 N Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod II Crimp 16 Pin Socket 325PN 325SN ZP-16-325PN ZP-16-325SN 16 Service Voltage Rating 16 9 8 D 243o 03 Grounding Contact Termination Symbol Pressure Crimp 7 10 1 15 11 14 16 6 13 12 5 2 3 01 90o 4 02 180 (R) 4 N Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Solder Well 3 12 13 14 15 Contacts Style 2 15 8 126o 01 11 9 02 36o 1 10 7 Style 4 5 6 15 Contacts Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG 3 12 14 7 Style 2 11 15 o 01 1 10 D D 36 o Contact Symbols Wire Size AWG 18 16 12 10 8 4 1/0 4/0 Metric 0.75 1.5 4.0 6.0 10.0 25.0 50.0 120.00 Pre-assembled insert should be ordered mounted in barrel. 350 MCM 500 MCM 646-777 185.00 240.00 300-400 SERVICE VOLTAGE RATING A = 240V, D = 600V 69 STAR-LINE(R) Insert Configurations front face of pin insert shown 16 Contacts Style Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod II Crimp 20 Pin Socket 358PN 358SN N Service Voltage Rating ZP-20-358PN 16 8 ZP-20-358SN 1 10 A 8 12 7 (R) Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod II Crimp 12 Pin Socket 323PN 323SN N Service Voltage Rating ZP-12-323PN 17 18 ZP-12-323PN 306 270 A o 08 o 07 234 o 12 17 11 10 06 16 9 8 Mod II Crimp 16 Pin Socket 324PN 324SN ZP-16-324PN ZP-16-324SN 2 16 13 2 300 D D o 06 01 14 Radsok 16 Crimp Pin Socket 377PN 377SN ZP-16-377PN ZP-16-377SN 19 13 12 255 2 15 17 10 Service Voltage Rating 9 7 8 7 Crimp 6 4 5 60o 02 90 03 19 14 15 4 01 10 18 17 (R) Pressure o 24o 9 16 6 5 Solder Well o 150o 8 Grounding Contact Termination Symbol o 108 01 o N A 3 16 05 11 o 211 12 03 144 19 Contacts Mod II 4 04 14 1 04 Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG 72 02 3 15 5 7 6 18 (R) Style o N Service Voltage Rating 10 16 1 o 18 Contacts Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG 36 05 198 (R) Style 4 5 6 17 Contacts Style 3 03 90 16 13 57 02 2 11 15 14 9 36 01 3 11 13 12 1 2 Contact Symbols Wire Size AWG 18 16 12 10 8 4 1/0 4/0 Metric 0.75 1.5 4.0 6.0 10.0 25.0 50.0 120.00 Pre-assembled insert should be ordered mounted in barrel. 350 MCM 500 MCM 646-777 185.00 240.00 300-400 SERVICE VOLTAGE RATING A = 240V, D = 600V 70 o Amphenol STAR-LINE(R) INDUSTRIAL Insert Configurations front face of pin insert shown 19 Contacts Style Mod II Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Radsok 16 Crimp Pin Socket 312PN 312SN ZP-16-312PN ZP-16-312SN 19 N Service Voltage Rating 12 48 02 1 12 13 2 11 18 14 3 19 10 17 15 4 16 9 5 8 7 6 A o 03 144 (R) 19 Contacts Style Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod II Crimp 16 Pin Socket 355PN 355SN ZP-16-355PN ZP-16-355SN 19 324 Service Voltage Rating 16 288 o 09 10 08 A 252 N o 9 07 o 8 18 19 17 7 06 Mod II Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Radsok 20 Crimp Pin Socket 376PN 376SN ZP-20-376PN ZP-20-376SN 19 11 18 10 17 19 Contacts 388PN 388SN ZP-20-388PN ZP-20-388SN 19 4 Solder Well Pressure Crimp o 108 04 2 13 3 4 14 15 5 6 5 6 7 14 15 8 19 13 16 9 2 18 17 1 10 11 12 3 D (R) Grounding Contact Termination Symbol 03 72 N Service Voltage Rating 12 02 144o 7 (R) Pin Socket 19 16 8 Mod II Crimp 20 5 1 12 D Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG 15 16 180o 9 Style 3 14 4 N Service Voltage Rating 12 13 2 05 19 Contacts Style 01 6 216o (R) 36o 12 1 11 o Contact Symbols Wire Size AWG 18 16 12 10 8 4 1/0 4/0 Metric 0.75 1.5 4.0 6.0 10.0 25.0 50.0 120.00 Pre-assembled insert should be ordered mounted in barrel. 350 MCM 500 MCM 646-777 185.00 240.00 300-400 SERVICE VOLTAGE RATING A = 240V, D = 600V 71 o STAR-LINE(R) Insert Configurations front face of pin insert shown 20 Contacts Wire Style Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod I Solder 20 Pin 32P ZP-20-32P 20 12 Socket 32S ZP-20-32S Mod II Radsok 20 Pin 332PN ZP-20-332PN Crimp Socket 332SN ZP-20-332SN N Service Voltage Rating B Center A Outer 15 14 1 16 20 17 Mod II Radsok 20 Crimp Pin Socket 387PN 387SN 12 19 11 10 9 2 B Center A Outer 5 17 8 01 56o 18 9 1 16 20 15 19 10 11 13 12 N Mod II Crimp 20 Pin Socket 334PN 334SN ZP-20-334PN ZP-20-334SN 4 16 Service Voltage Rating 8 16 300 15 o 05 16 14 13 D D 1 2 3 01 17 4 20 19 18 5 12 11 10 9 8 6 7 02 60o 120 03 (R) 180o 21 Contacts Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod II Crimp 16 Pin Socket 344PN 344SN ZP-16-344PN ZP-16-344SN 10 11 12 16 Grounding Contact Termination Symbol Pressure Crimp 30o N Service Voltage Rating 14 1 01 2 20 15 3 12 21 16 19 4 02 11 5 10 18 17 6 9 7 8 05 13 A A 90o 03 222o (R) 7 14 Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Solder Well 8 4 6 20 Contacts Style 6 7 18 3 (R) Style 4 N Service Voltage Rating ZP-20-387PN 20 12 ZP-20-387SN 01 5 20 Contacts Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG 3 13 (R) Style 2 43o 30' 150o Contact Symbols Wire Size AWG 18 16 12 10 8 4 1/0 4/0 Metric 0.75 1.5 4.0 6.0 10.0 25.0 50.0 120.00 Pre-assembled insert should be ordered mounted in barrel. 350 MCM 500 MCM 646-777 185.00 240.00 300-400 SERVICE VOLTAGE RATING A = 240V, D = 600V 72 o Amphenol STAR-LINE(R) INDUSTRIAL Insert Configurations front face of pin insert shown 22 Contacts Style N Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod II Crimp 20 Pin Socket 331PN 331SN ZP-20-331PN ZP-20-331SN 2 20 Service Voltage Rating 8 16 12 11 21 10 1 17 22 13 E D 16 15 14 2 18 7 8 9 01 3 4 02 5 19 20 45o 90o 6 03 (R) 191o15' 26 Contacts Style Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod I Solder 16 Pin 37P ZP-16-37P Socket 37S ZP-16-37S 4 4 18 12 16 18 N 324o Service Voltage Rating 288 A A A o 252 18 1 2 3 17 4 16 23 22 15 5 19 26 6 24 14 21 7 25 13 20 8 12 11 9 10 07 216 01 09 08 o o 06 Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod II Crimp 16 Pin Socket 335PN 335SN ZP-16-335PN ZP-16-335SN 3 24 12 16 A A 13 24 23 12 22 11 10 108o o 33 30' 1 16 15 14 25 03 144o 180o N Service Voltage Rating 72o 02 04 05 27 Contacts Style 36o 2 01 17 26 18 3 19 27 20 21 8 9 4 5 02 90 o 6 7 (R) 27 Contacts Style N Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod II Crimp 16 Pin Socket Grounding Contact Termination Symbol Solder Well Pressure Crimp 373PN 373SN ZP-16-373PN ZP-16-373SN 24 3 Service Voltage Rating 16 12 4 3 A A 7 6 5 19 20 18 26 2 1 17 16 25 27 24 01 8 9 21 10 22 11 23 12 54o 02 90o 13 15 14G Contact Symbols Wire Size AWG 18 16 12 10 8 4 1/0 4/0 Metric 0.75 1.5 4.0 6.0 10.0 25.0 50.0 120.00 Pre-assembled insert should be ordered mounted in barrel. 350 MCM 500 MCM 646-777 185.00 240.00 300-400 SERVICE VOLTAGE RATING A = 240V, D = 600V 73 STAR-LINE(R) Insert Configurations front face of pin insert shown 27 Contacts Style Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod II Crimp 20 Pin Socket 374PN 374SN ZP-20-374PN ZP-20-374SN 2 25 Service Voltage Rating 4 12 15 D A 2 19 26 24 27 13 12 23 11 o 21 22 4 7 04 Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod II Crimp C28 Pin 328PN ZP-C28-328PN Socket 328SN ZP-C28-328SN 4 2 23 22 Service Voltage Rating 1/0 8 12 1 24 3 26 28 18 7 8 16 27 15 11 13 12 10 9 04 05 155 37 Contacts Mod II Crimp 16 Pin 321PN ZP-16-321PN Socket 321SN ZP-16-321SN 37 Service Voltage Rating 16 A N 292o30' 260 07 o 195 Mod II Radsok 20 Crimp Pin Socket 386PN 386SN ZP-20-386PN ZP-20-386SN 37 Service Voltage Rating 12 10 9 24 8 A 22 6 5 (R) Grounding Contact Termination Symbol Pressure Crimp 11 25 34 23 33 7 21 4 65o 97o30' 130 o N Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Solder Well 01 162o30' 37 Contacts Style o 32 30' 05 06 o o 17 18 1 19 2 30 3 02 31 29 15 32 20 4 37 28 21 36 5 33 03 14 27 22 35 34 23 6 13 26 7 24 25 12 8 11 04 10 9 08 o 135 16 09 227 30' (R) o 03 90o 6 17 14 Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG 66 02 5 19 D D A o o 4 20 o 45o 01 2 25 21 120 05 150 23 o 03 90 N 29 Contacts Style 45 20 5 6 8 9 10 o 02 3 18 25 14 225 01 1 17 16 06 Style 30 N 37 32 20 3 12 26 13 35 27 14 36 28 15 31 30 29 16 17 19 18 1 2 Contact Symbols Wire Size AWG 18 16 12 10 8 4 1/0 4/0 Metric 0.75 1.5 4.0 6.0 10.0 25.0 50.0 120.00 Pre-assembled insert should be ordered mounted in barrel. 350 MCM 500 MCM 646-777 185.00 240.00 300-400 SERVICE VOLTAGE RATING A = 240V, D = 600V 74 Amphenol STAR-LINE(R) INDUSTRIAL Insert Configurations front face of pin insert shown 37 Contacts Style Mod II Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Radsok 20 Crimp Pin Socket 350PN 350SN ZP-20-350PN ZP-20-350SN 37 N Service Voltage Rating 12 30 32 37 Contacts Pin Socket 371PN 371SN ZP-24-371PN ZP-24-371SN 37 Service Voltage Rating 16 15 D 14 1 34 (R) Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod I Solder C24 Pin Socket 36P 36S ZP-C24-36P ZP-C24-36S 2 35 Service Voltage Rating 1/0 12 D A 17 16 28 254 05 1 20 29 37 14 o 18 19 36 15 27 35 13 6 7 01 30 2 3 21 4 31 02 22 6 33 25 24 23 11 8 10 9 7 03 04 (R) 76 o 5 32 34 26 12 o 25o N 37 Contacts 03 90 8 9 10 4 23 24 25 11 45o 22 5 33 35 26 100o 3 21 32 37 36 02 2 20 19 31 27 13 01 30 29 28 02 o 18 17 16 12 Style 3 21 15 N Mod II Crimp 24 20 4 37 15 28 36 5 22 33 14 27 35 34 6 23 13 26 7 25 24 12 8 11 10 9 A Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG 2 31 16 29 (R) Style 1 19 18 17 127 o 178o 38 Contacts Style Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod II Crimp 20 Pin Socket 323PN 323SN ZP-20-323PN ZP-20-323SN 3 35 Service Voltage Rating 10 16 A A 315 283o 07 08 19 06 15 05 Solder Well Pressure Crimp 28 13 2 21 34 23 24 27 26 25 11 10 9 02 4 22 37 35 36 12 3 5 6 7 8 03 04 60o 90o 117o 225o (R) Grounding Contact Termination Symbol 38 29 14 32 33 31 30 01 1 20 18 17 16 255o 27o N o Contact Symbols Wire Size AWG 18 16 12 10 8 4 1/0 4/0 Metric 0.75 1.5 4.0 6.0 10.0 25.0 50.0 120.00 Pre-assembled insert should be ordered mounted in barrel. 350 MCM 500 MCM 646-777 185.00 240.00 300-400 SERVICE VOLTAGE RATING A = 240V, D = 600V 75 STAR-LINE(R) Insert Configurations front face of pin insert shown 42 Contacts Style Mod II 30 N Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Radsok 28 Crimp Pin Socket 339PN 339SN ZP-28-339PN ZP-28-339SN 42 Service Voltage Rating 12 18 D 32 16 (R) 35 14 12 11 46 Contacts Style Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod II Crimp 16 Pin Socket 371PN 371SN ZP-16-371PN ZP-16-371SN 45 1 04 120 o 05 150o o N Service Voltage Rating 18 8 7 8 9 06 180 03 90o 6 26 27 10 o 5 25 28 29 13 24 38 39 60 02 4 23 37 40 30 3 36 42 31 15 22 41 01 2 21 34 33 17 1 20 19 o 23 1 22 2 21 40 24 3 39 20 25 4 19 38 45 41 18 37 26 5 46 A A 17 36 44 16 15 43 34 14 27 6 42 35 33 13 31 32 12 11 28 7 29 30 8 9 10 (R) N 47 Contacts Style Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod II Crimp 20 Pin Socket 354PN 354SN ZP-20-354PN ZP-20-354SN 2 45 Service Voltage Rating 8 16 22 25 41 21 40 19 38 17 16 3 27 43 46 18 37 4 6 29 7 30 31 33 32 10 34 15 11 14 13 12 35 60 02 5 28 44 45 36 o 01 2 26 42 47 20 39 D A 1 24 23 30 03 90o 8 04 9 120o 05 06 o 150o 180o N 47 Contacts Style 25 Mod I Solder C28 Pin 15P ZP-C28-15P Socket 15S ZP-C28-15S 1 3 43 o Service 300 22 05 Voltage 21 36 Rating 1/0 4 12 18 240o 04 47 27 42 34 16 45 33 15 4 14 13 6 29 39 12 7 8 30 31 32 11 60o 5 28 44 40 01 43 46 17 3 38 41 35 19 2 26 37 20 D D A 1 24 23 Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG 9 02 10 03 180o Grounding Contact Termination Symbol Solder Well Pressure Crimp Contact Symbols Wire Size AWG 18 16 12 10 8 4 1/0 4/0 Metric 0.75 1.5 4.0 6.0 10.0 25.0 50.0 120.00 Pre-assembled insert should be ordered mounted in barrel. 350 MCM 500 MCM 646-777 185.00 240.00 300-400 SERVICE VOLTAGE RATING A = 240V, D = 600V 76 120 o Amphenol STAR-LINE(R) INDUSTRIAL Insert Configurations front face of pin insert shown 50 Contacts Style Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod III Crimp 20 Pin Socket 673PN 673SN 4 46 Service Voltage Rating 8 16 22 55 Contacts Mod III Crimp 16 Pin Socket 640PN 640SN 55 Inst. o 150 18 09 37 17 36 15 08 8 4 12 16 45 31 43 44 28 30 29 180 11 D D A A 16 6 12 150 o o o o 01 5 10 14 15 9 13 17 90 o 18 21 19 25 22 28 29 26 27 35 36 33 31 30 34 32 39 42 37 43 44 41 45 40 49 38 48 47 46 51 55 50 52 53 54 20 23 o 117 05 3 8 7 04 30 2 1 6 8 N 4 60 03 5 26 27 7 9 10 11 4 24 25 06 24 02 90 03 58 Contacts Style 52 12 o 23 40 41 120o o 02 3 42 53 32 13 51 55 46 33 55 Contacts 3 6 5 41 39 54 2 22 50 49 07 Service Voltage Rating 60o o 01 1 21 34 47 14 32 N 38 16 35 48 220 Mod II Crimp 28 Pin 324PN ZP-28-324PN Socket 324SN ZP-28-324SN o 20 19 285o 03 04 10 255o Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG 02 5 30 05 345 (R) Style 47 4 50 42 Service Voltage Rating 18 3 29 31 6 48 32 7 33 41 19 49 8 34 40 18 9 39 35 10 17 38 37 36 11 16 15 14 13 12 225 Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG 2 46 27 28 45 44 01 1 25 26 24 43 21 20 (R) Style 06 23 D A 30o N 315o 180o Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod I Solder 24 Mod II Radsok 24 Crimp Pin Socket Pin Socket 84P 84S 384PN 384SN ZP-24-84P ZP-24-84S ZP-24-384PN ZP-24-384SN 58 N Service Voltage Rating 12 A 6 5 4 2 (R) 44 27 26 1 33 46 45 28 11 32 31 30 29 3 10 9 8 7 25 24 49 57 50 51 52 41 23 14 56 58 42 13 35 48 53 43 34 47 55 54 12 22 40 21 15 36 16 37 17 38 18 39 19 20 01 165o Grounding Contact Termination Symbol Solder Well Pressure Crimp Contact Symbols Wire Size AWG 18 16 12 10 8 4 1/0 4/0 Metric 0.75 1.5 4.0 6.0 10.0 25.0 50.0 120.00 Pre-assembled insert should be ordered mounted in barrel. 350 MCM 500 MCM 646-777 185.00 240.00 300-400 SERVICE VOLTAGE RATING A = 240V, D = 600V 77 o STAR-LINE(R) Insert Configurations front face of pin insert shown 58 Contacts Style Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod II Radsok 24 Crimp Pin Socket 352PN 352SN ZP-24-352PN ZP-24-352SN 58 Service Voltage Rating 12 1 24 23 A 22 21 20 52 49 37 47 48 36 35 Pin Socket 35P 35S ZP-20-35P ZP-20-35S 60 16 A 270 o 05 21 51 38 20 19 37 225 48 46 15 20 Mod II Crimp 24 Pin Socket 331PN 331SN ZP-24-331PN ZP-24-331SN 7 53 12 16 A A 270 o 05 22 19 04 (R) 225o 59 51 50 49 37 17 16 56 57 48 47 35 15 30 43 54 44 14 46 6 12 7 8 32 33 34 13 5 31 45 55 36 18 4 42 60 58 21 38 20 52 3 29 53 o 01 2 28 41 24 40 39 1 27 26 25 23 120o 180o N Service Voltage Rating 02 03 o 60 Contacts Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG 8 10 11 12 13 14 7 9 33 34 35 16 6 32 45 47 36 04 56 5 31 44 55 60 57 49 4 30 43 54 58 3 29 42 59 50 18 (R) 2 53 52 22 39 01 1 28 40 17 11 9 10 03 120 06 180o 60 Contacts Mod II 20o 41 24 23 27 26 25 9 10 11 N Mod I Solder 20 Style 32 12 13 8 31 33 34 14 7 30 46 55 56 60 Contacts Service Voltage Rating 6 29 45 58 18 Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG 28 44 54 50 15 Style 5 53 57 39 16 4 43 51 40 17 01 3 27 41 19 (R) 2 25 26 42 38 Style o 45 N Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Radsok 24 Crimp Pin Socket 389PN 389SN ZP-24-389PN ZP-24-389SN 60 Service Voltage Rating 16 A (R) Grounding Contact Termination Symbol Solder Well Pressure Crimp Contact Symbols Wire Size AWG 18 16 12 10 8 4 1/0 4/0 Metric 0.75 1.5 4.0 6.0 10.0 25.0 50.0 120.00 Pre-assembled insert should be ordered mounted in barrel. 350 MCM 500 MCM 646-777 185.00 240.00 300-400 SERVICE VOLTAGE RATING A = 240V, D = 600V 78 o Amphenol STAR-LINE(R) INDUSTRIAL Insert Configurations 61 Contacts Style front face of pin insert shown Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod II Crimp 16 Pin Socket 333PN 333SN Service Voltage Rating N ZP-16-333PN 61 18 Inst. ZP-16-333SN 21 20 19 17 (R) 37 232o30' 15 04 53 59 51 50 36 35 14 24 1 25 43 13 2 26 3 27 4 44 55 60 52 38 16 42 54 40 39 18 23 22 41 61 46 29 6 57 58 34 12 33 11 31 32 10 02 30 7 47 48 49 75o 01 28 5 45 56 8 105o 9 03 150o 62 Contacts Style Mod II Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Radsok 20 Crimp Pin Socket 362PN 362SN ZP-24-362PN ZP-24-362SN 44 18 Service Voltage Rating 12 16 A (R) 64 Contacts Style N Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod II Crimp 20 Pin Socket 329PN 329SN ZP-20-329PN ZP-20-329SN 2 62 Service Voltage Rating 10 16 45 22 21 44 A A 59 19 42 Pin Socket Grounding Contact Termination Symbol 39 3 29 4 30 49 31 38 14 37 13 6 7 51 33 63 54 5 50 32 53 36 12 52 34 35 11 10 313PN 313SN ZP-20-313PN ZP-20-313SN 68 Service Voltage Rating 16 292o30' 8 02 Crimp 25 26 1 24 2 27 46 3 23 28 45 60 47 29 4 22 44 59 48 30 5 61 21 43 58 67 49 62 31 6 68 20 42 50 66 63 32 7 19 57 51 33 8 18 41 56 65 64 52 55 34 17 40 9 54 53 35 16 39 10 38 37 36 15 11 14 13 12 02 05 A 04 228o 01 90 9 N (R) Pressure 48 62 55 15 2 202 30' Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Solder Well 28 47 o 68 Contacts Mod II Crimp 20 1 27 61 56 40 03 (R) 26 64 57 18 41 17 25 60 20 43 58 16 Style 24 46 23 135 45 o o 03 o 157 30' Contact Symbols Wire Size AWG 18 16 12 10 8 4 1/0 4/0 Metric 0.75 1.5 4.0 6.0 10.0 25.0 50.0 120.00 Pre-assembled insert should be ordered mounted in barrel. 350 MCM 500 MCM 646-777 185.00 240.00 300-400 SERVICE VOLTAGE RATING A = 240V, D = 600V 79 o STAR-LINE(R) Insert Configurations 72 Contacts Style front face of pin insert shown Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod II Radsok 24 Crimp Pin Socket 388PN 388SN Service Voltage Rating (01) 30 N (02) 60 ZP-24-388PN 72 16 A ZP-24-388SN (03) 90 (04) 120 (05) 150 75 Contacts Style (06) 180 Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod II Crimp 24 Pin 354PN ZP-24-354PN Socket 354SN ZP-24-354SN 3 11 61 Service Voltage Rating 8 12 16 A A A N o 311 15' 09 27 26 53 25 270 o 08 23 50 64 47 20 19 46 18 07 Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod II Crimp 20 Pin Socket 344PN 344SN ZP-20-344PN ZP-20-344SN 11 70 300 A A 270 o o 180 19 43 42 17 06 12 04 15 38 37 58 05 o 71 25 4 26 27 5 28 52 02 90o 6 29 53 30 54 31 7 32 33 8 9 03 10 11 04 180 90 Contacts 45o 55 34 12 49 68 69 70 56 35 127o 3 67 51 78 79 24 66 50 77 80 57 36 48 65 76 81 59 72 39 64 75 74 61 01 2 23 46 47 63 40 60 73 13 225 135o o N Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod II Crimp 20 Pin Socket 345PN 345SN ZP-20-345PN ZP-20-345SN 90 Service Voltage Rating 18 A 27 26 270 06 46 21 66 05 (R) Grounding Contact Termination Symbol Pressure Crimp 18 65 44 17 84 90 88 79 55 72 82 89 45 20 225o 54 83 47 67 80 22 31 71 48 68 81 23 2 53 52 70 49 69 24 1 30 29 51 50 25 o 28 19 11 1 22 45 44 62 41 16 (R) Solder Well 10 40 160 o 21 20 03 90 8 9 39 05 06 18 07 14 Style 38 N Service Voltage Rating 12 18 59 13 14 15 60o 7 37 41 02 6 36 42 43 44 16 207o30' 81 Contacts Style 45 17 5 58 61 62 63 4 35 60 72 73 01 57 71 65 48 21 34 56 74 66 3 70 75 67 49 22 2 33 69 68 52 51 1 32 55 54 24 31 30 29 28 30o 3 32 57 73 5 33 56 85 74 86 01 4 34 58 59 6 7 35 36 75 37 60 76 38 61 10 78 77 39 62 11 64 63 40 87 43 42 16 41 15 14 13 12 04 54o 02 90o 8 9 03 130o 180o Contact Symbols Wire Size AWG 18 16 12 10 8 4 1/0 4/0 Metric 0.75 1.5 4.0 6.0 10.0 25.0 50.0 120.00 Pre-assembled insert should be ordered mounted in barrel. 350 MCM 500 MCM 646-777 185.00 240.00 300-400 SERVICE VOLTAGE RATING A = 240V, D = 600V 80 Amphenol STAR-LINE(R) INDUSTRIAL Insert Configurations front face of pin insert shown 100 Contacts Style Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod II Crimp 24 Pin Socket 313PN 313SN ZP-24-313PN ZP-24-313SN 100 Service Voltage Rating 16 N 1 32 30 A 29 28 27 31 57 56 55 54 76 93 100 98 51 73 88 97 72 87 23 50 86 71 49 22 70 48 21 47 20 19 18 24 (R) 100 Contacts Style Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod II Crimp 24 Pin Socket 385PN 385SN ZP-24-385PN ZP-24-385SN 100 Service Voltage Rating 16 A 3 62 61 34 2 60 33 59 79 28 96 89 88 74 73 53 87 45 16 68 69 46 17 70 47 18 21 22 19 48 49 50 23 24 14 44 15 71 72 13 43 85 86 51 52 12 67 84 97 26 25 42 66 95 98 75 54 11 41 83 100 90 27 10 40 82 99 76 55 9 20 N Pin Socket 314PN 314SN ZP-28-314PN ZP-28-314SN 17 83 Service Voltage Rating 12 16 53 25 A A 74 51 71 48 20 19 46 18 95 87 63 37 64 7 38 39 40 8 9 10 11 12 13 14 15 36 41 42 43 44 16 62 65 66 67 68 45 84 85 86 69 17 83 60o 6 35 61 82 01 5 34 60 80 96 4 33 81 100 97 70 47 79 98 88 3 32 59 94 99 89 72 49 (R) 91 58 93 92 90 73 50 21 76 2 31 78 77 75 52 24 23 54 1 57 56 55 26 30 29 28 27 22 N 143 Contacts Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Pin Socket 322PN 322SN ZP-28-322PN ZP-28-322SN 143 Service Voltage Rating 16 34 33 Grounding Contact Termination Symbol Crimp 35 68 67 36 37 38 39 71 72 40 70 69 97 98 99 120 1 73 2 41 74 100 3 42 75 4 43 5 44 01 46o30' 6 76 7 101 45 102 77 8 122 103 78 46 9 30 93 116 131 141 143 136 123 104 79 47 10 64 48 29 130 137 92 115 124 105 80 11 63 140 138 125 49 28 139 91 114 129 106 81 12 62 126 128 113 50 127 27 107 82 61 90 112 13 108 51 111 26 83 89 110 109 60 14 84 88 52 59 25 87 86 85 15 53 58 24 16 57 56 55 54 23 17 22 21 20 19 18 32 31 A (R) 9 10 65 41 11 66 84 12 67 42 68 43 13 14 44 45 15 16 81 93 91 77 57 29 Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Pressure 8 64 40 82 64 65 94 100 Contacts Solder Well 7 39 83 63 80 92 30 56 (R) Mod II Crimp 28 17 39 38 37 36 35 31 Style 46 8 7 6 5 4 1 Mod II Crimp 28 81 6 38 63 N 32 58 78 Style 85 69 37 62 80 95 96 5 36 61 94 89 4 35 60 79 99 90 52 74 25 3 34 59 92 91 53 75 26 77 2 58 33 78 66 65 96 95 118 94 117 119 133 134 121 132 142 135 Contact Symbols Wire Size AWG 18 16 12 10 8 4 1/0 4/0 Metric 0.75 1.5 4.0 6.0 10.0 25.0 50.0 120.00 350 MCM 500 MCM 646-777 185.00 240.00 300-400 SERVICE VOLTAGE RATING A = 240V, D = 600V Pre-assembled insert should be ordered mounted in barrel. 81 STAR-LINE(R) V.F.D. Insert Configurations A variable-frequency drive (VFD) controls the rotational speed of an alternating current (AC) electric motor by controlling the frequency of the electrical power supplied to the motor. VFD motors operate at varied voltages and frequencies, which in turn create higher operating temperatures - creating issues for most electrical connectors. Amphenol is able to meet the operating requirements of a VFD motor by incorporating a specially designed insert material. The inserts can carry a higher dielectric rating. allowing them to withstand the voltage spikes found in a VFD application. In addition, Amphenol utilizes our patented RADSOK(R) contact design in our VFD inserts. The RADSOK(R) contacts allow a higher amperage, and result in lower temperature rise in our connectors. These specific inserts have been selected to accommodate the phase conductors, as well as grounding conductors present in VFD rated cables In addition, shielding contacts are provided in these inserts to allow for terminating the overall cable shield to reduce EMI. These inserts are all also rated to 1000 V.A.C. front face of pin insert shown 6 Contacts Style Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod I Pressure 20 Pin Socket 43PR 43SR ZP-20-43PR ZP-20-43SR Mod III Crimp 20 Pin Socket 643PN 643SN 4 2 Service Voltage Rating 4 10 D D 30o N 01 1 4G 3 270 o 05 (R) 240 o 6 04 5 2 02 120o 03 180 6 Contacts Style Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod I Solder C28 Mod I Radsok C28 Solder Pin Socket Pin Socket 18P 18S R18P R18S ZP-C28-18P ZP-C28-18S ZP-C28-R18P ZP-C28-R18S 4 2 350 MCM 12 Service Voltage Rating N D E 1 5 01 60o 4 2 3 6 02 120o 03 195o Grounding Contact Termination Symbol Solder Well Pressure Crimp Contact Symbols Wire Size AWG 18 16 12 10 8 4 1/0 4/0 Metric 0.75 1.5 4.0 6.0 10.0 25.0 50.0 120.00 350 MCM 500 MCM 646-777 185.00 240.00 300-400 SERVICE VOLTAGE RATING A = 240V, D = 600V Pre-assembled insert should be ordered mounted in barrel. 82 Amphenol STAR-LINE(R) INDUSTRIAL V.F.D. Insert Configurations front face of pin insert shown N 6 Contacts Style Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Mod I Solder C28 Mod I Pressure C28 Pin Socket Pin Socket 42P 42S 42PR 42SR ZP-C28-42P ZP-C28-42S ZP-C28-42PR ZP-C28-42SR Mod I Pin Socket R42PR R42SR ZP-C28-R42PR ZP-C28-R42SR Radsok C28 Pressure 4 2 Service Voltage Rating 4/0 10 1 6 4G D D 01 90 2 U (R)L 02 3 126 o 03 180o N 7 Contacts Style Mod I 5 Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Radsok C24 Pin R44PR ZP-C24-R44PR 3 1/0 Pressure Socket R44SR ZP-C24-R44SR 3 8 Service Voltage Rating D D Refer to factory for current alternate keyways. N 7 Contacts Style Mod I Wire Terminal Shell Insert Dash Catalog Qty. Size Type Size Type Number Number AWG Radsok C28 Pin R44PR ZP-C28-R44PR 3 4/0 Pressure Socket R44SR ZP-C28-R44SR 3 8 1 10 Grounding Contact Termination Symbol Solder Well Pressure Crimp Service Voltage Rating D D D Contact Symbols Wire Size AWG 18 16 12 10 8 4 1/0 4/0 Metric 0.75 1.5 4.0 6.0 10.0 25.0 50.0 120.00 Pre-assembled insert should be ordered mounted in barrel. 350 MCM 500 MCM 646-777 185.00 240.00 300-400 SERVICE VOLTAGE RATING A = 240V, D = 600V 83 o STAR-LINE(R) Connector Components Spare Parts and Accessories male skirt for Straight Plug Shell Size 12 16 20 C20 24 C24 28 C28 Male skirts only for Mod I are designated by a four-digit number. Example: ZP-W-1312 (Star-Line) Male skirts only for Mod II are designated by a seven-digit number. Example: ZP-W-1312-200 (Star-Line) Mod II inserts must not be used in Mod I shells or Mod I inserts in Mod II shells as the method of accomplishing environmental sealing differs A Cat. No. Mod I ZP-W-1312 ZP-W-1316 ZP-W-1320 ZP-C-1320 ZP-W-1324 ZP-C-1324 ZP-W-1328 ZP-C-1328 Tapered left-hand thread Female Skirt for In-Line Receptacle A E Female skirts only for Mod I are designated by a four-digit number. Example: ZP-WO-1512 (Star-Line) Female skirts only for Mod II are designated by a seven-digit number. Example: ZP-WO-1512-200 (Star-Line) B ZP-WO-1512 ZP-WO-1516 ZP-WO-1520 ZP-CO-1520 ZP-WO-1524 ZP-CO-1524 ZP-WO-1528 ZP-CO-1528 Basic Barrel for Panel, Square Flange Receptacle 1-3/4 2-1/4 2-3/4 2-3/4 3-1/4 3-1/4 3-3/4 3-3/4 A Sq. B Sq. 1-61/64 2-31/64 3-1/32 3-1/32 3-9/16 3-9/16 4-1/16 4-1/16 1-1/2 2 2-1/2 2-1/2 3 3 3-1/2 3-1/2 D Tapered left-hand thread 1-3/32 1-19/32 2-3/32 2-3/32 2-19/32 2-19/32 3-3/32 3-3/32 Max Panel Thickness when back mounted using jack nut plugs Square flange receptacles only for Mod I are designated by a four digit number. Example: ZP-WO-1712 (Star-Line) G D Modified Acme thread H hole Dia. DIMENSIONS Shell Cat. No. Mod II inserts must not be used in Mod I Size Mod I A B C D 12 16 20 C20 24 C24 28 C28 ZP-WO-1712 ZP-WO-1716 ZP-WO-1720 ZP-CO-1720 ZP-WO-1724 ZP-CO-1724 ZP-WO-1728 ZP-CO-1728 1-3/4 2-1/4 2-3/4 2-3/4 3-1/4 3-1/4 3-3/4 3-3/4 1-3/8 1-11/16 2-3/32 2-3/32 2-17/32 2-17/32 3-1/32 3-1/32 1-1/2 2 2-1/2 2-1/2 3 3 3-1/2 3-1/2 2-1/64 2-1/64 2-1/64 2-33/64 2-1/64 2-33/64 2-1/64 2-33/64 E F 1 1 1 1-1/2 1 1-1/2 1 1-1/2 2-1/64 2-1/64 2-1/64 2-33/64 2-1/64 2-33/64 2-1/64 2-33/64 Tapered left-hand thread E C Square flange receptacles only for Mod II are designated by a seven digit number. Example: ZP-WO-1712-200 (Star-Line) 3/16 C DIMENSIONS Shell Cat. No. Size Mod I A B C D 12 16 20 C20 24 C24 28 C28 F Modified Acme thread Safety wire holes (3) .062 Dia. Mod II inserts must not be used in Mod I shells or Mod I inserts in Mod II shells as the method of accomplishing environmental sealing differs. shells or Mod I inserts in Mod II shells as the method of accomplishing environmental sealing differs. DIMENSIONS A 2-1/64 2-1/64 2-1/64 2-33/64 2-1/64 2-33/64 2-1/64 2-33/64 E 1-3/8 1-7/8 2-3/8 2-3/8 2-7/8 2-7/8 3-3/8 3-3/8 1/16" Gasket fits front or back of flange F F G H 1 1 1 1-1/2 1 1-1/2 1 1-1/2 1/4 1/4 1/4 3/4 1/4 3/4 1/4 3/4 11/64 13/64 7/32 7/32 9/32 9/32 11/32 11/32 Drill hole on panel 1/64" larger than Dimension "E" for front mounting or Dimension "C"for back mounting. **Maximum panel thickness may be increased 1/8" when using Standard Coupling Nut Plugs. 84 Amphenol STAR-LINE(R) Cable Grip Components Gland washers are not required when grommets are used with basket weave cable grips. B A 1-3/16 Grommets Washer ShellDimensions Size A B 12 16 20 & C20 24 & C24 28 & C28 See cable dia. column "A" for cable range 1-7/32 1-3/4 2-7/32 2-3/4 3-1/4 1/16 INDUSTRIAL Basket Weave Cable Dia. Cable Grommets Grips Dimension Dia. Oil Resistant Gland Washer Nominal Shell Code Rubber Steel Stainless Steel Length Size Min. Max. No.* Cat. No. Cat. No. Cat. No. Inches .062 .125 02 ZP-6312-2C ZP-8012-4E ZP-5012-4E 3 .125 .250 04 ZP-6312-4C .250 .375 06 ZP-6312-6C ZP-5012-6E 4 ZP-8012-8E .375 .500 08 ZP-6312-8C ZP-5012-8E 5 12 .500 .625 10 ZP-6312-10C ZP-5012-10E 6 ZP-8012-12E .625 .750 12 ZP-6312-12C ZP-5012-12E 7 .750 .875 14 ZP-6312-14C ZP-5012-14E 7-1/2 ZP-8012-15E .875 .937 15 ZP-6312-15C ZP-5012-15E 8 .250 .375 06 ZP-6316-6C ZP-5016-6E 4 ZP-8016-8E .375 .500 08 ZP-6316-8C ZP-5016-8E 5 .500 .625 10 ZP-6316-10C ZP-5016-10E 6 ZP-8016-12E .625 .750 12 ZP-6316-12C ZP-5016-12E 7 .750 .875 14 ZP-6316-14C ZP-5016-14E 7-1/2 16 ZP-8016-16E .875 1.000 16 ZP-6316-16C ZP-5016-16E 8-1/2 1.000 1.125 18 ZP-6316-18C ZP-5016-18E 9 ZP-8016-20E 1.125 1.250 20 ZP-6316-20C ZP-5016-20E 10 1.250 1.375 22 ZP-6316-22C ZP-8016-23E ZP-5016-23E 10-1/2 1.375 1.437 23 ZP-6316-23C .500 .625 10 ZP-6320-10C ZP-5020-10E 6 ZP-8020-12E ZP-5020-14E 7-1/2 .625 .750 12 ZP-6320-12C .750 .875 14 ZP-6320-14C ZP-5020-14E 7-1/2 ZP-8020-16E ZP-5020-18E 9 .875 1.000 16 ZP-6320-16C 1.000 1.125 18 ZP-6320-18C ZP-5020-18E 9 ZP-8020-20E 1.250 20 ZP-6320-20C ZP-5020-20E 10 20/C20 1.125 1.250 1.375 22 ZP-6320-22C ZP-8020-24E ZP-5020-24E 11 1.375 1.500 24 ZP-6320-24C 1.500 1.625 26 ZP-6320-26C ZP-8020-28E ZP-5020-28E 13 1.625 1.750 28 ZP-6320-28C 1.750 1.875 30 ZP-6320-30C ZP-8020-31E ZP-5020-31E 14-1/2 1.875 1.937 31 ZP-6320-31C .875 A E Gland Washers Washer ShellDimensions Size A B 12 16 20 & C20 24 & C24 28 & C28 See cable dia. column "A" for cable range 1-1/4 1-3/4 2-1/4 2-3/4 3-1/4 * Substitute Symbol for in Cable Adapter Catalog Number 1.000 16 ZP-6324-16C ZP-8024-16E ZP-5024-16E 1.000 1.125 18 ZP-6324-18C ZP-8024-20E ZP-5024-20E 1.125 1.250 20 ZP-6324-20C 1.250 1.375 22 ZP-6324-22C ZP-8024-24E ZP-5024-24E 1.375 1.500 24 ZP-6324-24C 1.500 1.625 26 ZP-6324-26C 24/C24 ZP-8024-28E ZP-5024-28E 1.625 1.750 28 ZP-6324-28C 1.750 1.875 30 ZP-6324-30C ZP-8024-32E ZP-5024-32E 1.875 2.000 32 ZP-6324-32C 2.000 2.125 34 ZP-6324-34C ZP-8024-36E ZP-5024-36E 2.125 2.250 36 ZP-6324-36C 2.250 2.375 38 ZP-6324-38C ZP-8024-39E ZP-5024-39E 2.375 2.437 39 ZP-6324-39C 1.375 1.500 24 ZP-6328-24C ZP-8028-24E ZP-5028-28E 1.500 1.625 26 ZP-6328-26C ZP-8028-28E ZP5028-28E 1.625 1.750 28 ZP-6328-28C 1.750 1.875 30 ZP-6328-30C ZP-8028-32E ZP-5028-32E 1.875 2.000 32 ZP-6328-32C 2.000 2.125 34 ZP-6328-34C 28/C28 ZP-8028-36E ZP-5028-36E 2.125 2.250 36 ZP-6328-36C 2.250 2.375 38 ZP-6328-38C ZP-8028-40E ZP-5028-40E 2.375 2.500 40 ZP-6328-40C 2.500 2.625 42 ZP-6328-42C ZP-8028-44E ZP-5028-46E 2.625 2.750 44 ZP-6328-44C 2.750 2.875 46 85 ZP-6328-46C ZP-8028-46E ZP-5028-46E 8-1/2 10 11 13 15 16 17-1/2 13 13 15 16 17-1/2 19 19 STAR-LINE(R) Connector Accessories Coupling Nuts (Star-Line only) A B Modified Acme Thread A1 B1 (3) Safety Wire Holes Insert Clamp Nuts A Shell Size 12 16 20/C20 24/C24 28/C28 Catalog No.DIMENSIONS Jacking Nut A B ZP-7012-30A 1-1/32 1-13/16 ZP-7016-30A 1-1/32 2-5/16 ZP-7020-30A 1-1/32 2-13/16 ZP-7024-30A 1-1/32 3-5/16 ZP-7028-30A 1-1/32 3-13/16 Shell Size 12 16 20/C20 24/C24 28/C28 Catalog No.DIMENSIONS Delay Nut A1 B1 ZP-7012-20A 3.09 1.71 ZP-7016-20A 3.09 2.00 ZP-7020-20A 3.09 2.50 ZP-7024-20A 3.75 3.00 ZP-7028-20A 3.75 3.50 Without Potting Sleeve Cat. No. 12 16 20 & C20 24 & C24 28 & C28 ZP-W-7512 ZP-W-7516 ZP-W-7520 ZP-W-7524 ZP-W-7528 With Type 8200DIMENSIONS Potting Sleeve Cat. No. A B ZP-W-7512-B ZP-W-7516-B ZP-W-7520-B ZP-W-7524-B ZP-W-7528-B 1-11/32 1-27/32 1-11/32 2-27/32 3-11/32 1-3/32 1-19/32 2-3/32 2-19/32 3-3/32 For use with insert clamp nut or panel board adapter to accept compound for sealing wire terminals. Potting sleeves are not for use with pressure-type contact units with insulator extension at back. Shell Size CatalogDIMENSIONS No. Overall Length O. D. I. D. 12 16 20 & C20 24 & C24 28 & C28 Metal potting Adapter Catalog No.DIMENSIONS Standard Nut A B ZP-7012-10A 47/64 1-13/16 ZP-7016-10A 47/64 2-5/16 ZP-7020-10A 47/64 2-13/16 ZP-7024-10A 47/64 3-5/16 ZP-7028-10A 47/64 3-13/16 Used when open-back wiring is desired behind panelboards or within large junction boxes on which the basic barrel is mounted Shell Size potting Sleeve Shell Size 12 16 20/C20 24/C24 28/C28 ZP-8212-11 ZP-8216-11 ZP-8220-11 ZP-8224-11 ZP-8228-11 1-1/4 1-1/4 1-1/4 1-1/4 1-1/4 1-3/64 1-35/64 2-3/64 2-35/64 2-63/64 Shell Size 12 16 20 & C20 24 & C24 28 & C28 Standard LengthDIMENSIONS Cat. No. A B C ZP-8612-11 2-15/32 1.4675 1.12 ZP-8616-11 2-15/32 1.8575 1.62 ZP-8620-11 2-15/32 2.3675 2.12 ZP-8624-11 2-15/32 2.8425 2.62 ZP-8628-11 2-15/32 3.4325 3.12 Shell Size 12 16 20 & C20 24 & C24 28 & C28 Short VersionDIMENSIONS Cat. No. A B C ZP-8612-12 1-3/4 1.4675 1.12 ZP-8616-12 1-3/4 1.8575 1.62 ZP-8620-12 2 2.3675 2.12 NA NA 86 55/64 1-23/64 1-55/64 2-23/64 2-51/64 D 1-3/32 1-19/32 2-3/32 2-19/32 3-3/32 D 1-3/32 1-19/32 2-3/32 Amphenol STAR-LINE(R) INDUSTRIAL Cable Adapter Components and Accessories For use with all inserts other than those with pressure terminals. Internal tapered pipe thread takes various types of threaded connectors. conduit adapters Tapped for Conduit Shell Size 12 16 20 & C20 24 & C24 28 & C28 NPT ConduitDIMENSIONS Tap Catalog Size No. A B C 3/4 1-1/4 1-1/2 2 2-1/2 ZP-W-2812 ZP-W-2816 ZP-W-2820 ZP-W-2824 ZP-W-2828 2-5/8 2-3/4 2-7/8 3 3-15/32 1-13/32 1-29/32 2-13/32 2-29/32 3-13/32 1-1/2 2 2-1/2 3 3-1/2 D 1-3/8 1-7/8 2-3/8 2-7/8 3-3/8 E 3/4 1-1/4 1-1/2 2 2-1/2 Shell Size Metric Conduit Tap Size Catalog No. A Dim. B Dim. C Dim. D Dim. E Dim. 12 M25 ZP-W-2412-H402 4.00 1.39 1.50 1.38 M25 DIMENSIONS 16 M40 ZP-W-2416-H402 6.00 1.89 2.00 1.88 M40 20 & C20 M50 ZP-W-2420-H40 6.00 2.39 2.50 2.38 M50 24 & C24 M63 ZP-W-2424-H402 6.00 2.89 3.00 2.88 M63 28 & C28 M75 ZP-W-2428-H402 6.00 3.9 3.50 3.38 M75 A B E Thread D Cable Adapter Thread Shell Size Size 1-3/8-12 1-7/8-12 2-3/8-12 2-7/8-12 3-3/8-12 12 16 20 & C20 24 & C24 28 & C28 C Standard Style Long Style Cat. No. Cat. No. ZP-W-2012 ZP-W-2016 ZP-W-2020 ZP-W-2024 ZP-W-2028 ZP-W-2412 ZP-W-2416 ZP-W-2420 ZP-W-2424 ZP-W-2428 Extra LongDIMENSIONS Style A Cat. No. Std. Lg. X Lg. ZP-W-2912 ZP-W-2916 ZP-W-2920 ZP-W-2924 ZP-W-2928 Tapered Left-hand Thread A B Thread 87 3 3-1/4 3-3/4 4-1/4 4-3/4 5-1/4 5-1/2 6 6-1/2 6-3/4 6-1/2 6-3/4 7-1/4 7-3/4 8 B 1-3/8 1-7/8 2-3/8 2-7/8 3-3/8 STAR-LINE(R) Cable Adapter Components and Accessories Mechanical Clamp Nut Shell Size CatalogDIMENSIONS No. A B C 12 16 20 & C20 24 & C24 28 & C28 ZP-W-5312 ZP-W-5316 ZP-W-5320 ZP-W-5324 ZP-W-5328 2-3/8 3 3-3/4 4-1/2 5-1/8 1-3/4 2-1/4 2-3/4 3-1/4 3-3/4 D 7/8 15/16 1 1-1/16 1-1/8 2 2-1/16 2-1/8 2-3/16 2-1/4 B Reversible clamps for complete cable range A Maximum C D For Basic Barrels. Used when a completely external mounting is required. Gasket furnished may be used for front panel mounting only. panelboard adapters (Star-Line only) Shell Size Catalog DIMENSIONS No. A B C D E F 12 16 20 & C20 24 & C24 28 & C28 ZP-W-2112 ZP-W-2116 ZP-W-2120 ZP-W-2124 ZP-W-2128 C 1-1/4 1-11/16 2-3/32 2-17/32 3-1/32 1-1/8 1-5/8 2-1/8 2-5/8 3-1/8 A Square F E 1-5/8 2-1/8 2-5/8 3-1/8 3-3/4 B Square Tapered Left-hand Thread H G J Hole Dia. 88 1-3/32 1-19/32 2-3/32 2-19/32 2-3/32 3/32 1/8 5/32 3/16 9/32 9/16 9/16 9/16 9/16 29/64 G 3/4 25/32 13/16 27/32 27/32 H 1-3/8 1-7/8 2-3/8 2-7/8 3-3/8 J 3/16 7/32 9/32 11/32 11/32 Amphenol STAR-LINE(R) INDUSTRIAL Cable Adapter Components and Accessories Transition adapters provide for using cable adapters one shell size larger than that of the basic barrel selected. They are used when terminating shielded cables require an increase in adapter diameter for additional wiring space. Transition adapters Adapter Shell DIMENSIONS Size Catalog No. A B C Shell Size 12 16 20 & C20 24 & C24 C D ZP-W-2316-40 ZP-W-2320-40 ZP-W-2324-40 ZP-W-2328-40 2 2-1/2 3 3-1/2 2-15/64 2-49/64 3-9/32 3-15/16 1-19/32 2-3/32 2-19/32 3-3/32 D 1-3/32 1-19/32 2-3/32 2-19/32 B Tapered left-hand thread 13/32 16 20 & C20 24 & C24 28 & C28 A 3/8 Gland Nut Use plain, or with basket weave cable grip 1-1/4 Shell Size B A 12 16 20 & C20 24 & C24 28 & C28 CatalogDIMENSIONS No. A B ZP-7312-10A ZP-7316-10A ZP-7320-10A ZP-7324-10A ZP-7328-10A 1-1/2 2 2-1/2 3 3-1/2 1-9/32 1-25/32 2-9/32 2-25/32 3-9/32 To securely lock plug coupling nut or threaded dust cap. Jam nut cannot be used on barrels with hinged spring cover. Safety jam nuts B 1/4 Modified Acme Thread A 89 Shell Size 12 16 20 & C20 24 & C24 CatalogDIMENSIONS No. A B ZP-7212-10A ZP-7216-10A ZP-7220-10A ZP-7224-10A 1-3/4 2-1/4 2-3/4 3-1/4 1-61/64 1-32/64 3-1/2 3-9/16 STAR-LINE(R) Connector Accessories - Protection Covers & Caps Environmental Covers with Chain Environmental covers are furnished with a six-inch length of stainless steel link chain. The chain is freely attached to a shouldered swivel post to avoid twisting when covers are applied or removed. The opposite end has a stainless steel ring for back of barrel attachment or a stainless steel eyelet for flange screw or separate screw attachment. Example: ZP-W-5512-A (Starline) APPLICATION: RING TYPE: For use with plugs and inline receptacles. To assemble slide ring over back end of barrel before applying cable adapter. EYELET TYPE: For use with flange mount plugs and flange mount receptacles. To assemble attach eyelet to flange mounting screw or drill and tap hole in adjacent mounting surface. Threaded Cap for Plugs Shell Size Cover Catalog No. with Ring and Chain Cover Catalog No.DIMENSIONS with Eyelet and Chain A D E 12 ZP-W-5512-A ZP-WF-5512-A 1-1/2 1-1/2 1-1/4 11/64 16 ZP-W-5516-A ZP-WF-5516-A 2 1-1/2 1-3/4 13/64 20 C20 ZP-W-5520-A ZP-C-5520-A ZP-WF-5520-A ZP-CF-5520-A 2-1/2 2-1/2 1-1/2 2 2-1/4 2-1/4 7/32 7/32 24 C24 ZP-W-5524-A ZP-C-5524-A ZP-WF-5524-A ZP-CF-5524-A 3 3 1-1/2 2 2-3/4 2-3/4 9/32 9/32 28 C28 ZP-W-5528-A ZP-C-5528-A ZP-WF-5528-A ZP-CF-5528-A 3-1/2 3-1/2 1-1/2 2 3-1/4 3-1/4 11/32 11/32 F D E Ring Dia. A Modified Acme Thread Dia. Threaded Cap for Receptacles Cap has a captive gasket for sealing. 6" Chain Shell Size Cover Catalog No. with Ring and Chain Cover Catalog No. DIMENSIONS with Eyelet and Chain E F G 12 ZP-W-5612-A ZP-WF-5612-A 1-1/4 11/64 1-23/32 16 ZP-W-5616-A ZP-WF-5616-A 1-3/4 13/64 2-7/32 20/C20 ZP-W-5620-A ZP-WF-5620-A 2-1/4 7/32 2-23/32 24/C24 ZP-W-5624-A ZP-WF-5624-A 2-3/4 9/32 3-7/32 28/C28 ZP-W-5628-A ZP-WF-5628-A 3-1/4 11/32 3-23/32 1-1/16 Modified Acme Thread Dia. G 90 F Dia. on Eyelet Amphenol STAR-LINE(R) INDUSTRIAL Connector Accessories - Protection Covers & Caps Hinged Spring Door Covers-Gasketed Covers have a stainless steel band to clamp over the coupling thread of female receptacles. The cover plate with a captive rubber gasket is pressed aluminum. A self-aligning seal is assured by the floating action of the cover on the center stainless-steel shouldered post. The hinge arm and support are machined aluminum extrusions. C Shell Size 12 16 20 & C20 24 & C24 28 & C28 Short Hinged Type Catalog No. ZP-C-5712 ZP-C-5716 ZP-C-5720 ZP-C-5724 ZP-C-5728 DIMENSIONS A B C 1-19/32 1-1/2 2-1/2 1-19/32 1-3/4 2-3/4 1-41/64 2-9/64 3-9/16 1-41/64 2-25/64 3-25/64 1-41/64 2-5/8 3-5/8 APPLICATION: SHORT HINGED TYPE: To clear standard coupling nut - Use with Square Flange Receptacles when front or back mounted. Shell Size 12 16 20 & C20 24 & C24 28 & C28 Long Hinged Type Catalog No. ZP-C-5712-14 ZP-C-5716-14 ZP-C-5720-14 ZP-C-5724-14 ZP-C-5728-14 DIMENSIONS A1 B C 1-23/32 1-1/2 2-1/2 1-23/32 1-3/4 2-3/4 1-49/64 2-9/64 3-9/16 1-49/64 2-25/64 3-25/64 1-41/64 2-5/8 3-5/8 APPLICATION: LONG HINGED TYPE: To clear coupling jack nut Use with Square Flange Receptacles when front mounted only. B 9/32 A (Short Hinged Type) A1 (Long Hinged Type) Plastic dust caps For temporary protection of assembled barrels while in storage and shipment. For Receptacles D For Plugs D1 L L1 91 Shell Size Receptacle Caps Catalog No. Shell Size Plug Caps Catalog No. 12 16 20 & C20 24 & C24 28 & C28 12 16 20 & C20 24 & C24 28 & C28 ZP-5612-11 ZP-5616-11 ZP-5620-11 ZP-5624-11 ZP-5628-11 ZP-5512-11 ZP-5516-11 ZP-5520-11 ZP-5524-11 ZP-5528-11 DIMENSIONS D L 1-3/4 2-1/4 2-22/32 3-7/32 3-15/16 5/8 11/16 21/32 21/32 1/2 DIMENSIONS D1 L1 1-13/32 1-29/32 2-3/8 2-29/32 3-11/16 11/16 11/16 11/16 11/16 1/2 STAR-LINE(R) conduit system accessories FS and FD Conduit Adapter Covers and Conduit Fitting Bodies Adapter covers and Bodies have environmental resistance adequate for most general applications. All adapter covers are supplied with screws and clips for mounting receptacle as well as bolts, washers and gasket for mounting cover to panel or conduit fitting body. Cast aluminum alloy adapter covers accept type ZRLP barrels. Conduit Adapter Covers - FS and FD Type Style Adapter Cover Catalog No. Shell Size 12 ZP-C-2512-11 Straight 16 ZP-C-2516-11 A 2-7/8 DIMENSIONS (Including Barrel) B C D 4-5/16 1-1/2 E 3-1/4 1-7/8 12 ZP-C-2512-13 45 Degree 2-7/8 4-5/16 2-5/16 3-1/4 16 ZP-C-2516-13 1-7/8 Conduit Fitting Bodies - FS and FD Type available in die cast copper-free aluminum or cadmium plated ferrous alloy A C B Die Cast Copper-Free Aluminum Type FS Cadmium Plated Ferrous Alloy Type FD Hub Size 1/2 3/4 1 Conduit Body Catalog No. N-FS18 N-FS28 N-FS38 Shell Size Hub Size Conduit Body Catalog No. 16 1 Shell Size 12 12 12 N-FD38 DIMENSIONS A B C 4-9/16 2-13/16 2-1/16 4-9/16 2-13/16 2-1/16 4-9/16 2-13/16 2-1/16 A 4-9/16 DIMENSIONS B C 2-13/16 Note: 1/2" and 3/4" hub deep junction boxes information available upon request. 92 3-1/16 Amphenol STAR-LINE(R) INDUSTRIAL conduit system accessories Adapter covers and Bodies have environmental resistance adequate for most general applications. All adapter covers are supplied with screws and clips for mounting receptacle as well as bolts, washers and gasket for mounting cover to panel or conduit fitting body. Cast aluminum alloy adapter covers accept type ZRLP barrels. Watertight Conduit Adapter Covers and Conduit Fitting Bodies STRAIGHT COVER Conduit Adapter Covers - Watertight Type Style Shell Size Adapter Cover Catalog No. 12 ZP-C-2512-10 DIMENSIONS (Including Barrel) A B D F Pitch UNC-2B 3-9/16 1 1-27/32 1/4-20 16 ZP-C-2516-10 4-3/16 3-9/16 20/C20 ZP-C-2520-10 4-1/2 3-7/8 1 1-27/32 1/4-20 Straight STANDARD COVER C 4-3/16 C 1-7/32 2-1/16 1/4-20 24 ZP-C-2524-10 8 7 1-1/2 2-9/16 1/2-13 C24 ZP-C-2524-10 8 7 1-1/2 2-27/32 1/2-13 28 ZP-C-2528-10 8 7 1-1/2 2-9/32 1/2-13 C28 ZP-C-2528-10 8 7 1-1/2 2-25/32 1/2-13 Above should not be used with pressure-type contact inserts. Conduit Adapter Covers cont. F 1 16 Shell Size D DEEP COVER Adapter Cover Style Standard Deep Cat. No. Cat. No. A ZP-C-2512-12 16 ZP-C-2516-12 16 A B 12 B FITTING DIMENSIONS CONDUIT FITTING BODY Mount with hub at top, bottom or either side. DIMENSIONS (Including Barrel) P-202704-16 A B C D F Pitch UNC-2B 4-3/16 3-9/16 2-13/16 2-7/16 1/4-20 4-3/16 3-9/16 2-15/16 2-17/32 1/4-20 4-3/16 3-9/16 4-7/16 4-1/16 1/4-20 20 4-1/2 3-7/8 3-39/64 3 ZP-C-2520-12 C20 4-1/2 3-7/8 3-39/64 3-3/8 1/4-20 1/4-20 4-1/2 3-7/8 5 4-1/2 20/C20 ZP-C-2520-26 4-1/2 3-7/8 5 4-7/8 1/4-20 24 8 7 3-33/64 2-19/64 ZP-C-2524-12 C24 8 7 3-33/64 2-21/32 1/2-13 24 8 7 5-3/4 4-9/16 P-202708-24 C24 8 7 5-3/4 5 1/2-13 28 8 7 3-5/8 2-7/16 ZP-C-2528-12 C28 8 7 3-5/8 2-3/4 1/2-13 28 8 7 5-3/4 4-9/16 P-202708-28 C28 8 7 5-3/4 5 1/2-13 1/4-20 1/2-13 1/2-13 1/2-13 1/2-13 Conduit Fitting Bodies - Cadmium Plated Ferrous Alloy Shell sizes 24/C24 and 28/C28 Conduit Body Hub Size 3/4 12 or 16 1 1-1/4 1-1/2 1-1/4 20 or C20 1-1/2 2 Conduit Body Cat. No. P-202760-42 P-202760-43 P-202760-64 P-202760-65 JRZ-610064 JRZ-610065 JRZ-610066 24 or C24 28 or C28 JR-720036-A JRZ-820036-A Shell Size 2-1/2 3 93 A1 5-1/4 5-1/4 5-1/4 5-1/4 6 6 6 A2 5-1/4 5-1/4 5-1/4 5-1/4 6 6 6 B 25/64 25/64 25/64 25/64 9/16 9/16 9/16 DIMENSIONS C1 C2 D 4-5/8 4-5/8 4-3/16 4-5/8 4-5/8 4-3/16 4-5/8 4-5/8 4-3/16 4-5/8 4-5/8 4-3/16 5-1/4 5-1/4 4-1/2 5-1/4 5-1/4 4-1/2 5-1/4 5-1/4 4-1/2 SEE BOTTOM DRAWING SEE BOTTOM DRAWING E 2-3/8 2-3/8 2-3/8 2-3/8 3-3/4 3-3/4 3-3/4 F 9/32 9/32 9/32 9/32 9/32 9/32 9/32 3-3/4 4-1/2 7/16 7/16 STAR-LINE(R) Contact Crimping Tools TP-201411-AG HAND CRIMP TOOL COMPLETE KIT This tool is complete with carrying case, checking gage, three contact locators and complete instructions for crimping #10 through #18 contacts of MOD II or MOD Ill design. TP-201411-TO Hand crimp tool only (less locators) TP-201411-16-18 Locator only for #16 and #18 pins and sockets TP-201411-10-12 Locator only for #10 pin and sockets and #12 sockets TP-201411-12P Locator only for all #12 pins any length TP-201351-TC HAND CRIMP TOOL This tool crimps #18 - #20 contacts utilizing thermocouple wire. TP-201351-TL HAND CRIMP TOOL This tool crimps #8 contacts only. TP-201352-HAND/FOOT PNEUMATIC CRIMP TOOL This tool is complete with foot control, checking gage, wrench, and complete instructions for crimping #10 through #18 contacts of MOD II or MOD III design. Thomas & Betts TOOL NUMBER TBM15 AND DIE NUMBER 15505 To terminate 500 MCM contact. TP-201328-F TP-201328 CRIMP TOOL TP-201328 PS-POWER SUPPLY TP-201328 BC-CARRYING CASE NOTE: Carrying case will accommodate crimp tool. NOTE: Power supply will include 5 dies and locators. * Foot control unit with 6 foot hose - Catalog No. TP-201328-F Normal operation 100 P.S.I. TP-201328 Crimping Tool Only and Accessories for Contacts #12 through #4/0 Contact Size Wire Size Die Number Check Gage Color Mod II (Locator) Mod III 12 W Length TP-201328-12 12-14 TP-201328-12D TP-201328-12G Yellow 12 C Length TP-201328-12C TP-201328-12L 10 W Length TP-201328-10 10-12 TP-201328-10D TP-201328-10G Black 10 C Length TP-210328-10C TP-210328-10L 8 W Length TP-201328-8 8-10 TP-201328-8D TP-201328-8G Red 8 C Length TP-201328-8C TP-201328-8L 4 W Length TP-201328-4 4-6 TP-201328-4D TP-201328-4G Brown 4 C Length TP-201328-4C TP-201328-4L 1/0-1 TP-201-328-0D TP-201328-0G 1/0 Blue TP-201328-0C 2 TP-201328-2D TP-201328-2G TP-201328-0L 4/0 4/0 - 3/0 TP-210328-41D TP-201328-41G 94 Green TP-201328-41 TP-201328-41L Amphenol STAR-LINE(R) INDUSTRIAL insertion and removal tools for MOD II & MOD III Tools for Crimp Type Contacts Insertion Tools Used for inserting contacts after they are terminated to conductor. Pin and socket contacts have identical terminal ends; the same tool is used for both. Size 8 4 0 0 A separate expander barrel is required for each cavity of the contact inset. Size Insertion Tool Catalog No. 18 16 12 10 TP-201047-1 TP-201048-1 TP-201049-1 TP-201046-1 Expander Barrel Catalog No. Use Same Tool for Pin or Socket Tapered Lead Style TP-201007-A TP-201007-B TP-201033-A TP-201033-B TP-201000-EBL TP-201000-TL TP-201000-EBS T-Bar Handle Style - - TP-201000-TH The T-Bar handle should be used in the insertion and extraction of the expander barrel for the 1/0 cavities -only one is required. An even number of long and short barrels should be used: Example: if the insert contains four cavities, use two long (EBL) and two short (EBS). Insert the short ones first and remove them last. One tapered lead required only. NOTE: EBS = Expander Barrel Short, EBL= Expander Barrel Long. Removal Tools Used for extracting contacts from the insert assembly after contacts have been seated. Expanders and taper leads are required for sizes 8, 4, 1/0 MOD II contacts only. Removal Tools for MOD II 95 Size Removal Tool Number for Pin Removal Tool Number for Socket 18 16 12 10 TP-201459 TP-201459 TP-201459 TP-201459 TP-201011-3 TP-201010-3 TP-201009-3 TP-201008-3 STAR-LINE(R) Star-Line connector Assembly and Termination Instructions Proper assembly of multiple-contact connectors, for the most part requires common sense. The simplicity of these instructions is perhaps the reason why they are easily overlooked or taken for granted. These 27 reminders can help eliminate connector failures caused by improper assembly. 1. Read the assembly instructions carefully before actually starting to assemble connectors. Besides the matter of instruction on correct procedures, there are two important reasons for this preliminary step: To identify the various component parts, and to check for any missing parts. 13. When inserts have more cavities than conductors, plug unused cavities with either plain contacts or special seal plugs designed for the purpose. Some connectors require both a contact and seal plug in unused cavities to meet military specifications and to assure complete internal environmental sealing. 2. Cut cable jackets and sheathing squarely and to correct length, using only wire strippers that have been approved for the operation. In preparing the individual wires in cables and harnesses for assembly, make allowances in length for reaching the outermost circle of contact cavities in the connector insert. This, of course, means that the conductors and the insulation should be cut progressively longer as they extend out from the center of the cable or harness to assure sufficient length for any necessary forming. 14. After all terminated contacts are inserted in their respective cavities and inspected, the cable adapter or insert clamp nut should be tightened with a wrench. This assembly operation should be done by placing the components in a vise with smooth-faced jaws and using a strap wrench. 4. Before starting actual termination wires, it is essential that cables and harnesses be laid out in a specified order in accordance with the wiring diagram. Proper layout will reduce the need for twisting and crossover of conductors. If the wiring layout is not correct, the termination operation will be difficult or even impossible and the chances for making errors will be increased. Cable and harness assemblies having a spiral layout also must be matched carefully to the correct contacts in both the male and female inserts. 16. When handling cables, use adequate support to prevent damage to the internal wires. Gland nuts and grommets are intended for sealing purposes and should not be used as a cable grip. 15. If for any reason terminated conductors have to be removed from an insert because of any assembly error or change in circuitry, be sure to remove the cable clamp or insert clamp nut first before extracting the contact and reinserting it. This step is important because any attempt to remove the contacts when the resilient insulator components are compressed will result in damage. 3. Follow specifications covering maximum cable stripping lengths for efficient cable grommet sealing. All wires should be cut squarely so that they will fit into contact wire wells correctly. 17. If one of the connector poles is a grounding wire, make sure that it is grounded properly before the connector is actually engaged. 18. When connectors having the same configuration are to be mounted close together, different or alternate keying arrangements should be used to prevent mismating or cross-mating and possible damage to the electrical system or human injury. 5. Some cables have a soft filler or braid on the conductors which, compresses when external pressure is applied. As a result, the cable diameter may be reduced to a point where the sealing range of the grommet is exceeded. In addition, the seal may take a permanent set and further reduce sealing efficiency. To avoid leakage at the seal under these conditions, it is suggested that, where construction of the cable permits, a metal ferrule be slipped under the cable jacket at the stressed position. This ferrule will serve as a compression supporting member and enable the gland seal to withstand high external pressures. 19. Always inspect all aspects of connector assembly operations before putting connectors into actual operation. 20. Crimping and terminating of conductors to contacts must be done carefully. Make certain that wire strands are fully bottomed in contact wells by checking through inspection hole provided. 21. Soldering conductors to contacts must be done carefully and a non-conductive flux should be used to avoid corrosion or hygroscopic action. Do not use solder salts or acids because they may affect the dielectric properties of insulation materials. 6. Use only correct size sealing grommets to assure resistance to moisture and other contaminants. Make certain that cable jacket is smooth where grommet is to seal. Remove any grooves or ridges if present by sanding or scarfing. 22. Be careful not to damage wire grommets or contact retaining collets when inserting or extracting contacts. 23. Never try to straighten bent contacts. Straightening cannot be done properly and the plating on contacts will very likely be marred. This will result in a high resistance connection and will expose the base metal to possible corrosion. 7. Use only the proper crimping tools that have been set or calibrated with precision gages. 8. When contacts are to be soldered, avoid direct contact of soldering tools to inserts. An open flame or hot soldering tip can carbonize insulating materials and make them useless. 24. Do not attempt to remove inserts that are bonded or locked in place in their shells. 9. Make certain that all contacts are the correct size before attempting to assemble them into insert cavities. This point is particularly important when both power and control types of contacts are used in the same connector. 25. Be certain that all components of connectors are assembled. Each part performs a vital function and it would not be included if it wasn't useful. 26. Each assembler of connectors should be his own inspector. Assembly workmanship is a significant factor in determining the quality of multiple-contact connectors. Quality cannot be "inspected" into connectors; it must be "built-in" during each and every assembly operation. 10. Be sure that grounding contacts are correctly located. 11. Seat all contacts properly so that they will not be damaged or become disengaged during connector mating operations. 12. Use only the proper insertion tools and be sure that they are aligned axially when pushing contacts into their fully seated position. 27. When potting connectors be sure to apply potting only in mated condition to assure that contacts will align properly. 96 Amphenol STAR-LINE(R) Additional Amphenol(R) Industrial Connector Products INDUSTRIAL Amphe EX The Amphe-EXTM is a new miniature explosion-proof threaded connector family from Amphenol Industrial. The Amphe-EXTM product line offers inserts that accommodate standard copper contacts, as well as coax and fiber optic contacts, to allow power and signal to pass through Hazardous rated areas. In addition, the Amphe-EXTM offers the availability of RJ45 and USB inserts. The Amphe-EXTM family provides an overall smaller package than most hazardous area connectors. The rugged AMPHE-EXTM connectors are ATEX and IECEx approved for Zone 1 (and Class 1, Div. 2) rated applications. Consult factory for certificate details. For more information, refer to Amphenol Catalog 12-056 or visit www.amphenol-industrial.com. Amphenol Cable Glands Amphenol Industrial Operations, the worldwide leader of explosion proof and hazardous environment interconnects, introduces a broad range of explosion proof and industrial cable glands. The cable gland products are designed to perform in the most demanding environments. Amphenol provides a complete line of EX Zone 1 and 2 rated cable glands along with general duty cable glands that are suitable for armored and unarmored cable. Brass and stainless steel types are available. IP66/68; deluge; NEMA rated products. SIRA/ATEX certified to Exd/Exe (Class I, Div. I) and CSA approved. Reference Catalog 12-055 Cable Assemblies & Value Add Solutions Amphenol Industrial, one of the world's premiere interconnect solutions providers, offers a complete array of cable assemblies and turnkey junction box options. From standard cable harnesses, to complete ATEX and IECEx rated junction boxes, Amphenol can provide all your value add solutions. Amphenol can provide simple cable assemblies using any of our full line of connectors. Also available are over-molded cable assemblies that provide a water tight, molded solution that requires no additional strain relief hardware. For an overview of Amphenol Industrial Connector Products ask for Amphenol brochure SL-381. Call your local Amphenol sales office or 800-678-0141 for further information. The Industrial Overview brochure and all the product brochures listed above can be viewed, printed and downloaded from the Amphenol website: www.amphenol-industrial.com. 97 STAR-LINE(R) STAR-LINE Connectors with RADSOK(R) Contacts RADSOK Contact Design: * Socket cylinder within female contact has several equally spaced longitudinal beams twisted into a hyperbolic shape. * As male pin is inserted, axial members in the female half deflect, imparting high current flow across the connection with minimal voltage loss. * The hyperbolic, stamped grid configuration ensures a large, coaxial, face-to-face surface area engagement. * Ideal for crimp termination applications requiring repeated mating cycles and high current with a low milli-volt drop. Certain designs are available for variable frequency drive (VFD) applications. Consult Amphenol Industrial Operations for further information. The new RADSOK contact design has been incorporated into the Star-Line connector family of connectors. Insert arrangements with RADSOK's are shown in this catalog. For information on availability of additional inserts with RADSOK's consult Amphenol Industrial Operations. Amphe-Power connectors with RADSOK sockets can handle up to 50% higher amperages than connectors with standard contacts. Current Amphe-Power product lines support from 50A to 500A continuous duty. RADSOK contacts are available in size 8 (69 amps), size 4 (120 amps), and size 0 (250 amps). RADSOK Contact Advantages: * Low contact resistance - the RADSOK contact's multiplicity of flat grid surfaces assures the greatest possible contact area on the mating pin. This results in longer life - reduced contact pressure yields reduced wear. * Low milli-volt drop performance - due to the intimate contact provided by the spring force of the grid, the flat contact surface and the wiping action during insertion. * Higher current capacity with minimized temperature rise. Lower overall contact resistance reduces heat build-up, thereby allowing higher current capacities at given temperature limits. Connectors with RADSOK contacts may be produced in various sizes with a variety of amperage capabilities. * Reliability under vibration and shock. System inertia is minimized by the small package and the fact that the contact is under a spring load. * High quality, consistency and lower cost with high speed, automated precision stamping and assembly technology See Brochure SL-391, Amphenol Amphe-Power Connectors with RADSOK Technology for more information on other Amphenol connector types that incorporate RADSOK contacts. 98 Amphenol STAR-LINE(R) Amphenol Industrial Oceanus Subsea Connectors Amphenol Industrial Operations offers a broad range of harsh environment interconnect solutions. Our new OCEANUS Series of Connectors are tailored to meet the rugged demands of the subsea market. The OCEANUS series consists of 3 new product ranges: POSEIDON, AQUA POWER and SUBMARINER. The product family offers versatile, high performance characteristics including 9,000 PSI open face pressure ratings, underwater wet mate-able connectors, multi-pin configurations, high speed (coax and fiber optic) and over-molded cable assembly options. POSEIDON * 500 VDC Signal and 3kv Power contacts * Up to 9,000 PSI open face pressure rating (6,000M) * Configurable for use with Solid and Oil -Filled Cables * Sealing caps, overmolding, and other options available * Solder contacts range from 22 awg through 10 awg * High Speed Coax (50 & 75 ) and Fiber Optic available * MIL-C-24217/4-005 spec, IP68 For more information reference IDS-42 * MIL-G-45204, Type II, Class 1 (50 microns Au) * Intermateable/intermountable with competitive products AQUA POWER * 316 stainless steel, Passivated per ATSM A967 * 500 vdc Signal and 3kv Power contacts * Up to 9,000 PSI open face pressure rating (6,000 M) * Configurable for use with Solid and Oil -Filled Cables * Sealing caps, overmolding (straight or 90) * Custom build option available * Optional coupling nut locking set screw available * Operating Temperature -50C to +60C * Solder contacts range from 20 awg through 2 awg For more information reference IDS-43 * IP68 rated SUBMARINER * ROVs and other Wet Mateable applications * Numerous configurations available * 1-16 contacts * Molded high-insulation neoprene * Heat-treated beryllium copper sockets, gold plating, and stainless steel bodies * Operating Temperature -50C to +60C For more information reference IDS-44 * Up to 9,000 PSI open face pressure rating (6,000 M) 99 INDUSTRIAL Amphenol Corporation Amphenol Aerospace Amphenol Industrial Operations 40-60 Delaware Avenue Sidney, NY 13838-1395 Phone: 607-563-5011 1-800-678-0141 Fax: 607-563-5157 www.amphenol-aerospace.com www.amphenol-industrial.com SALES OFFICES Amphenol Corporation Amphenol Aerospace Amphenol Industrial Operations 23276 South Pointe Drive, Suite 113 Laguna Hills, CA 92653 Phone: 949-855-4454 1-800-678-0141 Fax: 949-855-9115 Amphenol Corporation Amphenol Aerospace Amphenol Industrial Operations 2010 Corporate Ridge McLean, VA 22101 Phone: 1-800-678-0141 For information on International Products, a North American office can be contacted: Phone: 978-532-8800 Fax: 978-532-6800 Amphenol Industrial Operations Amphenol Power Solutions 34190 Riviera Drive Fraser, MI 48026 Phone: 586-294-7400 Fax: 586-294-7402 www.radsok.com Amphenol Pcd 2 Technology Drive Peabody, MA 01960 Phone: 978-532-8800 Fax: 978-532-6800 www.amphenolpcd.com Amphenol Canada 20 Melford Drive Scarborough, ON M1B 2X6 Canada Phone: 416-291-4401 Fax: 416-292-0647 www.amphenolcanada.com AUTHORIZED AMPHENOL DISTRIBUTORS Corporate Headquarters ALPHABETICAL LISTING APD (All Product Distributors): Arrow Electronics Englewood, CO 800-777-2776 Avnet EMG Dallas, TX 800-332-8638 PEI Genesis Philadelphia, PA 800-523-0727 Powell Electronics Philadelphia, PA 800-235-7880 TTI Inc. Fort Worth, TX 800-225-5884 Disadvantaged/Minority Distributors: Cherokee Nation Dist. Stilwell, OK 918-696-2777 Electro Enterprises Oklahoma City, OK 800-324-6591 JRH Electronics Marlton, NJ 800-467-9309 Amphenol/Pyle Industrial Distributors Bartec-Technor ASA Stavanger, Norway Phone: 47 51 84 4100 Fax: 47 51 84 4103 www.bartec-technor.no Crawford Electric Supply 10051Porter Rd. Laporte, TX 77571 Phone: 281-417-7540 Fax: 281-470-2659 www.cescoltd.com EC Systems, Division of Nelson Dunn, Inc. 17707 Valley View Ave. Cerritos, CA 90703 Phone: 1-800-635-3866 Fax: 714-523-9192 www.nelson-dunn.com Gaffney-Kroese Supply Piscataway, NJ 08854 Phone: 732-885-9000 Fax: 732-885-9555 E-mail: gksales@gaffney-kroese.com www.gaffney-kroese.com Geophysical Electrical Supply Co. (GESCO) Houston, TX Phone: 713-645-5999 Fax: 713-645-4999 E-mail: duggan@gesco-e.com www.gesco-e.com Hillcrest Enterprises Ashland, VA Phone: 800-848-3106 or 804-798-8390 Fax: 804-752-7830 E-mail: cordgrip@aol.com www.plugs.cc ITI Marine & Oilfield PTE, Ltd. Joo Koon Crescent, Singapore Phone: (65) 6266-6666 Fax: (65) 6266-0009 Jackson Power Edmonton, Alberta Canada Phone: 780-435-9275 Fax: 780-436-0308 E-mail: ljackson@jacksonpower.com www.jacksonpower.com National Oilwell Varco/L.S.I 12002 West Little York Houston, TX 77041 Phone: 713-464-1393 Fax: 713-464-7731 www.nov.com/Supply_Chain/ Electrical_Products.aspx PEI Genesis UK George Curl Way Southampton, SO182RZ Phone: +44(0)2380621260 Phone: +44(0)8448716060 Fax: +44 (0)8448716070 Email: peiuk@peigenesis.con www.peigenesis.com Steck Connections Mississauga, Ontario, Canada Phone: 905-608-2444 Fax: 905-608-2895 E-mail: steck@ican.net www.steckconnections.com Steiner Electric Elk Grove Village, IL Phone: 847-228-0400 Fax: 847-228-1352 E-mail: infor@stnr.com www.steinerelectric.com Wholesale Electric Houston, TX Phone: 800-486-8563 or 713-748-6100 Fax: 713-749-8415 E-mail: donniejr@wholesaleelectric.com www.wholesaleelectric.com INTERNATIONAL (Industrial Operations Offices) Latin America ARGENTINA Amphenol Argentina Avenida Callao 930, 2nd floor Office B Plaza C1023AAP Buenos Aires, Argentina Phone: (54 11) 48 15 68 86 Fax: (54 11) 48 14 57 79 E-mail:vendas@amphenol.com.ar BRAZIL Amphenol do Brasil Ltda. Rua Diogo Moreira 132 CEP 05423-010 Sao Paulo - SP, Brazil Phone: (55-11) 3815.1003 Fax: (55-11) 3815.1629 E-mail: vendas@amphenol.com.br MEXICO Amphenol Mexico Prolongacion Reforma 61-6 B2 Col. Paseo de las Lomas C.P. 01330 Mexico D.F., Mexico Phone: (52-55) 5258.9984 Fax: (52-55) 5081.6890 E-mail: info@amphenolmexico.com Europe AUSTRIA & EASTERN EUROPE Amphenol European Sales Oper. P.O. Box 63, 3990 DB Houton The Netherlands Phone: 31 30 6358000 Fax: 31 30 6377899 E-mail: info@amphenol-nl.com ENGLAND Amphenol Limited Thanet Way, Whitstable Kent CT5 3JF, United Kingdom Phone: (44-1-227) 773200 Fax: (44-1-227) 276571 www.amphenol.co.uk FRANCE Amphenol Socapex Promenade de l'Arve, BP29 Thyez 74301 948 Cedex, France Phone: (33-4) 50892800 Fax: (33-4) 5096-1941 www.amphenol-socapex.com FRANCE Amphenol-Air LB 29, Voie d'Y Vois F-00810 Blagny, France Phone: 33-3-2422-7849 Fax: 33-3-2422-7850 www.amphenol-airlb.fr GERMANY Amphenol-Tuchel Elect. GmbH August-Haeusser Strasse 10 Postfach 1110 74001 Heilbronn, Germany Phone: (49-7131) 929 0 Fax: (49-7131) 929 414 www.amphenol-tuchel.com GERMANY Amphenol-Air LB Am Kleinbahnhof 4 D-66740 Saarlouis, Germany Phone: (49-6831) 9810-87 Fax: (49-6831) 9810-30 www.amphenol-airlb.com ITALY Amphenol Italia S.p.A. Via Barbaiana 5 20020 Lainate (Milano), Italy Phone: 39-02-932541 Fax: 39-02-93254444 E-mail: info@amphenol-it.com BENELUX Amphenol European Sales Operations Amphenol Benelux BV P. O. Box 63, 3990 DB Houten The Netherlands Phone: 31-30-6358000 Fax: 31-30-6377034 E-mail: info@amphenol-nl.com SPAIN & PORTUGAL Amphenol Iberica Edificio "Burgosol" - Oficina No. 55 c/Comunidad de Madrid, 35-bis, 28230 Las Rozas, Madrid, Spain Phone: 34-91-6407303 Fax: 34-91-6407307 E-mail: infor@amphenol-it.com SWITZERLAND Amphenol Switzerland P.O. Box 63, 3990 DB Houton, The Netherlands Phone: 31 30 6358000 Fax: 31 30 6377899 E-mail: info @amphenol-nl.com Middle East / Africa ISRAEL Bar-Tec Ltd. 3 Hagavish St., P.O.B. 279 Kfir-Barkan Bldg., East Industrial Zone Kfar Sava 44102, Israel Phone: (972-9) 764.4100 Fax: (972-9) 7674324 E-mail: www.bar-tec.com SOUTH AFRICA Amphenol South Africa 30 Impapa Road 2196 Sandton - Chislehurston South Africa Tel: (27-11) 783-9517 Fax: (27-11) 783-9519 E-mail: amphenol_africa@csi.com TURKEY Amphenol Turkiye Ayazaga Mah. Meydan Sk. No. 28 Beybi Giz Plaza, Kat. 26 34396 Maslak/Islanbul Phone: 90(0212) 335 25 01 Fax: 90(0212) 335 25 00 Asia / Pacific AUSTRALIA Amphenol Australia Pty Ltd 2 Fiveways Blvd. Keysborough Melbourne, Victoria 31733, Australia Phone: 613 8796 8888 Fax: 613 8796 8801 E-mail: infor@amphenolaust.com.au CHINA Amphenol Shanghai Office 14/D, Dong Zhan Commercial Bldg. 669 Beijing Road West, Shanghai, 200041, China Phone: (86) 21 6267 5566 Fax: (86) 21 6272 7587 HONG KONG Amphenol East Asia Ltd. 26/F Railway Plaza 39 Chatham Road South Kowloon, Hong Kong Phone: 852-9090-5325 Fax: 852-2691-1774 INDIA Amphenol Interconnect India, Pvt, Ltd. 105 Bhosari Industrial Area Pune, 411 026, India Phone: (91-20) 27120 481 Fax: (91-20) 27120 581 E-mail: sales@amphenol-in.com JAPAN Amphenol Japan Mil Aero & Industrial 471-1, Deba, Ritto-city Shiga 520-3041, Japan Phone: 81-77553-8501 Fax: 81-77551-2200 KOREA Amphenol Daeshin #558 SoSa, SongNae Bucheon City, Kyungki-Do Korea 420-130 Phone: 82-32-680-3800 Fax: 82-32-673-2507 SINGAPORE Amphenol East Asia, Ltd. 300 Beach Road #34-06 The Concourse Singapore 199555 Phone: 65-6294-2128 Fax: 65-6294-3522 TAIWAN Amphenol Taiwan No. 116, Lane 956, Zhong Shan Rd. Taoyuan City, Taiwan, R.O.C. 330 Phone: (886-3) 379-5677 Fax: (886-3) 360-7259 AMPHENOL CORPORATION Amphenol Industrial Phone: 607-563-5011 40-60 Delaware Avenue Sidney, NY 13838-1395 www.amphenol-industrial.com Notice: Specifications are subject to change without notice. Contact your nearest Amphenol Corporation Sales Office for the latest specifications. All statements, information and data given herein are believed to be accurate and reliable but are presented without guarantee, warranty, or responsibility of any kind expressed or implied. Statements or suggestions concerning possible use of our products are made without representation or warranty that any such use is free of patent infringement and are not recommendations to infringe any patent. The user should not assume that all safety measures are indicated or that other measures may not be required. Specifications are typical and may not apply to all connectors. HKA 4-2012