PLUG Connection System - Intertech Engineeringintertech-eng.com.au/wp-content/uploads/2017/02/PLUG-System.pdf · Generator connections Converters Power supply to medium-voltage-transformers

PLUG Connection System

PLUG – the Connection System

Industry■ Motors ■ Pumps■ Vacuum furnaces■ Emergency power supplies■ Construction site cabling■ Converters

Railway technology■ Vehicle transformers■ Vehicle motors■ Converters■ Heating and air-conditioning systems■ On-board power supply■ Carriage transition points

Wind power■ Tower segment cabling■ Generator connections■ Converters■ Power supply to medium- voltage-transformers

Ship building■ Propulsion drives■ Cabling for modular ship-building methods■ On-board power supply■ Battery systems

PFISTERER PLUG connection systems enable safe transmission of high electrical power from the smallest possible size of unit. A simple and foolproof assembly or disassembly is assured through an encoded integrated modular system. The integration in IP 67/IP 68 allows for continuous use in the toughest conditions. Common areas of application are:

Benefits■ Faster and more cost effective replacement of motors, transformers and equipment■ Low weight and compact geometry■ Protection class IP 67/IP 68 acc. to DIN EN 60529■ Resistant to oil, petroleum, grease and solvents■ Simple and cost effective pre-packaging or on site assembly

■ Socket and connector available encoded differently to prevent connection errors■ Various connector sizes to cover a wide applicationfield■ Large cable cross section

Highlyefficientandcostlymanufacturingplantsfromall industrysectorswhereavailabilityandreliabilityare essential. As are rapid repairs when errors occur or maintenance is necessary. The swift and straight-forward replacement of drive components (motors, power converters etc.) can reduce the time lost to equip-ment failure or downtime to a minimum. For all kind of industry applications PLUG enables the modular designoflargemachineswithdefinedinterfacesbetweenitspowermodules.

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Contents

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PLUG Size P1 Page | 8 – 9

PLUG Size P0 Page | 6 – 7

Contents

PLUG Size P2/P3 Page | 10 – 18

PLUG connector determination sheet Page | 19

PLUG Assembly Tools Page | 20 – 23

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PLUG Size P0 Multi Poles

Size P0

Max. operating voltage (kV) signal 0.25 AC / 0.4 DCpower 0.63 AC / 0.8 DC

Nominal current (A) signal 9power 30

Protection degree IP 67 (DIN EN 60529)

Operation temperature (°C) -40 ... +125

Flame-resistant UL 94 V-0 (halogen-free)

P0 Straight Connector 5 + PE / 3 + PE + 4Cable termination: crimped

Order number Size Cable cross section flex

Cable diameter

Number of pins Weight

(mm2) Ø (mm) (g)

350 208 002 P0 power + PE 1.0 - 2.5 7 - 9 5 power + PE 40

350 208 003 P0 power + PE 1.0 - 2.5signal 0.14 - 1.0

7 - 9 3 power + PE + 4 signal 40

350 208 004 P0 power + PE 1.0 - 2.5 11 - 13 5 power + PE 40

350 208 005 P0 power + PE 1.0 - 2.5signal 0.14 - 1.0

11 - 13 3 power + PE + 4 signal 40

P0 Panel Socket 5 + PE / 3 + PE + 4Cable termination: crimped

Order number Size Cable cross section flex

Number of pins Weight

(mm2) (g)

350 207 002 P0 power + PE 1.0 - 2.5 5 power + PE 40

350 207 003 P0 power + PE 1.0 - 2.5signal 0.14 - 1.0

3 power + PE + 4 signal 40

PLUG Size P0

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Dimensions

PLUG Size P0

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PLUG Size P1

Size P1

Max. operating voltage (kV) 1 AC; 1.25 DC

Nominal current (A) 400

Cable Type Cuflex

High short circuit strength (kA / 1 sec) 8 kA / 1 sec



Vibration stress DIN IEC 68-2-6

Shock loading DIN IEC 68-2-27


P1SC Straight ConnectorCable termination: compressed

ArticleNo.onspecificationofwiringandencoding.*Original9-digitArticleNo.Thelast2digitsdefinethevariant.

Order number

Size Designation Cable cross section flex

Cable diameter

Coding Weight

(mm2) Ø (mm) (g)

350 205 0..* P1 P1SC 35/50 9.7 - 13.5 L1/L2/L3/PE 70

P1EC Elbow ConnectorCable termination: compressed


Order number

Size Designation Cable cross section flex

Cable diameter

Coding Weight

(mm2) Ø (mm) (g)

350 205 1..* P1 P1EC 25/35/50 8 - 13 L1/L2/L3/PE 160

P1PS Panel SocketCable termination: screwed


Order number

Size Designation Connecting part

Coding Weight

(g)

350 205 30.* P1 P1PS M6 L1/L2/L3/PE 65

350 205 32.* P1 P1PS M8 L1/L2/L3/PE 80

PLUG Size P1

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Dimensions

PLUG Size 1

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PLUG Size P2/P3 Elbow PlugFlexibleandcompactcableconnectorforalltypesofangledoutputs,e.g.formotors,transformers, converters, emergency power supplies and for air conditioning systems.

Size P2 P3

Max. operating voltage (kV) 4 6.6

Nominal current (A) 400 800

Cable Type Cuflex/RM Cuflex/RM

High short circuit strength (kA / 1 sec) 5.6 kA / 2 sec 16.7 kA / 2 sec

Protection degree IP 68 (DIN EN 60529) IP 68 (DIN EN 60529)

Operation temperature (°C) -40 ... +125 -40 ... +125

Vibration stress DIN IEC 68-2-6 DIN IEC 68-2-6

Shock loading DIN IEC 68-2-27 DIN IEC 68-2-27

Flame-resistant UL 94 V-0 (halogen-free) UL 94 V-0 (halogen-free)

P2EC1/P3EC1 Elbow ConnectorCable termination: crimped

ArticleNo.dependentoncablespecificationandcoding.*Original9-digitArticleNo.Thelast3digitsdefinethevariant.**NewArticleNo.plusVar.No.createdwiththeproductconfiguratorsince2007.

Example:ArticleNo.305321...or305990001plusVar.No.xxxx

Order number Product configurator Size Designation Cable cross section flex

Cable diameter Coding Weight

(mm2) Ø (mm) (g)

305 321 ...* 305990001Var.-No.xxxx** P2 P2EC1 25/35/50/70/95 9.5 - 22 AF01 - AF06 320

305 322 ...* 305990001Var.-No.xxxx** P3 P3EC1 70/95/120/150/185/240 16.5 - 29 AF01 - AF12 950

PLUG Size P2/P3

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Please Note:Variants for screened conductor on request.Further versions for contacting aluminium conductor on request.

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Dimensions

PLUG Size P2/P3

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PLUG Size P2/P3 Elbow Connector, 2 cablesTwin connector for angled power outputs with high power requirements or for serial connections of consumer loads (power bus).

Size P2 P3



Cable Type Cuflex/RM Cuflex/RM







P2EC2/P3EC2 Elbow Connector, 2 cablesCable termination: screwed

ArticleNo.dependentoncablespecificationandcoding.*Original9-digitarticleNo.Thelast3digitsdefinethevariant.**NewArticleNo.plusVar.No.createdwiththeproductconfiguratorsince2007.

Example:ArticleNo.305019...or305990001plusVar.No.xxxx

Order number Product configurator Size Designation Cable cross section flex


(mm2) Ø (mm) (g)

305 019 ...* 305990001Var.-No.xxxx** P2 P2EC2 25/35/50/70/95 9.5 - 19 AF01 - AF06 480

305 016 ...* 305990001Var.-No.xxxx** P3 P3EC2 70/95/120/150/185/240 17 - 35 AF01 - AF12 1600

PLUG Size P2/P3

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Please Note:Variants for screened conductor on request.Further versions for contacting aluminium conductor on request.

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Dimensions

PLUG Size P2/P3

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PLUG Size P3 Straight Connector / Coupling Socket

Size P3

Max. operating voltage (kV) 6.6

Nominal current (A) 800

Cable Type Cuflex/RM

High short circuit strength (kA / 1 sec) 16.7 kA / 2 sec



Vibration stress DIN IEC 68-2-6

Shock loading DIN IEC 68-2-27


P3SC Straight ConnectorStraightcableconnectortocreatestraightconnectionsandextensions.

Cable termination: crimped

ArticleNo.dependentoncablespecificationandcoding.*Original9-digitArticleNo.Thelast3digitsdefinethevariant.**NewArticleNo.plusVar.No.createdwiththeproductconfiguratorsince2007.

Example:ArticleNo.305015...plusVar.No.xxxxor305990001plusVar.No.xxxx

Order number Product configurator Size Cable cross section flex


(mm2) Ø (mm) (g)

305 015 ...* 305990001Var.-No.xxxx** P3 70/95/120/150/185/240 16.5 - 28 AF01 - AF06 660

P3CS Coupling SocketCouplingtocreatestraightconnectionsandextensions.Thecouplingiscompletelyencapsulated in insulating material.

Cable termination: crimped

ArticleNo.dependentoncablespecificationandcoding.*Original9-digitArticleNo.Thelast3digitsdefinethevariant.

Order number Size Designation Cable cross section flex


(mm2) Ø (mm) (g)

305 014 ...* P3 P3CS 95/120/150/185/240 16.5 - 28 AF01 - AF03 640

PLUG Size P2/P3

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Please note:Earthing set for screened conductor on request.Further versions for contacting aluminium conductor on request.

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Dimensions

PLUG Size P2/P3

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PLUG Size P2/P3 Panel SocketInstallationsocketforallfieldsofapplication.Foroutdooruseincombinationwithprotections against contact or in oil, e.g. in oil-cooled motors or transformers.

Size P2 P3









P2PS/P3PS Panel Socket

Article No. dependent on coding.*Original9-digitArticleNo.Thelast3digitsdefinethevariant.

Order number Size Designation Connecting part

Coding Weight

(g)

305 005 ...* P2 P2PS M12x25 AF01 - AF06 220

305 007...* P3 P3PS M20x37 AF01 - AF12 780

PLUG Size P2/P3

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Dimensions

PLUG Size P2/P3

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Voltage-proof Covers for PLUG Size P2/P3

Size P2 P3







P2/P3 Voltage-proof Socket Coverfor PLUG panel socket and coupler

Order number Size

305 405 001 P2

305 404 001 P3

P2/P3 Voltage-proof Connector Coverfor PLUG right-angle connectors and straight connectors

Order number Size

305 186 001 P2

305 185 001 P3

PLUG Size P2/P3

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PLUG connector determination sheet

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PLUG Cable and Application data

Company: Name:

Telephone: Date:

E-Mail: Signature:

Cable manufacturer: Cable type:

Size: P1 P2 P3

Application: straight tilted circular stranded circular

Voltages: nominal voltage UN (conductor-conductor)kVmax.operatingvoltageUM(2xU0) kV

Current: nominal current IN___A maximumcurrentIM___A max.durationofIM ___ s

Conductor: cross section ___ mm² diameter ___ mm

Cu Al

wire type: stranded circular RM flexible superflexible

Insulation: diameter over insulation ___ mm

Screened: yes no

Outer jacket: diameter over jacket ___ mm

Encoding: L1 L2 L3 PE

AF01 AF02 AF03 AF04 AF05 AF06

AF07 AF08 AF09 AF10 AF11 AF12

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Open Hand-operated Compression ToolThe open handheld crimping pliers are equipped with a crimping head that can be rotated through 360°. The telescopic handle is released and tightened by simply turning forinfinitelyvariablelengthadjustment.

Order number Total length Nominal compression force

Cross sections of Cu

Hexagonal dies max. width

Weight

(mm) (kN) (mm) (kg)

303 871 002 540 - 750 60 6 - 185 32 3.2

Hexagonal Compression DiesFor copper and steel crimp connections. Suitable for mechanical handheld crimping plier O6.

Order number

Tool code no.

Compress-ion width

Conductor cross section PLUG P1



Width

(mm) (mm2) (mm2) (mm2) (mm)

300 438 445 12 5 25 / 35 25 - 32

300 438 447 14 5 50 - - 32

300 438 448 16 5 - 35 / 50 / 70 35 32

300 438 451 20 5 - 95 - 32

300 438 454 21 5 - - 70 / 95 32

300 438 452 22 5 - 120 120 32

300 438 453 25 5 - - 150 / 185 32

PLUG Assembly Tools

Storage Battery Cable Cutting Tool REC-SH 50Efficient,handy,one-handoperation,nophysicalstress,forallCuandAlcablesupto50 mm diameter.

Included in delivery:■ Cordless cable cutting tool■ Battery■ Battery charger■ Carrying case

Order number Cuts per battery charge

Cutting force Cable diameter max.

Weight

(kN) max. Ø (mm) (kg)

305 911 001 approx.50 25 50 2.0

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Hydraulic Handheld Crimping Pliers EPC 410The hydraulic handheld crimping pliers are equipped with a head for C-inserts. The tool isextremelylightweightandthankstoitsslimdesignandshortlevertravelrangeitissuitable for use in hard to reach places.

Scope of delivery:■ Hydraulic handheld crimping pliers■ Carrying case

Order number Nominal compression force

Total length Cross sections of Cu

Weight

(kN) (mm) (kg)

305 919 001 108 580 10 - 300 5.2

PLUG Assembly Tools

The handy cordless crimping tools from PFISTERER make it very fast and easy to produce reliable crimp connections. Rapid feed ensures that no time is wasted for the idle stroke, pressure limitation provides for optimum crimping force, and the automatic returnstrokemakesthetoolimmediatelyreadyforthenextcrimpingjob.Thetool‘sso-phisticated electronics not only checks crimping continuously but also stores the number of crimping operations, monitors the battery and even reminds you when it is time for maintenance, which is very easy thanks to the built-in USB service interface. Latest-type lithium-ionbatteriesreducethetool‘sweightandenablealargenumberofcrimpingoperations.

Benefits:■ Fast feed thanks to 2-stage hydraulic system ■ Handy tool dimensions■ 360° rotating dies ■ LED control display ■ Diagnosis option via analysis software and USB connecting cable

Scope of delivery:■ Cordless crimping tool■ Compression die for C-inserts■ Lithium-ion battery ■ Charger■ USB 2.0 connecting cable with A-plug and 5-pole mini B-plug ■ Sheet steel case

Cordless crimping tools APE

No. Description Crimping force Cross sectionsof Cu

Weight approx.

(kN) (kg)

305 926 002 APE6-CPF 60 10 - 240 4.2

305 926 001 APE13-CPF 130 10 - 300 6.9

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C-Inserts Hexagonal Compression Diesfor copper and steel crimp connections.Suitable for hydraulic handheld crimping pliers EPC 410, hydraulic cordless crimping tools APE6-CPF and APE13-CPF.

Order number Tool code no. Compression width




(mm) (mm2) (mm2) (mm2)

300 513 008 12 14 25 / 35 25 -

300 513 010 14 14 50 - -

300 513 011 16 14 - 35 / 50 / 70 35

300 513 013 20 5 - 95 -

300 513 019 21 14 - - 70 / 95

300 513 014 22 14 - 120 120

300 513 015 25 14 - - 150 / 185

300 513 016 28 5 - - 240

C-Inserts Round-forming DieSuitable for hydraulic handheld crimping pliers EPC 410, hydraulic cordless crimping tools APE6-CPF and APE13-CPF.

For PLUG P3EC2 elbow connector, 2-core, for sealing conductor ferrules with conductor, only required for 240 mm2 cable.

Order number Conductor cross section stranded sector-shaped

Conductor cross section solid sector-shaped

Round-forming diameter

(mm2) (mm2) (mm)

300 516 009 240 300 20.3

Electro-hydraulic High-pressure Pump AP5

PLUG Assembly Tools

The new battery-powered high-pressure pump AP5 makes it more easy to produce reliable crimp connections. The unit features a high-power rechargeable battery which enables its use in any location and guarantees a large number of crimping operations. It is also equipped with a remote control on the hydraulic hose which actuates the crimping operation directly on the compression head and can interrupt the crimping operation atanytime,ifrequired.Whenmaximumpressureisreached,thecompressionheadretracts automatically, and an LED indicates successful completion of the crimping ope-ration. The coupling bush features non-drip coupling and decoupling. The high-pressure pumpAP5isextremelysturdy,isdesignedforalongservicelifeinharshworkenviron-ments and is suitable for all PFISTERER compression heads.

Scope of delivery: ■ Battery-powered high-pressure pump ■ High-pressure hose set with handle, length 3 m. Other lengths on request ■ Lithium ion battery 36 V / 2.6 Ah ■ Battery charger Makita DC36RA

Suitable tools: All PFISTERER cutting and compression heads designed for a crimping pressure of 850 bar, e.g.

No. Operating pres-sure

Hose length Line voltage Weight

(bar) (mm) (V AC) (kg)

305 940 001 850 3000 230 11.5

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Hydraulic Tool Heads 850 barHydraulic tool heads 850 bar with oil-tight coupling plug for electro-hydraulic high-pressure pumps AP5.

Order number

Type Operating pressure

Power stroke

Nominal compression force

Compressible cross section Cu

Weight

(bar) (mm) (kN) (mm2) (kg)

305 818 001 BIII 850 30 240 16 - 300 6.5

Hexagonal Compression DiesFor electro-hydraulic high-pressure pump AP5 for crimp connections of Cu, Al and Al/St.

For crimping PLUG contacts.

Order number Tool code no. Compression width




(mm) (mm2) (mm2) (mm2)

300 585 589 12 14 25 / 35 25 -

300 585 591 14 14 50 - -

300 585 593 16 14 - 35 / 50 / 70 35

300 585 597 20 14 - 95 -

300 598 598 21 14 - - 70 / 95

300 598 599 22 14 - 120 120

300 598 601 25 14 - - 150 / 185

300 598 603 28 14 - - 240

Round Compression Dies

PLUG Assembly Tools

necessary for P3EC2 2-cables to solidify the conductor sleeves with 240 mm2flexcable.

Order number Compression width Round compression diameter

(mm) (mm)

300 612 001 30 20.3

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PFISTERER S.A.Av.VelezSarsfield464C1282AFR Buenos AiresArgentinaPhone +54 11 4306 [email protected]

PFISTERER Ges.m.b.H.Augasse 171090 WienAustriaPhone +43 1 3176531 0 [email protected]

PFISTERER Power Connection Systems (Beijing) Co., Ltd. Unit 518, Landmark Tower 2 8 North Dongsanhuan Road Chaoyang District 100004 Beijing ChinaPhone +86 10 6590 6272 [email protected]

PFISTERER Representative OfficeBudova MediahallBidlaky 2063900 BrnoCzech RepublicPhone +420 533 337 [email protected]

PFISTERER SAS 35 avenue d’ItalieBP 1004568311lllzachCedexFrancePhone +33 389 [email protected]

PFISTERER Kontaktsysteme GmbH Rosenstraße 44 73650 Winterbach Germany Phone +49 7181 7005 0 [email protected]

PFISTERERRepresentative OfficeBég u. 3-5.1022 BudapestHungaryPhone +36 1 251 [email protected]

PFISTERER s.r.l.Via Sirtori 45 d20017 Passirana di Rho (MI)ItalyPhone +39 02 93158 [email protected]

PFISTERER Korea BranchRoom 1930, KwanghwamunOfficiaBuilding163 Shinmunro-1ga, Jongno-GuSeoul 110-999KoreaPhone +82 2 3276 [email protected]

PFISTERER Sp. z o.o.ul. Pogodna 1005-850PiotrkówekMałyPolandPhone +48 22 72241 [email protected]

PFISTERER Representative OfficeKrasnopresnenskaya nab., 12Entrance№6,office№921123610 MoscowRussiaPhone +7 495 258 [email protected]

PFISTERER (Pty.) Ltd.9 Willowton RoadPietermaritzburg 3201South AfricaPhone +27 33 397 [email protected]

PFISTERER UPRESA S.A.U.Calle Industria 90-9208025 BarcelonaSpainPhone +34 93 [email protected]

PFISTERER Komponent & System ABFlygfältsgatan 212830 SkarpnäckSweden Phone +46 8 7240 150 [email protected]

PFISTERER SEFAG AG Werkstrasse 7 6102 Malters, Luzern Switzerland Phone +41 41 4997 272 [email protected]

PFISTERER Representative OfficeP.O.Box184090, Gate 7, Floor 3Hamarain Center, DubaiUnited Arab EmiratesPhone +971 4 [email protected]

PFISTERER Ltd.Unit 9, Ellesmere Business ParkOff Swingbridge RoadGrantham NG31 7XTLincolnshireUnited KingdomPhone +44 1476 [email protected]

PFISTERERRepresentative Office7625 Wisconsin Avenue, Suite 306Bethesda, MD, 20814Maryland USAPhone +1 240 482 [email protected]

PFISTERER worldwide

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PLUG Connection System - Intertech Engineeringintertech-eng.com.au/wp-content/uploads/2017/02/PLUG-System.pdf · Generator connections Converters Power supply to medium-voltage-transformers