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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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II
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IV
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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
Protection degree IP 67 (DIN EN 60529)
Operation temperature (°C) -40 ... +125
Vibration stress DIN IEC 68-2-6
Shock loading DIN IEC 68-2-27
Flame-resistant UL 94 V-0 (halogen-free)
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
ArticleNo.onspecificationofwiringandencoding.*Original9-digitArticleNo.Thelast2digitsdefinethevariant.
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
ArticleNo.onspecificationofwiringandencoding.*Original9-digitArticleNo.Thelast2digitsdefinethevariant.
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
II
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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
Max. operating voltage (kV) 4 6.6
Nominal current (A) 600 1250
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)
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
Cable diameter Coding Weight
(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
Protection degree IP 68 (DIN EN 60529)
Operation temperature (°C) -40 ... +125
Vibration stress DIN IEC 68-2-6
Shock loading DIN IEC 68-2-27
Flame-resistant UL 94 V-0 (halogen-free)
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
Cable diameter Coding Weight
(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
Cable diameter Coding Weight
(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
Max. operating voltage (kV) 4 6.6
Nominal current (A) 600 1250
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)
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
Max. operating voltage (kV) 4 6.6
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)
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
IV
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
1
2
3
4
1 2 3 4
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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
Conductor cross section PLUG P2
Conductor cross section PLUG P3
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
Conductor cross section PLUG P1
Conductor cross section PLUG P2
Conductor cross section PLUG P3
(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
Conductor cross section PLUG P1
Conductor cross section PLUG P2
Conductor cross section PLUG P3
(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]
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PFISTERER Komponent & System ABFlygfältsgatan 212830 SkarpnäckSweden Phone +46 8 7240 150 [email protected]
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PFISTERER Representative OfficeP.O.Box184090, Gate 7, Floor 3Hamarain Center, DubaiUnited Arab EmiratesPhone +971 4 [email protected]
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PFISTERERRepresentative Office7625 Wisconsin Avenue, Suite 306Bethesda, MD, 20814Maryland USAPhone +1 240 482 [email protected]
PFISTERER worldwide
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