How to Specify Global High Power Pin and Sleeve Plugs and Connectors
IEC publication 60309 defines a family of connectors, including plugs, socket/outlets, and couplers for industrial purposes which can be used on equipment for both domestic and international markets. It is no longer necessary to use connectors for every country specific standard. Once the supply voltage, amperage draw, and the country where the product is going to be used is determined, it is easy to choose an IEC 60309 device.
High-power connection devices are used in applications where high-power connection needs include detachability, security, and protection against foreign materials and liquids. Industries which may use high-power connection devices are those requiring higher amperage and voltage than found in the normal circuit of a building. These industries include, but are not exclusive to: construction, by providing a power-source connection for equipment and lighting. The food service industry, to connect heating units, cookers, fryers, and warmers, and providing power to vendor carts at fairs, shows, and booths. The entertainment industry uses high power pin and sleeve devices to provide power for lighting, sound, camera, video displays, and movement of props, and the computer industry uses the products to connect large computers, servers, and main frames.
Selecting Voltage
When selecting a high power product it is essential to know what the voltage is of the machine to which the high power coupler is going to be connected. Countries around the world have different voltage and amperage ratings for their mains supplies.
Before selecting a high power plug, socket, inlet or outlet there are a few things to consider. First, what country is this product going to? What voltage is used in this country and what voltage is available for the machine. Also, it is important to know if it is a single or three-phase application. Next, what current is available for the machine?
These high power plugs and connectors are available with 3, 4, or 5 pins. This gives the end user some flexibility in how products are manufactured. Having a product with more than 3 pins gives the opportunity to use them in a three-phase system. Three-phase power is a common method of alternating–current electric power transmission. Three-phase systems are used to distribute power in electric power distribution grids worldwide. They are also used to power large motors and other large loads.The voltage ratings for IEC 60309 plugs and sockets are determined by color code and the hour position of the ground pin according to the governing standards. For easy identification, the products with the same voltage rating are always the same color. For example blue plugs and connectors are rated at 250V or 120/208V, depending on whether they are single or three-phase devices. Look at the chart below. Each color has the ground pin situated at a different clock hour position. Polarity is ensured with a key and key way. A key way is like a key hole in a door which allows the key to be inserted only one way. The diameter of the ground is greater than the other contacts guaranteeing proper connection of the ground pins. Additionally, the IEC 60309 system features a series of graduated connector sizes indicating the current rating and number of contacts. This prevents mismating of connectors, making it impossible to use a 3 pole 16 amp yellow plug with a 4 pole 32 amp red socket.
Selecting Amperage
When it is known what voltage the product needs to be, the amperage can be chosen. The amperage needs of the application and the available amperage of the mains system must be known to choose the correct connecting device. If the building has availability for 32 amps, a product requiring 63 amps would not safely operate and would require a larger service to be provided. Conversely, an application requiring 16 amps could be configured with a 32 amp device if the only service available at the location is 32 amps. However, this means the connection devices will be much larger and more expensive. Therefore, unless absolutely necessary, this strategy is not recommended. There are four amperage rating levels available for IEC 60309 devices; 16/20 amp, 30/32 amp, 60/63 amp, and 100/125 amp devices. The ratings of 20A, 30A, 60A and 100A apply only to North American systems. The other ratings are for international use outside North America. The first two rating groups are available in both single and three-phase. The last two groupings are only available in three-phase devices.
Ingress Protection and Safety Features
Knowing what type of environment the product will be used in is very critical. IEC 60309’s are rugged and impact resistant products which can also be sealed against dust and moisture intrusion. They are the ultimate choice in factory and other industrial locations. IEC 60309 plugs and sockets have seals which control the intrusion of solid objects and moisture. Interpower’s products are rated either IP44 or IP67.If it is going to be used inside where it might get splashed with water or any other liquids, choose a product with an Ingress Protection or IP rating of 44. This means it is protected from intrusion of objects greater than 1mm in diameter and protected against splashed water. On the other hand if the product is going to be used in an outdoor setting, possibly in puddles of water, the product should have an IP rating of at least 67. This means the product is dust tight and is protected against temporary immersion. The outer bodies are made of non-conducting plastic instead of metal giving the connectors an added measure of safety in the event of an internal short circuit. IEC 60309 connectors and socket outlets with an IP44 rating feature hinged, spring-loaded covers, which snap into place when the plug is removed. The hinged cover also serves as a locking mechanism to make certain once the plug and socket are mated, they will not be accidentally uncoupled. The shrouded housing protects the contacts from abuse and most importantly protects the end user from touching live parts when engaged. IEC 60309 devices with an IP67 rating also have covers on the connectors and outlets, but incorporate an added feature of a locking ring. When the lid is closed, it can be slightly turned to lock it shut. In addition, the plugs and inlets of the IP67 rated devices feature their own locking ring, that when mated with the female device, allows the user to slide the ring of the male device over the ring of the mating female device, and lock it in place by turning it a short distance. The ring of the male device incorporates a seal to help keep out contaminants and water.
Style Needed
High power pin and sleeve devices are offered in a few different styles. First there are the cable mount plugs and connectors. Typically 3, 4, or 5 conductor cable is used. These are used to connect a product into the service mains, another product, or a pIECe of stationary equipment. Next, are the panel mount inlets and outlets. Panel mount inlets and outlets are also an option when designing stationary equipment. These types of products use single conductor hook up wire for internal equipment connections. The product can be used on the basis of how easily it can be installed. Wiring instructions and specifications for the mating outlet can be sent ahead of time so when the connector arrives it can simply be plugged in and the equipment powered up, i.e. not requiring an electrician for installation.
Approvals
Keep in mind what country the product is going to be used. If it is used in North America a product must have UL and/or CSA approvals. If the product is going to Europe it is required to have the CE marking. In addition, it should have some type of European approval like VDE or OVE. Typically, all other countries and regions of the world will accept one of these approvals based on recognition and respect.In summary, it is easy to choose an IEC 60309 high power pin and sleeve device when several details are known ahead of time. Consider the country where the product is to be used to choose the correct voltage and amperage. Consider the environment: is it going to be occasionally splashed with liquids or temporarily under water? Finally what approvals need to be on the product, is it international or is the product staying in North America. Knowing all these factors will help you design the right product the first time.
Interpower Corporation Introduces New Range of High-Power Pin and Sleeve Devices
The Interpower High Power Connection Devices are configured with 3 or 5 pins; with either a 4, 6, or 9 hour earth pin position; inlets and outlets can be angled or panel mount. plugs and connectors can be cable mount. Interpower Corporation High-Power Inlets, Outlets, plugs and Connectors are IP44 or IP67 rated for dust and splashing water. They are used for connection to equipment rated from 16-32A with service at 120-250V. The connection devices have OVE and cULus approvals for North American and international use. These products have been checked with previously offered parts. All mating plugs and connectors are compatible.
Interpower Corporation houses over 4 million components in their warehouse so their customers don’t have to! Interpower Corporation has no minimum order requirements, and specification sheets and pricing are available online at www.interpower.com.
Immediate shipping is available for stock item orders received by 6:00 p.m. CST.
