Interconnection
secure the wires to each pin. The protective sleeve enclosure around the plug pins also serves as a seal against dust and moisture. Clear terminal markings are embossed on the contact block inside the connector, indicating the phase (L1, L2, or L3), neutral (N), line (L/+), or ground (G) to minimize errors during assembly.
Figure 3: Shown are the key features of a five-pin, 200 V to 415 V plug; the connector body is composed of PBT. (Image source: Amphenol Sine Systems, modified by Art Pini)
thereby minimizing the chance of incorrect connections.
The location of the ground pin relative to the keyway within the connector body determines the connector configuration. A ground pin can be located at any of 12 possible positions placed at 30? intervals, summarized by the “clock” diagram. It identifies each of them for three- (2P+E or 2P-3W), four- (3P+E or 3P-4W), or five- (3P+N+E or 4P-5W) cable connectors, using a colour code based on the voltage rating of the connector. The conductor and, therefore, the connector diameter are matched to the rated load current.
Examples of industrial power connectors
Amphenol Sine Systems offers a comprehensive range of industrial plug and socket power connectors designed for applications that require up to 100 A and 690 V.
For example, the Amphenol Sine Systems 2CMA104446R1000 inline power connector plug, intended for three-phase Wye-connected applications, has five conductors: one for each of the three phases, one for neutral, and one for ground. It is rated to handle 200 to 415 V at 32 A (maximum). Its ground pin is located at the
same 6 o’clock position as the connector keyway. The outer ring in the diagram (for five-pin connectors) at position 6, colour- coded red, indicates the voltage range, in this case from 200 V to 415 V.
Connector construction The Amphenol Sine Systems connectors use a modern, robust design (Figure 3). The connector body is composed of polybutylene terephthalate (PBT), a thermoplastic polyester. PBT is noted for superior electrical insulation, high strength, dimensional stability, and resistance to heat and chemicals. It has outstanding wear resistance, absorbs very little moisture, and is easy to machine.
The red hood signifies the 200 V to 415 V rating of the connector as shown in the clock diagram. The ground pin has a larger diameter than the other pins and, in this connector, based on its voltage specifications, is located at the bottom (6 o’clock position). It is also slightly longer than the others, so it makes contact first. The contact pins are made of brass and are self-cleaning when mated to the corresponding socket. The contacts are calibrated to maintain accurate contact pressure over time, ensuring quality and performance. Two stainless steel screws
Cables are secured within the connector body by dual clamps: an exterior clamp at the rear and an internal clamp. A watertight grommet placed between the clamps seals the cable entry, preventing liquids from entering the connector body through the cable. Depending on the model, connectors have ingress protection ratings of IP44 (splash resistant) or IP67 (dustproof and waterproof).
The receptacle connector has a similar structure, using sockets for the contact (Figure 4). The socket version of the connector incorporates the same type of seals and gaskets to protect the interior from dust and moisture. The contacts are also made of brass and feature dual locking screws to secure the wires. Additionally, the connector opening is safeguarded by a colour-coded plastic cap to minimize contamination when the connector is not mated. The Amphenol Sine Systems 2CMA166618R1000 is a five-contact receptacle connector that shares the same 32 A current and 200 V to 415 V rating as the 2CMA104446R1000 plug. With that voltage rating, its ground pin is located at the 6 o’clock position and features a red cap. Note that all connectors in this series conform to IEC 60309-1, 2, and 4, and are also approved by UL and CSA.
The receiving end of a power cable in a machine or other device typically connects through a panel-mount connector, such as the Amphenol Sine Systems 2CMA193146R1000 (Figure 5) two-pole, three-wire receptacle.
This receptacle is designed to be mounted on the outside of a device using the mounting flange. It is rated to handle 200 V to 250 V, single-phase, at 16 A. Referring to the clock diagram, the three- wire configuration (inner ring) uses a 6 o’clock setting with a blue cap. Panel- mount connectors are available in either straight or angled designs.
Figure 4: Shown is a cutaway view of an inline socket connector receptacle, revealing a similar structure to the plug to maintain the integrity of the wiring.
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Connectors for the power source are usually wall-mounted. The 2CMA178699R1000
Figure 5: The 2CMA193146R1000 is an example of a two-pole, three-wire, panel-mount power receptacle. (Image source: Amphenol Sine Systems)
Figure 6: The 2CMA178699R1000 is an example of a wall-mounted industrial power receptacle. (Image source: Amphenol Sine Systems)
(Figure 6) wall-mounted power connector is a 4-pole, five-wire receptacle.
This flush-mount wall receptacle is rated for 380 V to 415 V and 16 A. It appears in the 6 o’clock slot in the clock diagram and has a red identification colour, shown in a collar around the contact block. It has a protection rating of IP44, indicating it is splashproof. As with all socket connectors, it features a spring-loaded cover to protect the socket contacts when the connector is unmated.
Conclusion
Industrial equipment requires power connectors designed to meet the specific needs of each installation for safe, reliable, and long-lasting connections. Amphenol Sine System’s industrial plugs and sockets, available in various voltages, currents, and physical configurations, are designed to meet the specific requirements posed by the wide range of environmental conditions found in modern manufacturing, infrastructure, and data centre facilities.
https://www.digikey.co.uk/ Components in Electronics October 2025 49
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