Amphenol
Contents
Star-Line® Series Overview..........................................................................................2
Star-Line EX® 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® Product Instructions....................................................................... 23 - 24
Starline EX® Ordering Details, EEx d Cable Types............................................ 25 - 27
Starline EX® Hardware...................................................................................... 28 - 30
Starline EX® Description of Equipment & Part Number Code Logic...........................31
Starline EX® 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® High Amperage Contacts and
Other Amphenol®/Pyle® 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® 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, scratch-
resistant 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® 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.
* Star-line Series Connectors are certified to UL 1977 specifications. • RoHS COMPLIANT PRODUCT Amphenol
AVAILABLE – Consult R oHS
Amphenol Industrial Operations.
EU / 2002 / 95 / EC
Star-Line® 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 Star-Line EX Series connectors are certified for use in Zone
1-IIc hazardous environment
finished with a hard, scratch-resistant coating per MIL-A-8625,
Type III. Dielectric strength 1800 volts. Heat resistance of 750° F.
• 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
from single-contact to 143 contacts. Star-Line EX Connector with EX gland (EX-13-3 style shown)
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® 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.
• RoHS COMPLIANT PRODUCT Amphenol
AVAILABLE – Consult R oHS
Amphenol Industrial Operations
EU / 2002 / 95 / EC
STAR-LINE®
Environmental Why the Double-Lead
Highlights Acme Thread?
MIL-5015 The double-lead Acme thread is a moderate torque
Requirements quick-coupling thread which permits complete coupling
Classes A, B, E Star-Line, Star-Lok in approximately one turn of the coupling nut. In addition,
Property J&R Connectors there are actually two parallel threads having starting
TEMPERATURE -67° F to 225° F Temperature Classes A, B, E, points 180 degrees apart. All of this ensures that plugs and
(-55° C to 107° C) J and R can withstand 257° F receptacles are being mated or unmated axially.
continuously. For short duration The thread contour makes it self-cleaning.
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/ Exceeds Classes E
hour maximum and R specifications
HUMIDITY AND 1 1/2 times A.C. Exceeds Classes One parallel thread removed Standard double-lead
MOISTURE voltage rating after E and R. to show actual thread angle. Acme. Two parallel threads.
RESISTANCE 14 days. MIL-5015
Exposure to Meets MIL-STD-202B,
95% relative Method 106A
humidity at 160° F. Wire Limitation
CORROSION 48 Hours – Salt spray: 300 days Guide
RESISTANCE Method 1001 – No exposure of base metal.
MIL-STD-1344 There are restrictions to the maximum diameter of wire as
No exposure of they relate to the rear or wire side of the connector insert
base metal. as follows.
CHEMICAL No requirement Oil, most acids Mod I. When wires are passed through the rigid back
RESISTANCE and alkalis. insulation for ease of soldering:
Wire size Maximum diameter
DUST No requirement Meets MIL-STD-202B, #4/0 .747”
RESISTANCE Method 110, Condition B #1/0 .555”
#4 .400”
SHOCK 50 G minimum Exceeds 60 G’s #8 .262”
RESISTANCE Certain inserts available #10 .201”
to 200 G. #12 .150”
#16 .107”
VIBRATION Method 2005 Exceeds Method II & #18 .086”
Method II MIL-STD-167-1 (Ships). Mod II & III
MIL-STD-1344 #10 .248”
#12 .193”
TEST PROBE Contact size Exceeds MIL-5015 #16 .130”
ABUSE No. 16 and No. 18 on all contacts #18 .110”
No. 18 through 4/0.
STAR-LINE® Amphenol
INDUSTRIAL
MOD I Captive Contact Inserts
Shell Seal
Double Lead Acme Thread Adapter Seal Adapter
Washer
Pressure Pressure
Pad Pad
Plug Shell Cable Adapter
Receptacle Rigid Front Insulator Coupling Nut
Shell Resilient Contact Seal Laminant
Rigid Rear Insulator
Self-sealing Construction: all MOD I captive contact inserts The combined “sandwich” provides all the advantages of
are capable of being terminated after assembly in the basic resilient mounting plus all the advantages of rigid mounting,
barrel and are completely self-sealing when pressurized by any with none of the shortcomings of either. Under pressure,
selected adapter. Water, gas, vapor, moisture or dust positively between a shoulder and a thrust washer, the silicone reacts as
cannot pass in either direction through or around the insulation. a fluid and being non-compressible, flows against all surfaces
The “sandwich” construction of MOD I inserts consists of a to affect a reliable seal around the periphery of the insert and
resilient silicone laminate between two rigid plastic insulators. around all contacts where they penetrate the insulation.
The resilient laminate seals absorbs shock and vibration and Contact cavities are clearly numbered on the front and
allows the contacts to align themselves freely. The rigid faced rear insert face to facilitate identification during assembly,
plastic insulators impart just the right amount of restraint to inspection and maintenance. Socket insulator contact cavities
retain the contacts in place. are of a bellmouth guided entry design. These chamfered lead-
ins insure easy and positive mating of male contacts.
MOD II Insertable/Removable Crimp Contact Inserts
Shell Seal Insert Adapter Washer
Seal Adapter Seal
Double Lead Pressure Sleeve
Contact Seal Acme Thread
Red
Green
Pressurizing Plug Barrel Cable Adapter
Sleeve
Receptacle Barrel Rigid Insulator Coupling Nut
Resilient Insulator
MOD II insulations have one less rigid disc than their against leakage between the insert and shell, absorb shock
MOD I counterparts. and vibration, provide electrical insulation between contacts
Individual unmounted contacts are crimped to their respective and retain the contacts in the connector.
wires outside of the connector where ample working space is Contacts may be inserted and removed without degradation
available. The crimping operation can be by hand or power of the retention or environmental capability. The front rigid
operated tool. portion of the insert functions to stabilize and ensure positive
Contacts with crimped joint intact are inserted one by one, alignment of the contacts.
with a hand tool, into the insulation premounted within the Contact cavities are clearly numbered on the front and rear
connector barrel shell. insert face to facilitate identification during assembling,
The resilient portion of the insert functions to seal around the inspection and maintenance. Socket insulator contact cavities
contacts and prevent leakage through contact cavities, seal are of a bellmouth guided entry design. These chamfered lead-
ins ensure easy and positive mating of male contacts.
STAR-LINE®
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 PLUG RECEPTACLE SOCKET INSERT
CONFIGURATION CONFIGURATION CONFIGURATION 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).
STAR-LINE® Amphenol
INDUSTRIAL
please read carefully:
1. Hardware with a longer cable housing should be used if 3. To insure proper coupling the following torque values
the insert has: should be used on the coupling nut:
A. Any pressure contact – line or ground. Shell Size Torque Setting (lb. ft.)
B. More than 10 contacts-any size. 12 11.0
C. More than 4 #10 or larger contacts. 16 13.5
2. A jack coupling nut should be used if the insert has: 20 15.5
A. A configuration with shorter relay contacts. C20 15.5
B. A configuration of 37 or more contacts. 24 23.0
A JACK COUPLING NUT SHOULD NOT BE USED ON C24 23.0
ANY POWER INSERT CONNECTOR THAT IS TO BE 28 31.0
DISCONNECTED UNDER LOAD C28 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 MALE COUPLING ENVIRONMENTAL
CLAMP NUT GROMMET INSERT NUT COVER - MALE
WASHER CABLE ADAPTER PIN MALE
CONTACTS SKIRT
typical mod I receptacle components
ENVIRONMENTAL FLANGE INSERT
COVER - FEMALE GASKET CLAMP NUT
SOCKET
CONTACTS
SQUARE FLANGE FEMALE
RECEPTACLE INSERT
STAR-LINE®
Connector
Basic Components
Typical Assemblies
STAR-LINE® Amphenol
INDUSTRIAL
Code Logic
Star-Line Series
Cable Mounted Connectors
N for crimp
Long cable contact /
adapter / Insert pattern R for pres- Optional
Alternate
Environmental Blank for Grommet (32 for solder / sure / Key
standard 332 for Blank for
Cover / length code number Mod 2 crimp / solder Position
L for no cover (cable dia.)
Z P E K L J- 18 20- 332- P N K -01
Product Kellems Shell size K for gold
of connector plated con-
Series (Basket weave grip) / (physical size)/ tact /
Prefix M for
Z– Star-Line Mechanical C before Blank for
shell number standard
nut clamp / Jack nut for 100 amp. P for Pin
D for
gland nut (37 conductors & higher (male) /
or more / S for socket
P for Plug / Do not use for (female)
R for cable “C” power
mounted applications /
Receptable 100 amp or greater)
(Inline)
Fixed Connectors
Environmental S for K for
socket gold plated
Cover / (female) / contact /
L for no cover /
C for flip cover P for pin Blank for
Shell size (male) standard
of connector
Z R E P- 20- 332- S N K -01
Product P for N for Optional
crimp
Series panel mount / contact / Alternate
Prefix
Z– Star-Line BB for R for pressure / Key
Position
back box Blank for
(see pg. 22)
Insert pattern solder
(32 for solder /
R for receptacle / 332 for Mod 2 crimp)
P for plug
Amphenol
RoHS COMPLIANT PRODUCT R oHS
AVAILABLE – Consult
Amphenol Industrial Operations.
EU / 2002 / 95 / EC
STAR-LINE®
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 Cat. No. DIMENSIONS Catalog No.
Cable Size With Standard WITH STANDARD CABLE ADAPTER With Jack
Coupling Nut A B C Coupling Nut
12 ZPLD-▲-12-* 5-3/8 1-13/16 5-31/32 ZPLDJ-▲-12-*
ZPLD-▲-16-* ZPLDJ-▲-16-*
16 ZPLD-▲-20-* 5-5/8 2-5/16 5-7/32 ZPLDJ-▲-20-*
20 ZPLD-▲-C20-* 6-1/8 2-13/16 6-23/32 ZPLDJ-▲-C20-*
C20 ZPLD-▲-24-* 6-5/8 2-13/16 7-7/32 ZPLDJ-▲-24-*
24 ZPLD-▲-C24-* 6-5/8 3-5/16 7-7/32 ZPLDJ-▲-C24-*
Select C24 ZPLD-▲-28-* 7-1/8 3-5/16 7-23/32 ZPLDJ-▲-28-*
from 28 7-1/8 3-13/16 7-23/32
Table Below C28 ZPLD-▲-C28-* 7-5/8 3-13/16 8-7/32 ZPLDJ-▲-C28-*
and WITH LONG CABLE ADAPTER
Substitute 12 ZPLDL-▲-12-* 7-5/8 1-13/16 8-7/32 ZPLDLJ-▲-12-*
ZPLDL-▲-16-* ZPLDLJ-▲-16-*
Symbol No. 16 7-7/8 2-5/16 8-15/32
for Delta▲ ZPLDL-▲-20-* ZPLDLJ-▲-20-*
20 ZPLDL-▲-C20-* 8-3/8 2-13/16 8-31/32 ZPLDLJ-▲-C20-*
C20 ZPLDL-▲-24-* 8-7/8 2-13/16 9-15/32 ZPLDLJ-▲-24-*
24 ZPLDL-▲-C24-* 8-7/8 3-5/16 9-15/32 ZPLDLJ-▲-C24-*
C24 ZPLDL-▲-28-* 9-3/8 3-5/16 9-31/32 ZPLDLJ-▲-28-*
28 ZPLDL-▲-C28-* 9-1/8 3-13/16 9-23/32 ZPLDLJ-▲-C28-*
C28 9-5/8 3-13/16 10-7/32
A 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 Shell Shells Shells Shells Shell Shell Shell Shells Shells
Cable Dia. 12 16 20 & C20 24 & C24 28 & C28 Cable Dia. 12 16 20 & C20 24 & C24 28 & C28
.062 to .125 02 – – – – 1.500 to 1.625 – – 26 26 26
.125 to .250 04 – – – – 1.625 to 1.750 – – 28 28 28
.250 to .375 06 06 – – – 1.750 to 1.875 – – 30 30 30
.375 to .500 08 08 – – – 1.875 to 1.937 – – 31 – –
.500 to .625 10 10 10 – – 1.937 to 2.000 – – – 32 32
.625 to .750 12 12 12 – – 2.000 to 2.125 – – – 34 34
.750 to .875 14 14 14 – – 2.125 to 2.250 – – – 36 36
.875 to .937 15 – – – – 2.250 to 2.375 – – – 38 38
.937 to 1.000 – 16 16 16 – 2.375 to 2.437 – – – 39 –
1.000 to 1.125 – 18 18 18 – 2.437 to 2.500 – – – – 40
1.125 to 1.250 – 20 20 20 – 2.500 to 2.625 – – – – 42
1.250 to 1.375 – 22 22 22 – 2.625 to 2.750 – – – – 44
1.375 to 1.437 – 23 – – – 2.750 to 2.875 – – – – 46
1.437 to 1.500 – – 24 24 24
10
STAR-LINE® Amphenol
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 Shell Cat. No. DIMENSIONS Catalog No.
Cable Size With Standard WITH STANDARD CABLE ADAPTER With Jack
Coupling Nut A B C D E Coupling Nut
12 ZPLM-▲-12-* 6-1/8 1-13/16 6-23/32 2-3/8 1-3/4 ZPLMJ-▲-12-*
ZPLM-▲-16-* ZPLMJ-▲-16-*
16 ZPLM-▲-20-* 6-7/16 2-5/16 7-1/32 3 2-1/4 ZPLMJ-▲-20-*
20 ZPLM-▲-C20-* 7 2-13/16 7-19/32 3-3/4 2-3/4 ZPLMJ-▲-C20-*
C20 ZPLM-▲-24-* 7-1/2 2-13/16 8-3/32 3-3/4 2-3/4 ZPLMJ-▲-24-*
24 ZPLM-▲-C24-* 7-9/16 3-5/16 8-5/32 4-1/2 3-1/4 ZPLMJ-▲-C24-*
Select C24 ZPLM-▲-28-* 8-1/16 3-5/16 8-21/32 4-1/2 3-1/4 ZPLMJ-▲-28-*
from 28 8-1/8 3-13/16 8-23/32 5-1/8 3-3/4
Table Below C28 ZPLM-▲-C28-* 8-5/8 3-13/16 9-7/32 5-1/8 3-3/4 ZPLMJ-▲-C28-*
and ZPLML-▲-12-* WITH LONG CABLE ADAPTER ZPLMLJ-▲-12-*
Substitute 12 ZPLML-▲-16-* 8-3/8 1-13/16 8-31/32 2-3/8 1-3/4 ZPLMLJ-▲-16-*
Symbol No. 16 8-11/16 2-5/16 9-9/32 3 2-1/4
for Delta▲ ZPLML-▲-20-* ZPLMLJ-▲-20-*
20 ZPLML-▲-C20-* 9-1/4 2-13/16 9-27/32 3-3/4 2-3/4 ZPLMLJ-▲-C20-*
C20 ZPLML-▲-24-* 9-3/4 2-13/16 10-11/32 3-3/4 2-3/4 ZPLMLJ-▲-24-*
24 ZPLML-▲-C24-* 9-13/16 3-5/16 10-13/32 4-1/2 3-1/4 ZPLMLJ-▲-C24-*
C24 ZPLML-▲-28-* 10-5/16 3-5/16 10-29/32 4-1/2 3-1/4 ZPLMLJ-▲-28-*
28 ZPLML-▲-C28-* 10-1/8 3-13/16 10-23/32 5-1/8 3-3/4 ZPLMLJ-▲-C28-*
C28 10-5/8 3-13/16 11-7/32 5-1/8 3-3/4
A B
E
D Max. Reversible clamps for Safety wire holes
(3) .062 DIA.
complete cable range
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 Shell Shells Shells Shells Shell Shell Shell Shells Shells
Cable Dia. 12 16 20 & C20 24 & C24 28 & C28 Cable Dia. 12 16 20 & C20 24 & C24 28 & C28
.062 to .125 02 – – – – 1.500 to 1.625 – – 26 26 26
.125 to .250 04 – – – – 1.625 to 1.750 – – 28 28 28
.250 to .375 06 06 – – – 1.750 to 1.875 – – 30 30 30
.375 to .500 08 08 – – – 1.875 to 1.937 – – 31 – –
.500 to .625 10 10 10 – – 1.875 to 2.000 – – – 32 32
.625 to .750 12 12 12 – – 2.000 to 2.125 – – – 34 34
.750 to .875 14 14 14 – – 2.125 to 2.250 – – – 36 36
.875 to .937 15 – – – – 2.250 to 2.375 – – – 38 38
.875 to 1.000 – 16 16 16 – 2.375 to 2.437 – – – 39 –
1.000 to 1.125 – 18 18 18 – 2.375 to 2.500 – – – – 40
1.125 to 1.250 – 20 20 20 – 2.500 to 2.625 – – – – 42
1.250 to 1.375 – 22 22 22 – 2.625 to 2.750 – – – – 44
1.375 to 1.437 – 23 – – – 2.750 to 2.875 – – – – 46
1.375 to 1.500 – – 24 24 24
11
STAR-LINE®
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. Types
ZPLT ZPET
Shell Size Catalog No. DIMENSIONS Catalog No.
Size Conduit With Standard With Jack
Coupling Nut A B C D Coupling Nut
12 3/4 ZplT-2 12-* 4-1/4 1-13/16 4-27-32 3/4 ZPLTJ-2 12-*
16 1-1/4 ZplT-4 16-* 4-3/8 2-5/16 4-31/32 1-1/4 ZPLTJ-4 16-*
20 1-1/2 ZplT-5 20-* 4-1/2 2-13/16 5-3/32 1-1/2 ZPLTJ-5 20-*
C20 1-1/2 ZplT-5 C20-* 5 2-13/16 5-19/32 1-1/2 ZPLTJ-5 C20-*
24 2 ZplT-6 24-* 4-5/8 3-5/16 5-7/32 2 ZPLTJ-6 24-*
C24 2 ZplT-6 C24-* 5-1/8 3-5/16 5-23/32 2 ZPLTJ-6 C24-*
28 2-1/2 zplT-7 28-* 5-3/32 3-13/16 5-11/16 2-1/2 ZPLTJ-7 28-*
C28 2-1/2 zplT-7 C28-* 5-19/32 3-13/16 6-3/16 2-1/2 ZPLTJ-7 C28-*
A
D B
NPT Thread
Size
C S(3a)f.e0t6y2WDirIeA.Holes
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. Types
ZPLP ZPEP
Shell Open Catalog No. DIMENSIONS Catalog No.
Size Back With Standard With Jack
Coupling Nut A B C G H J Coupling Nut
12 Use with ZplP-12-* 2-3/8 1-13/16 2-31/32 1-17/64 1-5/8 3/16 ZPLPJ- 12-*
16 or without ZplP-16-* 2-13/32 2-5/16 3 1-11/16 2-1/8 7/32 ZPLPJ- 16-*
20 Potting ZplP-20-* 2-7/16 2-13/16 3-1/32 2-3/32 2-5/8 9/32 ZPLPJ- 20-*
C20 Sleeve ZplP-C20-* 2-15/16 2-13/16 3-17/32 2-3/32 2-5/8 9/32 ZPLPJ- C20-*
24 ZplP-24-* 2-15/32 3-5/16 3-1/16 2-17/32 3-1/8 11/32 ZPLPJ- 24-*
C24 ZplP-C24-* 2-31/32 3-5/16 3-9/16 2-17/32 3-1/8 11/32 ZPLPJ- C24-*
28 ZplP-28-* 2-15/32 3-13/16 3-1/16 3-1/32 3-3/4 11/32 ZPLPJ- 28-*
C28 zplP-C28-* 2-31/32 3-13/16 3-9/16 3-1/32 3-3/4 11/32 ZPLPJ- C28-*
J Hole Dia. B To specify plug with environmental cover,
A C G SQ. change third letter in Part No. “L” to “E”.
Example: ZPLP changes to ZPEP.
H SQ.
Safety Wire Holes (3) .062 Dia.
12
STAR-LINE® Amphenol
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
Types
ZPLK ZPEK
Size Shell Catalog No. DIMENSIONS Catalog No.
Cable Size With Standard WITH STANDARD CABLE ADAPTER With Jack
Coupling Nut A B C Coupling Nut
12 Zplk-▲-12-* 5-3/8 1-13/16 5-31/32 ZPLKJ-▲-12-*
Zplk-▲-16-* ZPLKJ-▲-16-*
16 Zplk-▲-20-* 5-5/8 2-5/16 6-7/32 ZPLKJ-▲-20-*
Select 20 Zplk-▲-C20-* 6-1/8 2-13/16 6-23/32 ZPLKJ-▲-C20-*
from C20 Zplk-▲-24-* 6-5/8 2-13/16 7-7/32 ZPLKJ-▲-24-*
Table Below 24 Zplk-▲-C24-* 6-5/8 3-5/16 7-7/32 ZPLKJ-▲-C24-*
and Substi- C24 zplk-▲-28-* 7-1/8 3-5/16 7-23/32 ZPLKJ-▲-28-*
tute 28 zplk-▲-C28-* 7-1/8 3-13/16 7-23/32 ZPLKJ-▲-C28-*
Symbol No. C28 7-5/8 3-13/16 8-7/32
for Delta ▲ WITH LONG CABLE ADAPTER
12 ZplkL-▲-12-* 7-5/8 1-13/16 8-7/32 ZPLKJ-▲-12-*
16 ZplkL-▲-16-* 7-7/8 2-5/16 8-15/32 ZPLKJ-▲-16-*
ZplkL-▲-20-* ZPLKJ-▲-20-*
20 ZplkL-▲-C20-* 8-3/8 2-13/16 8-31/32 ZPLKJ-▲-C20-*
C20 ZplkL-▲-24-* 8-7/8 2-13/16 9-15/32 ZPLKJ-▲-24-*
24 ZplkL-▲-C24-* 8-7/8 3-5/16 9-15/32 ZPLKJ-▲-C24-*
C24 zplkL-▲-28-* 9-3/8 3-5/16 9-31/32 ZPLKJ-▲-28-*
28 zplkL-▲-C28-* 9-1/8 3-13/16 9-23/32 ZPLKJ-▲-C28-*
C28 9-5/8 3-13/16 10-7/32
See cable grip A B
components page
for basket weave
grip lengths
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-*
Shell Shell Shells Shells Shells Shell Shell Shell Shells Shells
Cable Dia. 12 16 20 & C20 24 & C24 28 & C28 Cable Dia. 12 16 20 & C20 24 & C24 28 & C28
.062 to .125 02 – – – – 1.500 to 1.625 – – 26 26 26
.125 to .250 04 – – – – 1.625 to 1.750 – – 28 28 28
.250 to .375 06 06 – – – 1.750 to 1.875 – – 30 30 30
.375 to .500 08 08 – – – 1.875 to 1.937 – – 31 – –
.500 to .625 10 10 10 – – 1.875 to 2.000 – – – 32 32
.625 to .750 12 12 12 – – 2.000 to 2.125 – – – 34 34
.750 to .875 14 14 14 – – 2.125 to 2.250 – – – 36 36
.875 to .937 15 – – – – 2.250 to 2.375 – – – 38 38
.875 to 1.000 – 16 16 16 – 2.375 to 2.437 – – – 39 –
1.000 to 1.125 – 18 18 18 – 2.437 to 2.500 – – – – 40
1.125 to 1.250 – 20 20 20 – 2.500 to 2.625 – – – – 42
1.250 to 1.375 – 22 22 22 – 2.625 to 2.750 – – – – 44
1.375 to 1.437 – 23 – – – 2.750 to 2.875 – – – – 46
1.375 to 1.500 – – 24 24 24
13
STAR-LINE®
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.
Types
ZRLM ZREM
DIMENSIONS
Size Shell Cat. No.
Cable Size A C D E F G
12 ZRLM-▲-12-* 6-1/8 6-3/4 1-3/4 1-61/64 1-3/4 2-3/8
ZRLM-▲-16-*
16 ZRLM-▲-20-* 6-7/16 7-1/16 2-1/4 2-31/64 2-1/4 3
Select 20 ZRLM-▲-C20-* 7 7-5/8 2-3/4 3-1/32 2-3/4 3-3/4
from C20 ZRLM-▲-24-* 7-1/2 8-1/8 2-3/4 3-1/32 2-3/4 3-3/4
Table Below 24 ZRLM-▲-C24-* 7-9/16 8-3/16 3-1/4 3-9/16 3-1/4 4-1/2
and Substi- C24 ZRLM-▲-28-* 8-1/16 8-11/16 3-1/4 3-9/16 3-1/4 4-1/2
tute 28 ZRLM-▲-C28-* 8-1/8 8-3/4 3-3/4 4-1/16 3-3/4 5-1/8
C28 8-5/8 9-1/4 3-3/4 4-1/16 3-3/4 5-1/8
fS o yr m D be ol t la N ▲ o . 1 2 Z R L M L - ▲ - 1 2 - * 8 - 3 W/8ITH
LONG CABLEADAPTER
ZRLML-▲-16-* 9 1-3/4 1-61/64 1-3/4 2-3/8
16 ZRLML-▲-20-* 8-11/16 9-5/16 2-1/4 2-31/64 2-1/4 3
20 ZRLML-▲-C20-* 9-1/4 9-7/8 2-3/4 3-1/32 2-3/4 3-3/4
C20 ZRLML-▲-24-* 9-3/4 10-3/8 2-3/4 3-1/32 2-3/4 3-3/4
24 ZRLML-▲-C24-* 9-13/16 10-7/16 3-1/4 3-9/16 3-1/4 4-1/2
C24 ZRLML-▲-28-* 10-5/16 10-15/16 3-1/4 3-9/16 3-1/4 4-1/2
28 ZRLML-▲-C28-* 10-1/8 10-3/4 3-3/4 4-1/16 3-3/4 5-1/8
C28 10-5/8 11-1/4 3-3/4 4-1/16 3-3/4 5-1/8
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-*
Shell Shell Shells Shells Shells Shell Shell Shell Shells Shells
Cable Dia. 12 16 20 & C20 24 & C24 28 & C28 Cable Dia. 12 16 20 & C20 24 & C24 28 & C28
.062 to .125 02 – – – – 1.500 to 1.625 – – 26 26 26
.125 to .250 04 – – – – 1.625 to 1.750 – – 28 28 28
.250 to .375 06 06 – – – 1.750 to 1.875 – – 30 30 30
.375 to .500 08 08 – – – 1.875 to 1.937 – – 31 – –
.500 to .625 10 10 10 – – 1.875 to 2.000 – – – 32 32
.625 to .750 12 12 12 – – 2.000 to 2.125 – – – 34 34
.750 to .875 14 14 14 – – 2.125 to 2.250 – – – 36 36
.875 to .937 15 – – – – 2.250 to 2.375 – – – 38 38
.875 to 1.000 – 16 16 16 – 2.375 to 2.437 – – – 39 –
1.000 to 1.125 – 18 18 18 – 2.437 to 2.500 – – – – 40
1.125 to 1.250 – 20 20 20 – 2.500 to 2.625 – – – – 42
1.250 to 1.375 – 22 22 22 – 2.625 to 2.750 – – – – 44
1.375 to 1.437 – 23 – – – 2.750 to 2.875 – – – – 46
1.375 to 1.500 – – 24 24 24
14
STAR-LINE® Amphenol
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.
Types
Dimensions ZRLD ZRED
Size Shell Cat. No.
Cable Size A C D E
12 ZRLD-▲- 12-* 5-3/8 6 1-3/4 1-61/64
ZRLD-▲- 16-*
16 ZRLD-▲- 20-* 5-5/8 6-1/4 2-1/4 2-31/64
20 ZRLD-▲- C20-* 6-1/8 6-3/4 2-3/4 3-1/32
C20 ZRLD-▲- 24-* 6-5/8 7-1/4 2-3/4 3-1/32
24 ZRLD-▲- C24-* 6-5/8 7-1/4 3-1/4 3-9/16
Select C24 ZRLD-▲- 28-* 7-1/8 7-3/4 3-1/4 3-9/16
from 28 ZRLD-▲- C28-* 7-1/8 7-3/4 3-3/4 4-1/16
Ta an bd le S B u eb ls o t wi- C28 7-5/8 8-1/4 3-3/4 4-1/16
W i t h L o n g C able Adapter
tute 12 ZRLDL-▲-12-* 7-5/8 8-1/4 1-3/4 1-61/64
Symbol No. 16 ZRLDL-▲-16-* 7-7/8 8-1/2 2-1/4 2-31/64
for Delta ▲
20 ZRLDL-▲-20-* 8-3/8 9 2-3/4 3-1/32
ZRLDL-▲-C20-*
C20 ZRLDL-▲-24-* 8-7/8 9-1/2 2-3/4 3-1/32
24 ZRLDL-▲-C24-* 8-7/8 9-1/2 3-1/4 3-9/16
C24 ZRLDL-▲-28-* 9-3/8 10 3-1/4 3-9/16
28 ZRLDL-▲-C28-* 9-1/8 9-3/4 3-3/4 4-1/16
C28 9-5/8 10-1/4 3-3/4 4-1/16
A D
E
C S(3a).f0e6ty2WDiirae. Holes
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-*
Shell Shell Shells Shells Shells Shell Shell Shell Shells Shells
Cable Dia. 12 16 20 & C20 24 & C24 28 & C28 Cable Dia. 12 16 20 & C20 24 & C24 28 & C28
.062 to .125 02 – – – – 1.500 to 1.625 – – 26 26 26
.125 to .250 04 – – – – 1.625 to 1.750 – – 28 28 28
.250 to .375 06 06 – – – 1.750 to 1.875 – – 30 30 30
.375 to .500 08 08 – – – 1.875 to 1.937 – – 31 – –
.500 to .625 10 10 10 – – 1.875 to 2.000 – – – 32 32
.625 to .750 12 12 12 – – 2.000 to 2.125 – – – 34 34
.750 to .875 14 14 14 – – 2.125 to 2.250 – – – 36 36
.875 to .937 15 – – – – 2.250 to 2.375 – – – 38 38
.875 to 1.000 – 16 16 16 – 2.375 to 2.437 – – – 39 –
1.000 to 1.125 – 18 18 18 – 2.437 to 2.500 – – – – 40
1.125 to 1.250 – 20 20 20 – 2.500 to 2.625 – – – – 42
1.250 to 1.375 – 22 22 22 – 2.625 to 2.750 – – – – 44
1.375 to 1.437 – 23 – – – 2.750 to 2.875 – – – – 46
1.375 to 1.500 – – 24 24 24
15
STAR-LINE®
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.
Dimensions Types
Size Shell Cat. No. ZRLK ZREK
Cable Size A C D E
12 ZRLK-▲- 12-* 5-3/8 6 1-3/4 1-61/64
ZRLK-▲- 16-*
16 ZRLK-▲- 20-* 5-5/8 6-1/4 2-1/4 2-31/64
20 ZRLK-▲- C20-* 6-1/8 6-3/4 2-3/4 3-1/32
C20 ZRLK-▲- 24-* 6-5/8 7-1/4 2-3/4 3-1/32
24 ZRLK-▲- C24-* 6-5/8 7-1/4 3-1/4 3-9/16
Select C24 ZRLK-▲- 28-* 7-1/8 7-3/4 3-1/4 3-9/16
from 28 ZRLK-▲- C28-* 7-1/8 7-3/4 3-3/4 4-1/16
Ta an bd le S B u eb ls o t wi- C28 7-5/8 8-1/4 3-3/4 4-1/16
W i t h L o n g C able Adapter
tute 12 ZRLKL-▲-12-* 7-5/8 8-1/4 1-3/4 1-61/64
Symbol No. 16 ZRLKL-▲-16-* 7-7/8 8-1/2 2-1/4 2-31/64
for Delta ▲
20 ZRLKL-▲-20-* 8-3/8 9 2-3/4 3-1/32
ZRLKL-▲-C20-*
C20 ZRLKL-▲-24-* 8-7/8 9-1/2 2-3/4 3-1/32
24 ZRLKL-▲-C24-* 8-7/8 9-1/2 3-1/4 3-9/16
C24 ZRLKL-▲-28-* 9-3/8 10 3-1/4 3-9/16
28 ZRLKL-▲-C28-* 9-1/8 9-3/4 3-3/4 4-1/16
C28 9-5/8 10-1/4 3-3/4 4-1/16
A D
See cable grip
components page
for basket weave
grip lengths
E
Safety Wire Holes
C (3).062 Dia.
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-*
Shell Shell Shells Shells Shells Shell Shell Shell Shells Shells
Cable Dia. 12 16 20 & C20 24 & C24 28 & C28 Cable Dia. 12 16 20 & C20 24 & C24 28 & C28
.062 to .125 02 – – – – 1.500 to 1.625 – – 26 26 26
.125 to .250 04 – – – – 1.625 to 1.750 – – 28 28 28
.250 to .375 06 06 – – – 1.750 to 1.875 – – 30 30 30
.375 to .500 08 08 – – – 1.875 to 1.937 – – 31 – –
.500 to .625 10 10 10 – – 1.875 to 2.000 – – – 32 32
.625 to .750 12 12 12 – – 2.000 to 2.125 – – – 34 34
.750 to .875 14 14 14 – – 2.125 to 2.250 – – – 36 36
.875 to .937 15 – – – – 2.250 to 2.375 – – – 38 38
.875 to 1.000 – 16 16 16 – 2.375 to 2.437 – – – 39 –
1.000 to 1.125 – 18 18 18 – 2.437 to 2.500 – – – – 40
1.125 to 1.250 – 20 20 20 – 2.500 to 2.625 – – – – 42
1.250 to 1.375 – 22 22 22 – 2.625 to 2.750 – – – – 44
1.375 to 1.437 – 23 – – – 2.750 to 2.875 – – – – 46
1.375 to 1.500 – – 24 24 24
16
STAR-LINE® Amphenol
INDUSTRIAL
In-Line Receptacle
with conduit adapter
(for flexible conduit fittings)
To specify a complete receptacle, substitute the dash no. of the Types
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””. ZRLT ZRET
Dimensions
Shell Size
Size Conduit Cat. No. A B C D E
12 3/4 ZRLT-2 12-* 4-1/4 3/4 4-7/8 1-3/8 1-61/64
16 1-1/4 ZRLT-4 16-* 4-3/8 1-1/4 5 2-1/4 2-15/32
20 1-1/2 ZRLT-5 20-* 4-1/2 1-1/2 5-1/8 2-3/4 3-1/32
C20 1-1/2 ZRLT-5 C20-* 5 1-1/2 5-5/8 2-3/4 3-1/32
24 2 ZRLT-6 24-* 4-5/8 2 5-1/4 3-1/4 3-9/16
C24 2 ZRLT-6 C24 5-1/8 2 5-3/4 3-1/4 3-9/16
28 2-1/2 ZRLT-7 28-* 5-3/32 2-1/2 5-23-32 3-3/4 4-1/16
C28 2-1/2 ZRLT-7 C28-* 5-19/32 2-1/2 6-7/32 3-3/4 4-1/16
A D
B
NPT
Thread
E
Safety Wire Holes
(3) .062 Dia.
C
B To specify receptacle with threaded
NPT
Thread environmental cover, change third letter
in Part No. “L” to “E”.
Example: ZRLT changes to ZRET.
17
STAR-LINE®
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
DIMENSIONS
Shell Open WITH STANDARD CABLE ADAPTER
Size Back Catalog No. A B C* E F G J K L N
12 Use with ZRLP- 12-* 1-3/4 1-3/8 1-1/12 11/64 2-15/16 2-1/8 1 1-11/32 2-21/64 1/4
16 or without ZRLP- 16-* 2-1/4 1-11/16 2 13/64 2-15/16 2-1/8 1 1-27/32 2-21/64 1/4
20 Potting ZRLP- 20-* 2-3/4 2-3/32 2-1/2 7/32 2-15/16 2-3/16 1 2-11/32 2-21/64 1/4
C20 Sleeves ZRLP- C20-* 2-3/4 2-3/32 2-1/2 7/32 3-7/16 2-11/16 1-1/2 2-11/32 2-53/64 3/4
24 ZRLP- 24-* 3-1/4 2-17/32 3 9/32 2-15/16 2-3/16 1 2-27/32 2-21/64 1/4
C24 ZRLP- C24-* 3-1/4 2-17/32 3 9/32 3-7/16 2-11/16 1-1/2 2-27/32 2-53/64 3/4
28 ZRLP- 28-* 3-3/4 3-1/32 3-1/2 11/32 2-15/16 2-3/16 1 3-11/32 2-21/64 1/4
C28 ZRLP- C28* 3-3/4 3-1/32 3-1/2 11/32 3-7/16 2-11/16 1-1/2 3-11/32 2-53/64 3/4
A Sq. L
B Sq. J
3/16
C k
E Modified
hole Acme
Dia. thread
WITH THREADED ENVIRONMENTAL WITH HINGED SPRING COVER
COVER AND SASH CHAIN
G
F 5/8
N 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 To specify receptacle with spring
environmental cover, change third door cover, change third letter
letter in part number from “L” to “E”. in part number from “L” to “C”.
Example: ZRLP changes to ZREP. 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
STAR-LINE® Amphenol
INDUSTRIAL
Square Flange Receptacle
with Mechanical Clamp Nut
To specify a complete receptacle, substitute the dash no. of the contact insert selected, for the asterisk (*) Type
in the catalog no. below. ZRLPM ZRCPM ZREPM
Dimensions
Size Shell Catalog
Cable Size Number A B C D E F G H N
12 ZRLPM-▲- 12-* 6-1/8 1-3/4 6-3/4 1-3/8 11/64 1-3/4 2-3/8 1-1/2 1/4
16 ZRLPM-▲- 16-* 6-7/16 2-1/4 7-1/16 1-11/16 13/64 2-1/4 3 2 1/4
20 ZRLPM-▲- 20-* 7 2-3/4 7-5/8 2-3/32 7/32 2-3/4 3-3/4 2-1/2 1/4
C20 ZRLPM-▲- C20-* 7-1/2 2-3/4 8-1/8 2-3/32 7/32 2-3/4 3-3/4 2-1/2 3/4
Select 24 ZRLPM-▲- 24-* 7-9/16 3-1/4 8-3/16 2-17/32 9/32 3-1/4 4-1/2 3 1/4
from C24 ZRLPM-▲- C24-* 8-1/16 3-1/4 8-11/16 2-17/32 9/32 3-1/4 4-1/2 3 3/4
Table Below 28 ZRLPM-▲- 28-* 8-1/8 3-3/4 8-3/4 3-1/32 11/32 3-3/4 5-1/8 3-1/2 1/4
and Substi- C28 ZRLPM-▲- C28-* 8-5/8 3-3/4 9-1/4 3-1/32 11/32 3-3/4 5-1/8 3-1/2 3/4
tute With Long Cable Adapter
Symbol No. 12 ZRLPML-▲-12-* 8-3/8 1-3/4 9 1-3/8 11/64 1-3/4 2-3/8 1-1/2 1/4
for Delta ▲ 16 ZRLPML-▲-16-* 8-11/16 2-1/4 9-5/16 1-11/16 13/64 2-1/4 3 2 1/4
20 ZRLPML-▲-20-* 9-1/4 2-3/4 9-7/8 2-3/32 7/32 2-3/4 3-3/4 2-1/2 1/4
C20 ZRLPML-▲-C20-* 9-3/4 2-3/4 10-3/8 2-3/32 7/32 2-3/4 3-3/4 2-1/2 3/4
24 ZRLPML-▲-24-* 9-13/16 3-1/4 10-7/16 2-17/32 9/32 3-1/4 4-1/2 3 1/4
C24 ZRLPML-▲-C24-* 10-5/16 3-1/4 10-15/16 2-17/32 9/32 3-1/4 4-1/2 3 3/4
28 ZRLPML-▲-28-* 10-1/8 3-3/4 10-3/4 3-1/32 11/32 3-3/4 5-1/8 3-1/2 1/4
C28 ZRLPML-▲-C28-* 10-5/8 3-3/4 11-1/4 3-1/32 11/32 3-3/4 5-1/8 3-1/2 3/4
B Sq.
A D Sq.
Drill hole in panel 1/64” larger
H than Dimension “H” for back
F mounting..
G Max. Reversible clamps for 1/16" Gasket fits E hole Dia.
complete cable range front or back of flange
C E
Hole Dia.
To specify receptacle with To specify receptacle with spring
threaded environmental cover, door cover, change third letter in
change third letter in Part No. Part No. “L” to “C”.
“L” to “E”. Example: ZRLPM changes to
Example: ZRLPM changes to ZrCPm.
N ZrePm.
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-*
Shell Shell Shells Shells Shells Shell Shell Shell Shells Shells
Cable Dia. 12 16 20 & C20 24 & C24 28 & C28 Cable Dia. 12 16 20 & C20 24 & C24 28 & C28
.062 to .125 02 – – – – 1.500 to 1.625 – – 26 26 26
.125 to .250 04 – – – – 1.625 to 1.750 – – 28 28 28
.250 to .375 06 06 – – – 1.750 to 1.875 – – 30 30 30
.375 to .500 08 08 – – – 1.875 to 1.937 – – 31 – –
.500 to .625 10 10 10 – – 1.875 to 2.000 – – – 32 32
.625 to .750 12 12 12 – – 2.000 to 2.125 – – – 34 34
.750 to .875 14 14 14 – – 2.125 to 2.250 – – – 36 36
.875 to .937 15 – – – – 2.250 to 2.375 – – – 38 38
.875 to 1.000 – 16 16 16 – 2.375 to 2.437 – – – 39 –
1.000 to 1.125 – 18 18 18 – 2.437 to 2.500 – – – – 40
1.125 to 1.250 – 20 20 20 – 2.500 to 2.625 – – – – 42
1.250 to 1.375 – 22 22 22 – 2.625 to 2.750 – – – – 44
1.375 to 1.437 – 23 – – – 2.750 to 2.875 – – – – 46
1.375 to 1.500 – – 24 24 24
19
STAR-LINE®
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 Shell Catalog Dimensions ZRLPK, ZRCPK, ZREPK
Cable Size Number A B C D E F G
12 ZRLPK-▲- 12-* 5-3/8 1-3/4 6 1-3/8 11/64 1-1/2 1/4
16 ZRLPK-▲- 16-* 5-5/8 2-1/4 6-1/4 1-11/16 13/64 2 1/4
20 ZRLPK-▲- 20-* 6-1/8 2-3/4 6-3/4 2-3/32 7/32 2-1/2 1/4
C20 ZRLPK-▲- C20-* 6-5/8 2-3/4 7-1/4 2-3/32 7/32 2-1/2 3/4
Select 24 ZRLPK-▲- 24-* 6-5/8 3-1/4 7-1/4 2-17/32 9/32 3 1/4
from C24 ZRLPK-▲- C24-* 7-1/8 3-1/4 7-3/4 2-17/32 9/3 3 3/4
Table Below 28 ZRLPK-▲- 28-* 7-1/8 3-3/4 7-3/4 3-1/32 11/32 3-1/2 1/4
and Substi- C28 ZRLPK-▲- C28-* 7-5/8 3-3/4 8-1/4 3-1/32 11/32 3-1/2 3/4
tute With Long CableAdapter
Symbol No. 12 ZRLPKL-▲-12-* 7-5/8 1-3/4 8-1/4 1-3/8 11/64 1-1/2 1/4
for Delta ▲
16 ZRLPKL-▲-16-* 7-7/8 2-1/4 8-1/2 1-11/16 13/64 2 1/4
20 ZRLPKL-▲-20-* 8-3/8 2-3/4 9 2-3/32 7/32 2-1/2 1/4
C20 ZRLPKL-▲-C20-* 8-7/8 2-3/4 9-1/2 2-3/32 7/32 2-1/2 3/4
24 ZRLPKL-▲-24-* 8-7/8 3-1/4 9-1/2 2-17/32 9/32 3 1/4
C24 ZRLPKL-▲-C24-* 9-3/8 3-1/4 10 2-17/32 9/32 3 3/4
28 ZRLPKL-▲-28-* 9-1/8 3-3/4 9-3/4 3-1/32 11/32 3-1/2 1/4
C28 ZRLPKL-▲-C28-* 9-5/8 3-3/4 10-1/4 3-1/32 11/32 3-1/2 1/4
A
F Drill hole in panel 1/64” larger
than Dimension “H” for back
mounting..
C E
Hole Dia.
To specify receptacle To specify receptacle
with threaded environ- with spring door cover,
mental cover, change change third letter in
third letter in Part No. Part No. “L” to “C”.
“L” to “E”. Example: ZRLPM
G Example: ZRLPK changes to ZrCPR.
changes to ZrePR.
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-*
Shell Shell Shells Shells Shells Shell Shell Shell Shells Shells
Cable Dia. 12 16 20 & C20 24 & C24 28 & C28 Cable Dia. 12 16 20 & C20 24 & C24 28 & C28
.062 to .125 02 – – – – 1.500 to 1.625 – – 26 26 26
.125 to .250 04 – – – – 1.625 to 1.750 – – 28 28 28
.250 to .375 06 06 – – – 1.750 to 1.875 – – 30 30 30
.375 to .500 08 08 – – – 1.875 to 1.937 – – 31 – –
.500 to .625 10 10 10 – – 1.875 to 2.000 – – – 32 32
.625 to .750 12 12 12 – – 2.000 to 2.125 – – – 34 34
.750 to .875 14 14 14 – – 2.125 to 2.250 – – – 36 36
.875 to .937 15 – – – – 2.250 to 2.375 – – – 38 38
.875 to 1.000 – 16 16 16 – 2.375 to 2.437 – – – 39 –
1.000 to 1.125 – 18 18 18 – 2.437 to 2.500 – – – – 40
1.125 to 1.250 – 20 20 20 – 2.500 to 2.625 – – – – 42
1.250 to 1.375 – 22 22 22 – 2.625 to 2.750 – – – – 44
1.375 to 1.437 – 23 – – – 2.750 to 2.875 – – – – 46
1.375 to 1.500 – – 24 24 24
20
STAR-LINE® Amphenol
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. Types
ZRLBB ZRCBB ZREBB
Shell Hub Dimensions
Size Size† Cat. No. A B C D E F G H
12 3/4 ZRLBB- 2 12-* 5-1/4 4-5/8 4-3/16 3-9/16 2-3/8 2-13/16 2-7/16 9/32
1 ZRLBB-3 12-* 5-1/4 4-5/8 4-3/16 3-9/16 2-3/8 2-13/16 2-7/16 9/32
16 1 ZRLBB-3 16-* 5-1/4 4-5/8 4-3/16 3-9/16 2-3/8 2-15/16 2-17/32 9/32
1-1/4 ZRLBB-4 16-* 5-1/4 4-5/8 4-3/16 3-9/16 2-5/8 2-15/16 2-17/32 9/32
1-1/2 ZRLBB-5 16-* 5-1/4 4-5/8 4-3/16 3-9/16 2-5/8 2-15/16 2-17/32 9/32
20 1-1/4 ZRLBB-4 20-* 6 5-1/4 4-1/2 3-7/8 3-3/4 3-39/64 3 9/32
1-1/2 ZRLBB-5 20-* 6 5-1/4 4-1/2 3-7/8 3-3/4 3-39/64 3 9/32
2 ZRLBB-6 20-* 6 5-1/4 4-1/2 3-7/8 3-3/4 3-39/64 3 9/32
C20 1-1/4 ZRLBB-4 C20-* 6 5-1/4 4-1/2 3-7/8 3-3/4 3-39/64 3-3/8 9/32
1-1/2 ZRLBB-5 C20-* 6 5-1/4 4-1/2 3-7/8 3-3/4 3-39/64 3-3/8 9/32
2 ZRLBB-6 C20-* 6 5-1/4 4-1/2 3-7/8 3-3/4 3-39/64 3-3/8 9/32
24 2-1/2 ZRLBB-7 24-* 8 7 3-3/4 3-33/64 2-19/64 7/16
3 ZRLBB-8 24-* See 8 7 4-1/2 3-33/64 2-19/64 7/16
C24 2-1/2 ZRLBB-7 C24-* Drawing 8 7 3-3/4 3-33/64 2-21-32 7/16
3 ZRLBB-8 C24-* Below 8 7 4-1/2 3-33-64 2-21-32 7/16
28 2-1/2 ZRLBB-7 28-* 8 7 3-3/4 3-1/2 2-7/64 7/16
3 ZRLBB-8 28-* 8 7 4-1/2 3-1/2 2-7/64 7/16
C28 2-1/2 ZRLBB-7 C28-* 8 7 3-3/4 3-1/2 2-15/32 7/16
3 ZRLBB-8 C28-* 8 7 4-1/2 3-1/2 2-15/32 7/16
† Other hub sizes are available. Consult Amphenol Industrial Operations.
SHELL SIZES 12 - 16 - 20 - C20 SHELL SIZES 24 - C24 - 28 - C28
6-3/4
HUB E F 5/8 HUB 5-3/8
SIZE
SIZE
A B CD 9-1/2 7 8
G
D H
C 5/8 8 H
B
A
WITH HINGED SPRING COVER WITH THREADED ENVIRONMENTAL
COVER AND SASH CHAIN
To specify receptacle with spring To specify receptacle with threaded
door cover, change third letter environmental cover, change third letter
in part number from “L” to “C”. in part number from “L” to “E”.
Example: ZRLBB changes to ZRCBB Example: ZRLBB changes to ZREBB
21
STAR-LINE®
Receptacle Mounted
to Junction Box
with straight adapter
To specify a complete receptacle, substitute the dash no. of the contact insert selected, Types
for the asterisk (*) in the catalog no. below.
ZRLA ZRCA ZREA
Shell Hub Dimensions
Size Size† Cat. No. A B C D E F G H
12 3/4 ZRLA- 2 12-* 5-1/4 4-5/8 4-3/16 3-9/16 2-3/8 1-27/32 1 9/32
1 ZRLA-3 12-* 5-1/4 4-5/8 4-3/16 3-9/16 2-3/8 1-27/32 1 9/32
16 1 ZRLA-3 16-* 5-1/4 4-5/8 4-3/16 3-9/16 2-3/8 1-27/32 1 9/32
1-1/4 ZRLA-4 16-* 5-1/4 4-5/8 4-3/16 3-9/16 2-5/8 1-27/32 1 9/32
1-1/2 ZRLA-5 16-* 5-1/4 4-5/8 4-3/16 3-9/16 2-5/8 1-27/32 1 9/32
20 1-1/4 ZRLA-4 20-* 6 5-1/4 4-1/2 3-7/8 3-3/4 3-1/16 1-7/32 9/32
1-1/2 ZRLA-5 20-* 6 5-1/4 4-1/2 3-7/8 3-3/4 3-1/16 1-7/32 9/32
2 ZRLA-6-20-* 6 5-1/4 4-1/2 3-7/8 3-3/4 3-1/16 1-7/32 9/32
C20 1-1/4 ZRLA-4 C20-* 6 5-1/4 4-1/2 3-7/8 3-3/4 2-9/16 1-7/32 9/32
1-1/2 ZRLA-5 C20-* 6 5-1/4 4-1/2 3-7/8 3-3/4 2-9/16 1-7/32 9/32
2 ZRLA-6 C20-* 6 5-1/4 4-1/2 3-7/8 3-3/4 2-9/16 1-7/32 9/32
24 2-1/2 ZRLA-7 24-* 8 7 3-3/4 2-11/32 1-1/2 7/16
3 ZRLA-8 24-* See 8 7 4-1/2 2-11/32 1-1/2 7/16
C24 2-1/2 ZRLA-7 C24-* Drawing 8 7 3-3/4 2-27/32 1-1/2 7/16
3 ZRLA-8 C24-* Below 8 7 4-1/2 3-33-64 1-1/2 7/16
28 2-1/2 ZRLA-7 28-* 8 7 3-3/4 2-27/32 1-1/2 7/16
3 ZRLA-8 28-* 8 7 4-1/2 2-9/32 1-1/2 7/16
C28 2-1/2 ZRLA-7 C28-* 8 7 3-3/4 2-25/32 1-1/2 7/16
3 ZRLA-8 C28-* 8 7 4-1/2 2-25/32 1-1/2 7/16
† Other hub sizes are available. Consult Amphenol Industrial Operations.
SHELL SIZES 12 - 16 - 20 - C20 SHELL SIZES 24 - C24 - 28 - C28
6-3/4
HUB E F 5/8 HUB 5-3/8
SIZE
SIZE
A B C D 9-1/2 7 8
G
D H
C 5/8 8 H
B
A
WITH HINGED SPRING COVER WITH THREADED ENVIRONMENTAL
COVER AND SASH CHAIN
To specify receptacle with spring To specify receptacle with threaded
door cover, change third letter environmental cover, change third
in part number from “L” to “C”. letter in part number from “L” to “E”.
Example: ZRLA changes to ZRCA. Example: ZRLA changes to ZREA.
22
STAR-LINE EX® Amphenol
Amphenol® Star-Line EX® INDUSTRIAL
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
STAR-LINE EX®
Star-Line EX®
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)
Ingress Protection CE marking
ID# of Notified Body for the QA System
(IP) Ratings
EU Explosive Atmosphere symbol
First Number Second Number Above ground
Protection against solid bodies Protection against Liquids Category
0 No Protection 0 No Protection
1 Objects greater than 50mm 1 Vertically dripping water Gas, Dust
2 Objects greater than 12mm 2 75 to 90 dripping water 0518 II 2 GD
3 Objects greater than 2.5mm 3 Sprayed water
4 Objects greater than 1mm 4 Splashed water
5 Dust-protected 5 Water jets
* 66 DDuusstt--ttigighhtt 6 Heavy Seas
7 Temporary immersion
* 8 Indefinite immersion
Temperature Ratings HazLoc Hand Chart
UEC, EU (Europe) Protection Method IEC/EN (ATEX) ATEX
Surface USA (NEC 505)
Temperature Canada Ex Code Gas Ex Code Dust Category
450 C (842 F) T1 Intrinsic Safety ia 60079-11 Zone 0 iaD 61241-11 Zone 20 1
ib 60079-11 Zone 1 ibD 61241-11 Zone 21 2
300 C (572 F) T2 ic 60079-11 Zone 2 3
200 C (392 F) T3 * Flameproof dd 60079-1 Zone 1 2
135 C (275 F) T4 * EEnncclloossuurree ttDD 6611224411--11 ZZoonnee2200,,2211,2222
* 100 C (212 F) T5 Purge & Pressurization px 60079-2 Zone 1 2
85 C (185 F)
* T6 py 60079-2 Zone 1 2
pz 60079-2 Zone2 3
Pressurized pD 612441-4 Zone 21, 22
Note: Star-Line Ex® * Increased Safety e 6600007799--77 Zone 1 22
products certification Encapsulation ma 60079-18 Zone 0 maD 61241-18 Zone 20 1
denoted with a *. mb 60079-18 Zone 1 mbD 61241-18 Zone 21 2
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 1
* General Requirements 60079-0 61241-0
* Class. of Hazardous Areas 60079-1
* Electrical Installations 60079-14
Inspection & Maintenance 60079-17
24
STAR-LINE EX® Amphenol
INDUSTRIAL
Code Logic
Star-Line EX
“##” code for grommets Termination Method
used w/ type “2” or “4” N for crimp contact /
hardware styles(See page 67)/ R for pressure /
Letter code designation for Blank for solder
EEx d gland sizes Cable Type
Omit if unarmored.
Blank Aluminum (see chart below) -BS or -BSR
S = Stainless Steel Insert (see cable type
B = Brass
Configuration in charts on next page)
EX S 13 3 C 20 332 P N -01 -BS A376
Product Hardware Connector Optional Callout to
Series Style Shell Size Alternate designate
Prefix (see pgs. (12, 16, 20, Key T5 temperature
25-28) 24, 28, C20, Positions rating
C24, C28) -20o C to 55o C
13 for Male Plug / Contact Gender
15 for Female Inline/ P for Male Pin /
17 for Female Panel Mount S for Female Socket
18 for Panel Mount Circular Flange
19 for Thru Bulkhead-Dual Mate Receptacle
Example:
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®
PRODUCT CERTIFICATIONS
Certificate Number: SIRA 03ATEX1101X
Cert. No.: IECEx SIR 10.0064X
The Starline product family carries all of the
AEx North American Hazloc Listing industry standard approvals ranging from
Consult Factory for Listing No ATEX and IECEx to UL and CSA.
GOST-R Cert. No. РОСС MX.АИ96.В00012
(TUV) Brasil Cert. No. TUV 11.0147X
U® 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
STAR-LINE EX® Amphenol
INDUSTRIAL
EEx d Cable Types
EEx d Unarmored Armored & Sheathed Armored & Sheathed
Cable Cable Cable with reduced bore
Gland No deviation if -BS -BSR
Size Code Unarmored UA Standard OD-Reduced
Min Max Min Max Min Max Min Max
A1 .1575 (4.0) .3307 (8.4) .1339 (3.4) .3307 (8.4) .3543 (9.0) .5315 (13.5) .2638 (6.7) .4055 (10.3)
A2 .2835 (7.2) .4606 (11.7) .2835 (7.2) .4606 (11.7) .4528 (11.5) .6299 (16.0) .3701 (9.4) .4921 (12.5)
A .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.
Cables can be designed with a custom overmold
to any Amphenol cylindrical connector for
any industrial application. Consult Amphenol
27 Industrial Operations for further information.
STAR-LINE EX®
Hardware
*Notes: For “C” length inserts, add 1/2” to both dimensions “A” & “B”.
Plug with mechanical clamp (POTTING REQUIRED) EX-13-2 Style
Dimension A* B* C D E F
Shell
12 7-7/16 (189) 3-9/16 (91) 2-1/8 (54) 2 (51) 15/16 (24) 2-3/8 (60)
16 9-1/2 (241) 3-9/16 (91) 2-5/8 (67) 2-1/16 (52) 1-7/16 (37) 3 (76)
20 9-9/16 (243) 3-9/16 (91) 3-1/8 (79) 2-1/8 (54) 1-15/16 (49) 3-3/4 (95)
24 9-5/8 (245) 3-9/16 (91) 3-5/8 (92) 2-3/16 (56) 2-7/16 (62) 4-1/2 (114)
28 9-11/16 (246) 3-9/16 (91) 4-1/8 (105) 2 1/4 (57) 2-7/8 (73) 5-1/8 (130)
A
D B
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 A* B* C Gland
Shell Thread
12 6-1/16 (154) 3-9/16 (91) 2-1/8 (54) M25
16 8-1/16 (205) 3-9/16 (91) 2-5/8 (67) M40
20 8-1/16 (205) 3-9/16 (91) 3-1/8 (79) M50
24 8-1/16 (205) 3-9/16 (91) 3-5/8 (92) M63
28 8-1/16 (205) 3-9/16 (91) 4-1/8 (105) M75
D A (NOM)
B
C
(MAX)
Plug with Basketweave Cable Grip (POTTING REQUIRED) EX-13-4 Style
Dimension A* B* C D E F G
Shell
12 6-1/16 (154) 3-9/16 (91) 2-1/8 (54) 1-1/4 (32) 15/16 (24) 1-9/32 (33) 8 (203)
16 8-1/16 (205) 3-9/16 (91) 2-5/8 (67) 1-1/4 (32) 1-7/16 (37) 1-25/32 (45) 10-1/2 (267)
20 8-1/16 (205) 3-9/16 (91) 3-1/8 (79) 1-1/4 (32) 1-15/16 (49) 2-9/32 (58) 14-1/2 (368)
24 8-1/16 (205) 3-9/16 (91) 3-5/8 (92) 1-1/4 (32) 2-7/16 (62) 2-25/32 (71) 17-1/2 (445)
28 8-1/16 (205) 3-9/16 (91) 4-1/8 (105) 1-1/4 (32) 2-7/8 (73) 3-9/32 (83) 19 (483)
A
G (MAX) D B
C
(MAX)
E (MAX) F
28 (MAX)
STAR-LINE EX® Amphenol
*Notes: For “C” length inserts, add 1/2” to both dimensions “A” & “B”. INDUSTRIAL
In-line Receptacle with Mechanical Clamp (POTTING REQUIRED) EX-15-2 Style
Dimension A* B* C D E F
Shell
12 7 (178) 1-7/16 (37) 1-1/2 (38) 2 (51) 15/16 (24) 2-3/8 (60)
16 9-1/16 (230) 1-7/16 (37) 2 (51) 2-1/16 (52) 1-7/16 (37) 3 (76)
20 9-1/8 (232) 1-7/16 (37) 2-1/2 (64) 2-1/8 (54) 1-15/16 (49) 3-3/4 (95)
24 9-3/16 (233) 1-7/16 (37) 3 (76) 2-3/16 (56) 2-7/16 (62) 4-1/2 (114)
28 9-1/4 (235) 1-7/16 (37) 3-1/2 (89) 2-1/4 (57) 2-7/8 (73) 5-1/8 (130)
A
B D F (MAX)
C E (MAX)
In-line Receptacle with EEx d Gland (POTTING IS NOT REQUIRED) EX-15-3 Style
Note: ‘D’ Dimension varies according to cable gland. Detailed cable dimensions and type required.
Gland is included with the connector.
Dimension A* B* C Gland
Shell Thread
12 5-5/8 (143) 1-7/16 (37) 1-1/2 (38) M25
16 7-5/8 (194) 1-7/16 (37) 2 (51) M40
20 7-5/8 (194) 1-7/16 (37) 2-1/2 (64) M50
24 7-5/8 (194) 1-7/16 (37) 3 (76) M63
28 7-5/8 (194) 1-7/16 (37) 3-1/2 (89) M75
A
B D
C
In-line Receptacle with Basketweave Cable Grip (POTTING REQUIRED) EX-15-4 Style
Dimension A* B* C D E F G
Shell
12 6-1/4 (159) 1-7/16 (37) 1-1/2 (38) 1-1/4 (32) 15/16 (24) 1-9/32 (33) 8 (203)
16 8-1/4 (210) 1-7/16 (37) 2 (51) 1-1/4 (32) 1-7/16 (37) 1-25/32 (45) 10-1/2 (267)
20 8-1/4 (210) 1-7/16 (37) 2-1/2 (64) 1-1/4 (32) 1-15/16 (49) 2-9/32 (58) 14-1/2 (368)
24 8-1/4 (210) 1-7/16 (37) 3 (76) 1-1/4 (32) 2-7/16 (62) 2-25/32 (71) 17-1/2 (445)
28 8-1/4 (210) 1-7/16 (37) 3-1/2 (89) 1-1/4 (32) 2-7/8 (73) 3-9/32 (83) 19 (483)
A G
(MAX)
B D F (MAX)
E
(MAX)
C
29
STAR-LINE EX®
*Notes: For “C” length inserts, add 1/2” to both dimensions “A” & “B”.
Panel Mount Receptacle (POTTING REQUIRED) EX-17-1 Style
Dimension A* B* C D E F
Shell A
12 4 7/16 1.765 1-1/2 (38) 1.654 (42) 2-1/4 (57) M40 #10 (M5) B F
16 4 7/16 1.765 2 (51) 2.047 (52) 2-5/8 (67) M50 (THREAD)
20 4 7/16 1.765 2-1/2 (64) 2.441 (62) 3 (76) M63
24 4 7/16 1.765 3 (76) 2.835 (72) 3-1/2 (89) M75
28 4 7/16 1.765 3-1/2 (89) 3.228 (82) 4 (102) M90 D C 23/32
Square (MIN. FULL
E THREAD)
Square
Fixed In-Line Receptacle with Mechanical Clamp (POTTING REQUIRED) EX-17-2 Style
Dimension A* B* C D E F
Shell
12 7 (178) 1-7/16 (27) 1-1/2 (38) 2 (51) 5/16 (24) 2-3/8 (60)
16 9-1/16 (230) 1-7/16 (27) 2 (51) 2-1/16 (52) 1-7/16 (37) 3 (76)
20 9-1/8 (229) 1-7/16 (27) 2-1/2 (64) 2-1/8 (54) 1-15/16 (49) 3-3/4 (95)
24 9-3/16 (233) 1-7/16 (27) 3 (76) 2-3/16 (56) 2-7/16 (62) 4-1/2 (114)
28 9-1/4 (235) 1-7/16 (27) 3-1/2 (89) 2-1/4 (57) 2-7/8 (73) 5-1/8 (130)
A
B D F (MAX)
C E (MAX)
Fixed In-Line Receptacle with EEx d Gland (POTTING IS NOT REQUIRED) EX-17-3 Style
N o t e : ‘GDl’aDnidmiesninsicolundveadriewsithacthcoercdoinngnetoctcoar.ble gland. Detailed cable dimensions and type required. A
Dimension A* B* C Gland B D
Shell Thread
12 5-5/8 (143) 1-7/16 (37) 1-1/2 (38) M25
16 7-7/8 (194) 1-7/16 (37) 2 (51) M40
20 7-7/8 (194) 1-7/16 (37) 1-/12 (64) M50 C
24 7-7/8 (194) 1-7/16 (37) 3 (76) M63
28 7-7/8 (194) 1-7/16 (37) 3-1/2 (89) M75
Fixed In-Line Receptacle with Basketweave Cable Grip (POTTING REQUIRED) EX-17-4 Style
Dimension A* B* C D E F G
Shell
12 6-1/4 (159) 1-7/16 (27) 1-1/2 (38) 1-1/4 (32) 15/16 (24) 1-9/32 (33) 8 (203)
16 8-1/4 (210) 1-7/16 (27) 2 (51) 1-1/4 (32) 1-7/16 (37) 1-25/32 (45) 10-1/2 (267)
20 8-1/4 (210) 1-7/16 (27) 2-1/2 (64) 1-1/4 (32) 1-15/16 (49) 2-9/32 (58) 14-1/2 (368)
24 8-1/4 (210) 1-7/16 (27) 3 (76) 1-1/4 (32) 2-7/16 (62) 2-25/32 (71) 17-1/2 (445)
28 8-1/4 (210) 1-7/16 (27) 3-1/2 (89) 1-1/4 (32) 2-7/8 (73) 3-9/32 (83) 19 (483)
A G
(MAX)
B D F (MAX)
E
(MAX)
C
30
STAR-LINE EX® Amphenol
INDUSTRIAL
Description of equipment
The Star-line EX series of connectors is comprised of metallic bodied plug and receptacle shells, to form
in䯉line cable connections. Externally the main bodies are fitted with suitably certified cable glands. In-
ternally 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 exter-
nally 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 combina-
tions 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– Bulkhead Mount (w/ potting adapter; requires potting)
2– Mechanical Clamp (requires potting)
3– Threaded for use with EX certified Gland
4– Basketweave Grip (requires potting)
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, S- Socket
Termination Style (h) N - Crimp, R - Pressure
Insert Rotation (j) Normal (default, omit code)
For alternates, refer to catalog
Planned Additions (k) Certified Variations
31
STAR-LINE EX®
Star-Line EX®
Familiarization & Assembly Information
1. Read manufacturer’s assembly instructions before actually 8. Be sure that ground contacts (when applicable) are correctly
starting to assemble connectors. Besides the matter of located.
instruction on correct procedures, there are two important 9. Seat all contacts properly so that they will not be damaged or
reasons for this preliminary step: To identify the various become disengaged during connector mating operations
component parts, and to check for any missing parts.
2. Cut cable jackets and sheathing squarely and to correct 10. Use only the proper insertion tools and be sure that they are
length, using only wire strippers that have been approved for aligned axially when pushing contact into their fully seated
the operation. In preparing the individual wires in cables and position.
harnesses for assembly, make allowances in length for reaching 11. When inserts have more cavities than conductors, plug unused
the outermost circle of contact cavities in the conductors. The cavities with furnished contacts.
insulation should be cut progressively longer as they extend 12. After all terminated contacts are inserted in their respective
out from the center of the cable or harness to assure sufficient cavities and inspected (detailed on page 34), the cable adapter
length. or insert clamp nut should be tightened with a wrench. (detailed
3. Follow chart on page 34 covering maximum cable stripping on page 37).
lengths for effective cable gland or grommet sealing. All 13. When handling cables, use adequate support to prevent damage
conductors should be fit into contact wire wells correctly. A to the internal wires. Exd glands are intended for sealing purposes
practice layout should be done so that the assembler can and should not be used as a cable grip.
oversee what the finished will look like when finished.
4. Some cables that will be used will have a ‘basket weave’ type 14. If for any reason terminated conductors have to be removed from
of armor under the outer jacket (sheath) and over the inner an insert because of an assembly error or change in circuitry,
jacket. Since many regulatory entities require that the armor be sure to remove the cable gland or cable adapter first before
be grounded at least at the source end, it is beneficial to ground extracting the contact and reinserting it.
the armor via a spare contact within the connector. Following 15. If one of the connector poles is a ground wire, make sure that it
the removal of sufficient amount of outer jacket (see chart on is grounded properly before the connector actually is engaged.
page 34) ample amount of the armor can be clipped away, but
not all. An adequate amount should remain in order that a 16. When connectors having the same configuration are to
small cross-section conductor, short in length, be woven into be mounted close together, different or alternate keying
the remaining armor weave and either soldered or covered arrangements should be used to prevent mismatching and
with mastic impregnated heat shrink, creating an intimate bond possible damage to the electrical system.
to the armor. At the opposite end of the short piece of wire a 17. Always inspect all aspects of connector assembly operations
contact should be crimped and inserted into the insert. before putting connectors into actual operation.
5. Use only correctly sized and ingress protected certified glands 18. Crimping and terminating of conductors to contacts must be
or sealing grommets to assure resistance to moisture and other done carefully. Make certain that wire strands are fully bottomed
contaminants. in contact-wells by checking through inspection hole provided
6. Use only the proper crimping tools that have been set or (Detailed on page 34).
calibrated with precision gages. 19. Never try to straighten bent contacts. Straightening cannot be
7. Make certain that all contacts are the correct size before done properly and the plating on contacts very likely will be
attempting to assemble in insert cavities. This point is marred. This will result in a high resistance connection and will
particularly important when both power and control types of expose the base material to possible corrosion.
contacts are used in the same connector. 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
STAR-LINE EX® Amphenol
INDUSTRIAL
Star-Line EX®
Cable Types
It is the responsibility of the specifier/user to select the appro- Since there is no armor grounding contact path provided
priate cable to be used with the EX Star-Line connector sys- within the connector assembly, a suitable external method
tem. The specifier/user should favor the use of cables con- must be employed. It is recommended that a small strip of
structed with flexible conductors (IEC class 5 or higher/ICEA outer jacket be cut away a reasonable distance from the en-
type H or higher) as well as a flexible armor type (basket trance to the cable gland of the connector. A durable insu-
weave) if required. Armor systems such as those identified in lated conductor with a cross section not smaller than
IEC 92-3 or IEEE455 or UL1309 are recommended. An imper- #14awg/4mm should be bonded to the exposed armor. Pro-
vious jacket should always be furnished over the armor. IEC/ tective tapes or heat or cold shrink (3M PST) should be applied
BS cables such as armored with SWA (X), tape(Z), and NEC to protect this bonding point. The opposite end of this
style cables such as ‘interlocked’ or MC are not recommended grounding conductor should be terminated at the correspond-
with the EX connector system. ing receptacles’ panel via one of the receptacles’ fastening
The armor system should be grounded at the source point. screws or a dedicated grounding lug or bar. In an ‘in-line’
Periodically the specifier/user should investigate the need for configuration, a mirror image of the above should be used
armor grounding (earthing) within the plug or in-line connec- with a simple mating point in close proximity to the connector
tor itself. In addition to the weaving of the armor grounding set.
conductor, soldering and/or heat shrink and/or strong adhe- In summary the specifier/user should be versed in acceptable
sive electrical takes, and/or ‘tension banding’ should be ap- applications that are allowed by the regulatory/certifying bod-
plied on the armor and conductor to insure a permanent bond. ies having jurisdiction. Periodic inspection of this grounding
The armor grounding wire should be terminated (solder or arrangement should be implemented.
crimp) to an appropriate sized contact, and inserted into the All connectors are furnished with a protective cover. In actual-
connector insert. ity this cover is viewed as a critical part of the connector. The
The armor system should not be confused or associated with cover is compared to a cover on a flameproof (Eexd) enclo-
shielding which is employed with instrumentation/ sure. Absence of the cover voids the Ex certification. The
telecommunication cables. Shielding for pairs/triads have their covers should not be viewed as an incidental protection to the
own individual drain wires which should be terminated onto external elements, but a required component of a hazardous
dedicated contacts. These drain wires should be insulated certified device. When the connectors are plugged together
with heat shrink within the connector body to prevent contact the covers can be screwed into each other to protect the
with other drain wires or pair/triad shield faces. threads from damage. When the connectors are not mated, it
The above procedure does not apply to single conductor ca- is required that the covers be installed and the set screws on
bles, i.e., 444-1111mcm (150mm-500mm), or multiconductor the covers be fully driven into the body of the connector.
power or control cables. Replacement covers and ‘NYLOK’ set screws are available on
Single conductor Cables Periodically single conductor cables request.
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 Marking for all connectors used in standard
Sidney NY 13838 USA (+40°C max.) ambient:
Star-Line, Size Ref Ex d IIC T6 Gb (Inline Plugs and Receptacles)
Work Order Number; Date Code; Facility Ex tb IIIC T80°C Db IP68 (Inline Plugs and Receptacles)
Code Ex de IIC T6 Gb (Panel mount receptacle filled w/ cement)
Ex tb IIIC T80°C Db IP68 (Panel mount receptacle filled w/ cement)
0518 II 2 GD -20ºC Tamb +40°C
IP68-8
Marking for inline connectors, used in +55°C max. ambient:
Sira 03ATEX1101X & IECEx SIR 10.0064X (INCREASED TEMP RANGE ONLY ALLOWABLE FOR CONNECTORS
(EX-13-3, EX-15-3, EX-17-3) EMPLOYING SUITABLE EX CERTI-
FIED GLANDS. THIS MARKING IS NOT APPLICABLE FOR CE-
“Max volts, Max amp, Current rating per pin” MENTED CONFIGURATIONS)
DO NOT SEPARATE WHEN ENERGIZED Ex d IIC T5 Gb (Inline Plugs and Receptacles)
Ex tb IIIC T95°C Db IP68 (Inline Plugs and Receptacles)
-20ºC Tamb +55°C
33 Page 4
STAR-LINE EX®
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 tempe-
rature classes T6, T5, T4, T3, T2 & T1.
The equipment is only certified for use in ambient temperatures in the range -20°C 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 General requirements for electrical apparatus for explo-
(IEC 60079-0:2007 5th Ed) sive gas atmospheres
EN 60079-1:2007 Electrical apparatus for explosive gas atmospheres -
(IEC 60079-1:2007 6th Ed) Part 1: Flameproof enclosures "d
EN 60079-7:2007 Electrical apparatus for explosive gas atmospheres –
(IEC 60079-7:2006 4th Ed) Part 7: Increased safety "e"
EN 61241-0:2006 General requirements for electrical apparatus for use in
(IEC 61241-1:2004 1st Ed + Corr Nov 05) the presence of combustible dust
EN 61241-1:2004 Electrical apparatus for use in the presence of combusti-
(IEC 61241-1:2004 1st Ed) ble 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 non-
approved components/suppliers will invalidate the certification for that product.
The certification of this equipment relies upon the following materials used in its construction:
1. 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.
2. 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 materi-
als.
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
STAR-LINE EX® Amphenol
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 -20°C to +70.2°C.
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.
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®
Star-Line EX®
Assembly & Terminating Instructions
Cable Jacket & Wire Stripping
Shell Contact Mod 1 (Solder Contact) Mod 1 (Pressure Contact) Mod 2 & 3 (Crimp Contact)
Size Size Strip Lengths (mm) Strip Lengths (mm) Strip Lengths (mm)
AWG(mm) Conductor Jacket Conductor Jacket Conductor Jacket
12 18 (0.75mm) 7.2mm 99.2mm - 90.5mm 11.5mm 90.5mm
16 (1.5mm) 7.2mm 99.2mm - 90.5mm 14.6mm 90.5mm
12 (4.0mm) 8.7mm 99.2mm 17.5mm 90.5mm 15.5mm 90.5mm
10 (6.0mm) 11.9mm 99.2mm 14.3mm 84.1mm 17.1mm 92.1mm
16 18 (0.75mm) 7.2mm 105.5mm - 96.8mm 11.5mm 96.8mm
16 (1.5mm) 7.2mm 105.5mm - 96.8mm 14.6mm 96.8mm
12 (4.0mm) 8.7mm 105.5mm - 96.8mm 15.5mm 96.8mm
10 (6.0mm) 11.9mm 105.5mm - 90.5mm 17.1mm 98.4mm
8 (10.0mm) 15.1mm 105.5mm - 88.9mm 21.0mm 98.4mm
4 (25.0mm) 16.7mm 105.5mm 17.5mm 87.3mm 23.0mm 101.6mm
20 18 (0.75mm) 7.2mm 118.2mm - 109.5mm 11.5mm 109.6mm
16 (1.5mm) 7.2mm 118.2mm - 109.5mm 14.6mm 109.6mm
12 (4.0mm) 8.7mm 118.2mm - 109.5mm 15.5mm 109.6mm
10 (6.0mm) 11.9mm 118.2mm - 103.2mm 17.1mm 111.12mm
8 (10.0mm) 15.1mm 118.2mm - 101.6mm 21.0mm 111.12mm
4 (25.0mm) 16.7mm 118.2mm 17.5mm 101.6mm 23.0mm 113.9mm
1/0 (50.0mm) 18.3mm 118.2mm 19.1mm 98.4mm 31.0mm 115.2mm
535MCM 50.0mm 118.2mm - 90.0mm - -
(240mm)
24/C24 18 (0.75mm) 7.2mm 130.9mm - 122.2mm 11.5mm -
16 (1.5mm) 7.2mm 130.9mm - 122.2mm 14.6mm -
12 (4.0mm) 8.7mm 130.9mm - 122.2mm 15.5mm -
10 (6.0mm) 11.9mm 130.9mm - 115.9mm 17.1mm -
8 (10.0mm) 15.1mm 130.9mm - 114.3mm 21.0mm -
4 (25.0mm) 16.7mm 130.9mm 17.5mm 100.0mm 23.0mm -
1/0 (50mm) 18.3mm 130.9mm 19.1mm 117.5mm 31.0mm -
4/0 (120mm) 18.3mm 130.9mm 19.1mm 127.0mm 31.6mm -
535 MCM 50.0mm 130.9mm - 90.0mm - -
(240mm)
777 MCM 50.0mm 130.9mm - 90.0mm - -
(400mm)
28/C28 18 (0.75mm) 7.2mm 137.3mm - 125.6mm 11.5mm -
16 (1.5mm) 7.2mm 137.3mm - 125.6mm 14.6mm -
12 (4.0mm) 8.7mm 137.3mm - 125.6mm 15.5mm -
10 (6.0mm) 11.9mm 137.3mm - 122.2mm 17.1mm -
8 (10.0mm) 15.1mm 137.3mm - 120.7mm 21.0mm -
4 (25.0mm) 16.7mm 137.3mm 17.5mm 106.4mm 23.0mm -
1/0 (50mm) 18.3mm 137.3mm 19.1mm 123.8mm 31.0mm -
4/0 (120mm) 18.3mm 137.3mm 19.1mm 133.4mm 31.6mm -
350 MCM 21.4mm 137.3mm - 130.1mm 33.5mm -
(185mm)
36
STAR-LINE EX® Amphenol
Star-Line EX® INDUSTRIAL
Assembly & Terminating Instructions
Electrical Connectors with MOD I Inserts
The following table gives the wire sizes and cord/cable Amperes Rating Conductor Type
types to be used with the Star-line plugs, receptacles and of Device Size AWG Cord/Cable
cable connectors. The plugs and cable connectors are 20 #14 S, SO
intended for connection to 3, 4 or 5 conductor cords/
cables depending on the contact insert configuration. 30 #12, #10 S, SO
The cord sealing grips range for plugs and cord 60 #6, #4 W
connectors is 1/8”. For instance, if inside dia. of grommet 100 #0, #1, #2 W
is 3/4” it will seal and grip a cord dia. in the range of .750 200 #3/0, #4/0 W
dia. max. to .625 dia min. Inside diameter of grommets
are in sixteenth of an inch increments.
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:
20 amp. 30 amp. 40 amp. 60 amp. 100 amp. 200 amp.
#12 contact #10 contact #8 contact #4 contact #1/0 contact #4/0 contact
Lb-in N/A 15 25 20 50 100
N-M 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”. 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.
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”.
E. Apply cable adaptor or insulation clamp nut by strap wrench, turning MM PP
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
STAR-LINE EX®
Star-Line EX®
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 JJ
and proper environmental sealing.
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
1.The panel receptacle is comprised of two basic pieces. The first is the actual
Panel Gasket 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
Sealing Washer Brass Locknut 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
STAR-LINE EX® Amphenol
Star-Line EX® INDUSTRIAL
Potting Instructions
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 102°F 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 140°F.
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 encapsu- 1. CAUTION: Wear goggles or other eye protection during all
operations.
lant to the following levels:
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.
1-3/4" Empty
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.
Filled With Compound 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.
Cable Adapter
7. Install nozzle and remove bottom cap.
• In-line cable adapters are filled to within one & three
8. Load tube into a standard painters caulk gun.
quarter inches (1¾”) of the end of the adapter. The
9. Pot connectors in mated condition to assure contact
goal is to have all the volume filled without interrupting alignment.
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®
Star-Line EX®
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 Approx. Cement
in a 6” cable adapter* usage in a bulkhead
adapter*
(Fluid Ounces) (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
STSAinRg-lLeINPEo®le Power Amphenol
INDUSTRIAL
Rig-Power® Connectors
(1000v AC/DC)
Connector Standard RIG-Radsok®
Style Insert Gender Part Number* Part Number*
Plug w/ Mech. Clamp Dead Front Pin (Line side) RIG-10P▲-XX-M-◆ RIG-R10P▲-XX-M-◆
Plug w/ Mech. Clamp Socket Contact (Load Side) RIG-10S▲-XX-M-◆ RIG-R10S▲-XX-M-◆
Cable Receptacle w/ Mech. Clamp Dead Front Pin (Line side) RIG-15P▲-XX-M-◆ RIG-R15P▲-XX-M-◆
Cable Receptacle w/ Mech. Clamp Socket Contact (Load Side) RIG-15S▲-XX-M-◆ RIG-R15S▲-XX-M-◆
Fixed CableReceptacle w/ Mech. Clamp Dead Front Pin (Line side) RIG-17P▲-XX-M-◆ RIG-R17P▲-XX-M-◆
Fixed Cable Receptacle w/ Mech. Clamp Socket Contact (Load Side) RIG-17S▲-XX-M-◆ RIG-R17S▲-XX-M-◆
Panel Mount Receptacle (Bus Bar) Dead Front Pin (Line side) RIG-17PR-◆ RIG-R17PR-◆
Panel Mount Receptacle (Bus Bar) Socket Contact (Load Side) RIG-17SR-◆ RIG-R17SR-◆
Panel Mount Receptacle (Direct Cable Entry) Dead Front Pin (Line side) RIG-17PN-◆ RIG-R17PN-◆
Panel Mount Receptacle (Direct Cable Entry) Socket Contact (Load Side) RIG-17SN-◆ RIG-R17SN-◆
* ▲ Select Cable Size. See Cable Size & Amperage Guide below. NOTE: Radsok® version not backward
XX - Select Cable Diameter Code #. See Grommet Selection Guide below.
compatible with original contact design
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 & Amperage RIG-Power Grommet
Selection Guide (p) Selection Guide (XX)
Cable Size Standard RIG-Radsok® TBM 15 Cable Diameter Code No. (XX)
Amperage Amperage Die Code No.
2 = 313 kcmil 625 925 76 1.000-1.125 18
3 = 373 kcmil 700 1000 87 1.125-1.250 20
4 = 444 kcmil 800 1200 107 1.250-1.375 22
5 = 535 kcmil 900 1350 107 1.375-1.500 24
6 = 646 kcmil 1000 1500 107 1.500-1.625 26
7 = 777 kcmil 1135 1500 115 1.625-1.750 28
1.750-1.875 30
Color Code Options (t)
Current Type DC AC
Standard Color Code Blue Orange Yellow Brown Red White Black Green
Part Number Suffix ◆ -BL -OR -Y -BR -R -W -BK -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-R10P7-22-M-R RIG-R17SR-R
RIG-Power® Plug w/Radsok® Pin RIG-Power® Receptacle w/Radsok ®
(Color Code Red) Busbar Socket (Color Code Red)
Mated Pair Starline EX Rig-Power w/Radsok®
EX-13-3-D2-C24-R386PN EX-17-1-C24-R386SR
StarLine EX Plug w/Radsok® Pin
Starline EX Receptacle
w/Radsok® Socket
8.734 8.703
PLUG
RIG-10X -XX-M
.297 DIA. 4 HOLES
NOTE:
See page 20, shell size
C24 for full mounting
dimensions.
2.531 SQ.
3.250 SQ.
PANEL MOUNT RECEPTACLE
RIG-17X
42
Single Pole Power Amphenol
INDUSTRIAL
Single Pole Power Connectors
P-500TM / PD-501 POWER Connectors
Wire Type of Part Boot Part # Cable
Ampacity Size Termination Gender Number (See Color Code) Sealing Range
900* – Stud Socket P-500126-BS-◆ – –
900* 535MCM Solder Pin PD-501-L TMPC-10-◆ 1.125 - 1.500
900* 535MCM Crimp Pin P-500126-P TMPC-10-◆ 1.125 - 1.500
325 313MCM Solder Pin PD-501-S TMPC-10-◆ 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.
5.969 6.813
2.750 .547 MIN. PANEL THICKNESS 3.625 TMPC-10-R
1.875 1.375 BOOT
.750 2.250 2.656 D 1.375 D
.750 D 1.062 D
1.066 DIA. OVER KNURL PIN
MOUNTING HOLE 1.062 DIA. PIN PD-501-L
1.052
PANEL BOARD SOCKET 6.813 6.813
P-500126-BS 3.625 3.625
1.875 1.375 BOOT 1.875 1.375 BOOT
2.656 D 1.250 D 2.656 D 1.187 D
.750 D .955 D .750 D .875 D
PIN PIN
PIN P-500126-P PIN PD-501-S
TMPCTM Connectors
With Standard With Radsok
Contacts Contacts Cable
Type of Part Current Part Current Wire Boot Sealing
Gender Termination Number Range Number Range Size Part No. Range
Socket 7/8" Stud/Panel Board TMPC-41777-L-◆ 900-1135 amps TMPC-41777-RL-◆ 1500 N/A N/A N/A
Socket 2 Hole Bus Bar TMPC-41777-24L 900-1135 amps TMPC-41777-R24L 1500 N/A N/A N/A
Pin Crimp TMPC-40535-L 900 amps TMPC-40535-RL 1500 444-535 kcmil TMPC-10-◆ 1.125-1.500
Pin Crimp TMPC-40777-L 900-1135 amps TMPC-40777-RL 1500 646-777 kcmil TMPC-10-◆ 1.125-1.500
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
6.000 4-1/16 REF.
3.500
CLEVIS PIN 6.000
2.250
1.062 1.066 DIA. OVER KNURL 1.750 .656 DIA. 2 HOLES
1.052 DIA. MOUNTING HOLE
PANEL BOARD SOCKET MOTOR BUS BAR MOUNT
SOCKET TMPC-41777-24L
TMPC-41777-L
43
STAR-LINE®
TMPC POWER MOUNT
Amphenol® TMPC POWER MOUNT Flange Features & Benefits:
Mounted Traction Motor Power Connector • RADSOK contact provide increased
series featuring RADSOK® Contacts. amperages than competition
• Contacts rated at 1500 amp for 777 MCM
Amphenol Industrial Operations introduces the cables
addition of our “NEW” TMPC Power Mount flange • Contacts machined from high grade
mounted connector series. The New TMPC Power aluminum to offer longer life, more mating
Mount series is an addition to our time tested TMPC cycles
Single Pin power connector line. The TMPC Power • Lower insertion/removal forces is a by-
Mount incorporates our existing TMPC connectors product of our RADSOK contacts
with RADSOK® contacts into our new thermoplastic • Molded flange base mounts directly to
molded receptacle flange. Stainless or Aluminum panels, thus
eliminating the need for added secondary
Available in color codes per the NEC AC/DC mounting fixtures
Electrical requirements, the TMPC Power Mount • Color coded mounting bases and cable side
series is designed to work with current IEEE Type P boots available to help prevent cross mating,
drilling cables (sizes range from 313 MCM through while allowing easier electrical phase
777 MCM). The RADSOK® contacts allow for identification
higher amperages and reduced insertion/removal • Connector series comes complete with
forces when compared to similar products in the molded Hypalon caps and insulation boots
market. • Patent Pending
44
STAR-LINE® Amphenol
INDUSTRIAL
PLUG KIT PART NUMBER
COLOR 313 MCM 444 MCM 535 MCM 646 MCM 777 MCM
BLACK TMPC-SP3-BK TMPC-SP4-BK TMPC-SP5-BK 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 FLANGE KIT W/ CONTACT FLANGE KIT LESS CONTACT BOOT PART
Black TMPC-SR-BK TMPC-SRLC-BK 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
CONTACTS ONLY ACCESSORIES
(FOR PIN RETENTION RING DESCRIPTION PART NUMBER
RECEPTACLE CAP TMPC-SR-CAP
ADD -RR) BOOT CAP TMPC-SP-CAP
CABLE SIZE BUSBAR CONTACT MOUNTING GASKET TMPC-SR-G
313-777 BOOT RING 313 MCM SR1-313R
MCM TMPC-1 BOOT RING 444 MCM SR1-444R
CABLE SIZE PIN CONTACT BOOT RING 535 MCM SR1-535R
313-535 MCM TMPC-40535-RL BOOT RING 646 MCM SR1-646R
646-777 MCM TMPC-40777-RL BOOT RING 777 MCM SR1-777R
45
STAR-LINE®
Insert Configuration
Listing
For Amphenol®/ Pyle® 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® 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
STAR-LINE® Amphenol
INDUSTRIAL
ELECTRICAL MIlitary N.E.C. Ratings
Ratings
Ratings MIL-5015 Non- Circuit Over
Specifications Circuit Breaking Surface Thru-Air
Non-Circuit Distance Spacing
Service Voltage Ratings Breaking Inches Inches
The voltage to which contact inserts are limited Service D.C. A.C. D.C. A.C. Nominal Nominal
is a function of the dielectric separation between Voltage Volts Volts RMS RMS
adjacent contacts and between contacts RMS RMS
and shell. Instrument 250 200 – – 1/16 –
The voltage rating is designated by a service A 700 500 250 240 1/8 1/16
voltage rating letter which is shown in the D 1250 900 600 600 3/16 1/8
service voltage rating table with each contact E 1750 1250 600 600 1/4 3/16
configuration listing. B 2450 1750 600 600 5/16 1/4
C 4200 3000 600 600 1 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..
Non-Circuit NOTE: The N.E.C. circuit breaking and non-circuit breaking
Breaking † MV Drop ratings are based on test results of contacts and connectors.
Contact Ampere Rating Consult the N.E.C. when selecting wire/cable for specific
applications. Under certain conditions, a wire size may be
Size rated higher or lower than the table indicates for a given
AWG/ MS N.E.C. Solder Crimp contact size.
MCM *** Contacts Contacts
#18 – 9 22 30 † Measurements made at extreme ends of mated
#16 13 16 21 29 contacts with probe touching contact and wire (MIL-5015
specifications).
#12 23 30 20 27 ** Based on temperature rise (National Electrical Code
#10 33 40 16 26 Requirement).
#8 46 50 12 23 *** Based on Arcing Control (National Electrical Code
Requirement).
#4 80 90 10 22
#1/0 150 155 10 22
#4/0 225 225 8 22 For Amphenol Star-Line product insert de-rating
350 MCM – 325 8 – information per the National Electric Code,
500 MCM – 750 – 30 please consult the Amphenol Industrial website,
535 MCM – 839 – – www.amphenol-industrial.com. Chart is located
646 MCM – 937 – – under literature tab.
777 MCM – 1048 – –
47
STAR-LINE®
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 “W” “C” “W” Polarizing Polarizing
Awg/MCM Length Length Ground Standard “C”
18 Pin ZP-4018-36L
18 Socket ZP-4118-36L
16 Pin ZP-4016-36L ZP-4016-37L
16 Socket ZP-4116-36L
12 Pin ZP-4012-36L ZP-4012-37L3
12 Socket ZP-4112-36L
10 Pin ZP-4010-36L ZP-4010-37L2
10 Socket ZP-4110-36L
8 Pin ZP-4008-66L
8 Socket ZP-4108-66L
4 Pin ZP-4004-66L ZP-4804-66L
4 Socket ZP-4104-66L ZP-4904-66L
1/0 Pin ZP-4000-66LB ZP-4800-66LKB
1/0 Socket ZP-4100-66L ZP-4900-66LK
4/0 Pin ZP-4041-76LB
4/0 Socket ZP-4141-76L
500 MCM Pin P-206053-CP
500 MCM Socket P-206053-CS
535 MCM Pin RIG-C24-535PN
535 MCM Socket RIG-C24-535SN
646-777 MCM Pin RIG-C24-386PN
646-777 MCM Socket 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
STAR-LINE® Amphenol
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
Size Solder Mod I Crimp* Mod II Crimp* Mod III
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 Torque Data for
Conductor Crimp Retention Pressure Contacts
Contact Wire Size (AWG) Min. Force MOD I
Size Crimped Lbs. (N) Contact/Conductor Torque Req. Retention Force
#18 38 (169.0) Size/Awg (mm) In./Lbs. (N•m) Lbs. (N)
#18 (0.75) #20 19 (84.5) 4/0 (120.00) 100 (11.3) 4/0 450 (2001.7)
#22 15 (66.7) 3/0 350 (1556.9)
#16 50 (222.4) 2/0 300 (1334.5)
#16 (1.5) #18 38 (169.0) 1/0 (50.0) 50 (5.7) 1/0 250 (1112.0)
#20 19 (84.5) #1 200 (889.6)
#12 110 (489.3) #2 180 (800.7)
#12 (4.0) #14 70 (311.4) #4 (25.0) 20 (2.3) #4 140 (622.8)
#16 50 (222.4) #6 100 (444.8)
#10 180** (800.7) #8 90 (400.3)
#10 (6.0) #12 110 (489.3) #8 (10.0) 25 (2.8) #8 75 (333.6)
#14 70 (311.4) #10 (6.0) 15 (1.7) #10 80 (355.9)
#8 225 (1000) #12 70 (311.4)
#8 (10.0) to #14 60 (266.9)
#10 180 (800)
#4 400 (1779)
#4 (25.0) to
#6 300 (1334)
#2 550 (2447)
1/0 (50.0) to
1/0 700 (3114)
4/0 875 (3892)
4/0 (120.00) 3/0 825 (3670)
2/0 750 (3336)
500(240.00) 500 MCM 2500 (11120)
535 Recommend using Thomas & Betts
646 TBM 15 crimp tool with appropriate
777 sized dies.
** Stranded wire
49
STAR-LINE®
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 Thermocouple Table Temperature Range
Size Gender Cat. No. Code Material*
# 16 Pi n Z P-4016-10MF of Thermocouple Material
Socket ZP-4116-10MF Black Iron
Pin ZP-4016-10NF Temperature Range
#16 Yellow Constantan Material* Degrees Short Time
Socket ZP-4116-10NF Continuous
Pin ZP-4016-10PO Electrolytic Copper 190-350°C to 600°C
#16 White Chromel
Socket ZP-4116-10PO & Constantan
Pin ZP-4016-10RO Chromel & Constantan 0-900°C to 1100°C
#16 Green Alumel
Socket ZP-4116-10RO Iron & Constantan 0-1100°C to 1100°C
Pin ZP-4016-10CF Chromel & Alumel 0-1100°C to 1350°C
#16 Red Copper
Socket ZP-4116-10CF
ISA Color Military Color Conductor Identification
ISA Coding Coding
Symbol Nomenclature* (+) (–) Jacket (+) (–) Positive (+) Negative (–)
J Iron/Constantan White Red Black Black Yellow Magnetic Non-Magnetic
K Chromel/Alumel Yellow Red Yellow White Green Non-Magnetic Magnetic
T Copper/Constantan Blue Red Blue Red Yellow Copper Color Non-Magnetic
E Chromel/Constantan Purple Red Purple White Yellow Non-Magnetic Silver Color Non-Magnetic
B Copper/Copper Black White Black Red Red Copper Color Non-Magnetic
S Alloy #11
* 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
STAR-LINE® Amphenol
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 MOD MOD MOD Radsok Total 18 16 12 10 8 4 1/0 4/0 313MCM 350 MCM 373 MCM 444 MCM 535 MCM 646-777 Page
Arrangement I II III Contacts Number (0.75) (1.5) (4.0) (6.0) (10.0) (250) (50.0) (120.0) (185.0) (240.0) (300-400) No.
Number of Contacts
RIG-C24-386 X 1 1 54
RIG-C24-R386 X X 1 1 54
RIG-C24-535 X 1 1 54
RIG-C24-R535 X X 1 1 54
RIG-C24-313 X 1 1 54
RIG-C24-R313 X X 1 1 54
RIG-C24-373 X 1 1 54
RIG-C24-R373 X X 1 1 54
RIG-C24-444 X 1 1 54
RIG-C24-R444 X X 1 1 54
ZP-12-310 X(G) X 7 7 64
ZP-12-14 X 4 4 56
ZP-12-314 X 4 4 56
ZP-12-316 X 4 4 56
ZP-12-22 X(G) 4 4 56
ZP-12-322 X(G) 4 4 56
ZP-12-323 X 17 17 70
ZP-12-24 X 5 5 59
ZP-12-324 X X 5 5 59
ZP-12-326 X 5 3 2 61
ZP-12-27 X 3 3 55
ZP-12-327 X X 3 3 55
ZP-12-330 X(G) X 3 3 55
ZP-12-33 X 4 4 56
ZP-12-333 X 4 4 56
ZP-12-334 X(G) 10 10 67
ZP-12-348 X 7 7 64
ZP-12-53 X(G) 5 5 59
ZP-12-653 X(G) 5 5 59
ZP-12-354 X X 7 7 65
ZP-12-355 X 10 10 67
ZP-12-56 X(G) 3 3 55
ZP-C-16-341 X 1 54
ZP-16-312 X(G) X 19 19 71
ZP-16-16 X 5 5 59
ZP-16-316 X 5 5 59
ZP-16-321 X 37 37 74
ZP-16-22 X 4 4 57
ZP-16-322 X 4 4 57
ZP-16-324 X 18 16 2 70
ZP-16-325 X 16 16 69
ZP-16-28 X 4 4 57
ZP-16-328 X 4 4 57
ZP-16-29 X 9 8 1 66
ZP-16-333 X 61 61 79
ZP-16-335 X 27 24 3 73
ZP-16-37 X 26 18 4 4 73
ZP-16-38 X(G) 4 4 57
ZP-16-638 X(G) 4 4 57
ZP-16-640 X 55 55 77
ZP-16-344 X 21 11 10 72
ZP-16-346 X 9 6 3 66
ZP-16-349 X 14 12 2 68
ZP-16-355 X 19 19 71
(G) depicts arrangement with grounded contact 51
STAR-LINE®
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 MOD MOD MOD Radsok Total 18 16 12 10 8 4 1/0 4/0 350 MCM 500MCM 646-777 Page
Arrangement I II III Contacts Number (0.75) (1.5) (4.0) (6.0) (10.0) (250) (50.0) (120.0) (185.0) (240.0) (300-400) No.
Number of Contacts
ZP-16-70 X 3 3 55
ZP-16-371 X 46 45 45 1 76
ZP-16-373 X(G) 27 24 3 73
ZP-16-74 X(G) 3 3 55
ZP-16-75 X(G) 5 5 59
ZP-16-376 X(G) 10 6 4 67
ZP-16-377 X X 19 19 70
ZP-16-378 X(G) 7 7 65
ZP-16-381 X 10 6 4 67
ZP-20-313 X 68 68 79
ZP-20-323 X 38 35 3 75
ZP-20-329 X 64 62 2 79
ZP-20-331 X 22 20 2 73
ZP-20-32 X 20 20 72
ZP-20-332 X X 20 20 72
ZP-20-334 X 20 16 4 72
ZP-20-35 X 60 60 78
ZP-20-38 X(G) 5 5 60
ZP-C20-40 X(G) 4 4 57
ZP-C20-640 X(G) 4 4 57
ZP-C20-42 X 4 4 58
ZP-20-43 X(G) 6 2 4 62 & 82
ZP-20-643 X(G) 6 2 4 62
ZP-20-344 X 81 70 11 80
ZP-20-345 X 90 90 80
ZP-20-46 X 6 4 2 62
ZP-20-646 X 6 4 2 62
ZP-20-48 X 6 3 3 62
ZP-20-648 X 6 3 3 62
ZP-20-49 X 5 3 2 61
ZP-20-649 X 5 3 2 61
ZP-20-350 X(G) X 37 37 75
ZP-20-354 X 47 45 2 76
ZP-20-55 X 10 8 2 68
ZP-20-358 X 16 16 70
ZP-20-359 X 7 7 65
ZP-20-673 X 50 46 4 77
ZP-20-374 X 27 25 2 74
ZP-20-375 X 12 12 68
ZP-20-376 X X 19 19 71
ZP-C20-379 X 1 1 54
ZP-20-84 X 5 5 60
ZP-20-384 X 5 5 60
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 100 100 81
ZP-C24-26 X(G) 4 4 58
(G) depicts arrangement with grounded contact
52
STAR-LINE® Amphenol
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 MOD MOD MOD Radsok Total 18 16 12 10 8 4 1/0 4/0 350 MCM 500MCM 646-777 Page
Arrangement I II III Contacts Number (0.75) (1.5) (4.0) (6.0) (10.0) (250) (50.0) (120.0) (185.0) (240.0) (300-400) No.
Number of Contacts
ZP-24-331 X 60 53 7 78
ZP-C24-36 X 37 35 2 75
ZP-C24-38 X 4 4 58
ZP-24-40 X 15 10 5 69
ZP-C24-47 X 15 10 5 69
ZP-C24-48 X 5 2 3 61
ZP-C24-49 X(G) 5 5 60
ZP-24-352 X(G) X 58 58 78
ZP-C24-353 X 8 4 4 65
ZP-24-354 X 75 61 11 3 80
ZP-24-362 X 62 62 79
ZP-24-371 X 37 37 75
ZP-C24-72 X 6 3 3 63
ZP-C24-79 X 5 5 60
ZP-C24-680 X(G) 10 6 4 68
ZP-C24-81 X(G) 15 10 5 69
ZP-24-83 X 4 4 58
ZP-24-84 X 58 58 77
ZP-24-384 X X 58 58 77
ZP-24-385 X 100 100 81
ZP-24-388 X 72 72 80
ZP-24-389 X 60 60 78
ZP-28-314 X 100 83 17 81
ZP-C28-15 X 47 43 3 1 76
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 X 143 143 81
ZP-C28-23 X(G) 5 5 61
ZP-28-324 X 55 41 5 3 6 77
ZP-C28-327 X 6 6 63
ZP-C28-328 X 29 23 2 4 74
ZP-28-339 X X 42 42 76
ZP-C28-42 X(G) 6 2 4 64 & 83
ZP-C28-43 X(G) 8 4 4 66
ZP-C28-R44 X X 7 1 3 4 64 & 83
ZPC28-R44 83
(G) depicts arrangement with grounded contact
53
STAR-LINE®
Insert Configurations
1 Contact (Dead Front Male Contact/Line Side) front face of pin insert shown
Wire N
Style Terminal Shell Insert Dash Catalog Qty. Size Current
Type Size Type Number Number AWG (mm) Rating Voltage
Mod II Crimp C24 Pin 386PN RIG-C24-386PN 1 646-777 1135A 1000V
Socket 386SN RIG-C24-386SN (300-400)
Mod II Radsok C24 Pin R386PN RIG-C24-R386PN 1 646-777 1135A 1000V 777 MCM
Crimp Socket R386SN RIG-C24-R386SN (300-400)
Mod II Radsok C24 Pin R386PR RIG-C24-R386PR 1 646-777 1135A 1000V
Busbar Socket R386SR RIG-C24-R386SR (300-400)
Mod II Crimp C24 Pin 535PN RIG-C24-535PN 1 535 900A 1000V
Socket 535SN RIG-C24-535SN (240)
N
Mod II Radsok C24 Pin R535PN RIG-C24-R535PN 1 535 900A 1000V
Crimp Socket R535SN RIG-C24-R535SN (240)
Mod II Crimp C24 Pin R444PN RIG-C24-444PN 1 444 800A 1000V
Socket R444SN RIG-C24-444SN (185)
Mod II Radsock C24 Pin R444PN RIG-C24-R444PN 1 444 800A 1000V
Crimp Socket R444SN RIG-C24-R444SN (185)
Mod II Crimp C24 Pin R373PN RIG-C24-373PN 1 373 700A 1000V 535 MCM, 444 MCM
Socket R373SN RIG-C24-373SN (150)
373 MCM, 313 MCM
Mod II Radsock C24 Pin R373PN RIG-C24-R373PN 1 373 700A 1000V
Crimp Socket R373SN RIG-C24-R373SN (150)
Mod II Crimp C24 Pin R313PN RIG-C24-313PN 1 313 625A 1000V
Socket R313SN RIG-C24-313SN (120)
Mod II Radsock C24 Pin R313PN RIG-C24-R313PN 1 313 625A 1000V
Crimp Socket R313SN RIG-C24-R313SN (120)
N
1 Contact
Wire Service
Style Terminal Shell Insert Dash Catalog Qty. Size Voltage
Type Size Type Number Number AWG Rating
Mod II Crimp C20 Pin 379PN ZP-C20-379PN 1 500MCM D
Socket 379SN ZP-C20-379SN
NOTE: Will accept 535 standard stranding 500 MCM extra flexible cable.
N
1 Contact
Wire Service
Style Terminal Shell Insert Dash Catalog Qty. Size Voltage
Type Size Type Number Number AWG Rating
Mod II Crimp C16 Pin 341PN ZP-C16-341PN 1 4/0 D
Socket 341SN ZP-C16-341SN 341 MCM
Grounding Contact Termination Symbol Contact
Symbols
Wire Size 18 16 12 10 8 4 1/0 4/0 350 MCM 500 MCM 646-777
Solder Well Pressure Crimp AWG
Metric 0.75 1.5 4.0 6.0 10.0 25.0 50.0 120.00 185.00 240.00 300-400
★ Pre-assembled insert should be ordered mounted in barrel. SERVICE VOLTAGE RATING
A = 240V, D = 600V
54
STAR-LINE® Amphenol
INDUSTRIAL
Insert Configurations front face of pin insert shown
3 Contacts N 36o
Wire Service 01 72o
Style Terminal Shell Insert Dash Catalog Qty. Size Voltage 1 02
Type Size Type Number Number AWG Rating 2
Mod I Solder 12 Pin 27P ZP-12-27P 3 12 D 3 03 108o
Socket 27S ZP-12-27S 04
Mod II Radsok 12 Pin 327PN ZP-12-327PN U® L 05 144o
Crimp Socket 327SN ZP-12-327SN 180o
3 Contacts N 36o
Wire Service 01 72o
Style Terminal Shell Insert Dash Catalog Qty. Size Voltage 1 2 02
Type Size Type Number Number AWG Rating
Mod II Crimp 12 Pin 330PN ZP-12-330PN 3 12 D 3 03 108o
Radsok Socket 330SN ZP-12-330SN 05 04
180o 144o
3 Contacts N
Wire Service 1 80o
Style Terminal Shell Insert Dash Catalog Qty. Size Voltage 01
Type Size Type Number Number AWG Rating 3 2
Mod I Solder 12 Pin 56P ZP-12-56P 3 8 A 04 02
Socket 56S ZP-12-56S 220o 03 140o
180o
3 Contacts
Wire Service
Style Terminal Shell Insert Dash Catalog Qty. Size Voltage
Type Size Type Number Number AWG Rating 01
Mod I Solder 16 Pin 74P ZP-16-74P 3 4 D
Socket 74S ZP-16-74S 02
Mod I Pressure 16 Pin 74PR ZP-16-74PR
Socket 74SR ZP-16-74SR
3 Contacts
Wire Service 01
Style Terminal Shell Insert Dash Catalog Qty. Size Voltage
Type Size Type Number Number AWG Rating
Mod I Solder 16 Pin 70P ZP-16-70P 3 4 D
Socket 70S ZP-16-70S
Mod I Pressure 16 Pin 70PR ZP-16-70PR
Socket 70SR ZP-16-70SR
Grounding Contact Termination Symbol Contact
Symbols
Wire Size 18 16 12 10 8 4 1/0 4/0 350 MCM 500 MCM 646-777
Solder Well Pressure Crimp AWG
Metric 0.75 1.5 4.0 6.0 10.0 25.0 50.0 120.00 185.00 240.00 300-400
★ Pre-assembled insert should be ordered mounted in barrel. SERVICE VOLTAGE RATING
A = 240V, D = 600V
55
STAR-LINE®
Insert Configurations
4 Contacts front face of pin insert shown
Wire Service
Style Terminal Shell Insert Dash Catalog Qty. Size Voltage
Type Size Type Number Number AWG Rating
Mod I Solder 12 Pin 33P ZP-12-33P 4 16 D
Socket 33S ZP-12-33S
Mod II Crimp 12 Pin 333PN ZP-12-333PN
Socket 333SN ZP-12-333SN
4 Contacts
Wire Service
Style Terminal Shell Insert Dash Catalog Qty. Size Voltage
Type Size Type Number Number AWG Rating
Mod I Solder 12 Pin 14P ZP-12-14P 4 10 D
Socket 14S ZP-12-14S
Mod I Pressure 12 Pin 14PR ZP-12-14PR U® L
Socket 14SR ZP-12-14SR
Mod II Crimp 12 Pin 314PN ZP-12-314PN
Socket 314SN ZP-12-314SN
4 Contacts
Wire Service 324o N 36o
Style Terminal Shell Insert Dash Catalog Qty. Size Voltage 04 01
Type Size Type Number Number AWG Rating 1 2
Mod II Crimp 12 Pin 316PN ZP-12-316PN 4 10 D
Socket 316SN ZP-12-316SN 252o 03 4 3 02 108o
U® L
4 Contacts
Wire Service
Style Terminal Shell Insert Dash Catalog Qty. Size Voltage
Type Size Type Number Number AWG Rating
Mod I Solder 12 Pin 22P ZP-12-22P 4 10 D
Socket 22S ZP-12-22S U® L
Mod I Pressure 12 Pin 22PR ZP-12-22PR
Socket 22SR ZP-12-22SR
Mod II Crimp 12 Pin 322PN ZP-12-322PN
Socket 322SN ZP-12-322SN
Grounding Contact Termination Symbol Contact
Symbols
Wire Size 18 16 12 10 8 4 1/0 4/0 350 MCM 500 MCM 646-777
Solder Well Pressure Crimp AWG
Metric 0.75 1.5 4.0 6.0 10.0 25.0 50.0 120.00 185.00 240.00 300-400
★ Pre-assembled insert should be ordered mounted in barrel. SERVICE VOLTAGE RATING
A = 240V, D = 600V
56
STAR-LINE® Amphenol
INDUSTRIAL
Insert Configurations
4 Contacts front face of pin insert shown
Wire Service N 45o
Style Terminal Shell Insert Dash Catalog Qty. Size Voltage
Type Size Type Number Number AWG Rating 1 01
Mod I Solder 16 Pin 28P ZP-16-28P 4 8 D
Socket 28S ZP-16-28S 4 2
Mod II Crimp 16 Pin 328PN ZP-16-328PN U® L 02 112o30'
Socket 328SN ZP-16-328SN 3
NOTE: Cannot be
used with short
cable adapter
4 Contacts
Wire Service N
Style Terminal Shell Insert Dash Catalog Qty. Size Voltage
Type Size Type Number Number AWG Rating 1
Mod I Solder 16 Pin 22P ZP-16-22P 4 4 D 4
Socket 22S ZP-16-22S 01
Mod I Pressure 16 Pin 22PR ZP-16-22PR 255o 04 3 2 105o
Socket 22SR ZP-16-22SR U® L 03 02
Mod II Crimp 16 Pin 322PN ZP-16-322PN 240o 135o
Socket 322SN ZP-16-322SN
4 Contacts 3303o 45o
Wire Service N
Style Terminal Shell Insert Dash Catalog Qty. Size Voltage 315o 04 05
Type Size Type Number Number AWG Rating 03 1
Mod I Solder 16 Pin 38P ZP-16-38P 4 4 D 2
Socket 38S ZP-16-38S 4G 01
Mod I Pressure 16 Pin 38PR ZP-16-38PR U® L 3 02 105o
Socket 38SR ZP-16-38SR 120o
Mod III Crimp 16 Pin 638PN ★
Socket 638SN ★
4 Contacts 15o
Wire
N
Style Terminal Shell Insert Dash Catalog Qty. Size Current 01
Type Size Type Number Number AWG Rating 1
Mod I Solder C20 Pin 40P ZP-C20-40P 4 1/0 D 2
Socket 40S ZP-C20-40S
Mod I Pressure C20 Pin 40PR ZP-C20-40PR U® L 4G
Socket 40SR ZP-C20-40SR 3
Mod III Crimp C20 Pin 640PN ★ 02
Socket 640SN ★ 165o
Grounding Contact Termination Symbol Contact
Symbols
Wire Size 18 16 12 10 8 4 1/0 4/0 350 MCM 500 MCM 646-777
Solder Well Pressure Crimp AWG
Metric 0.75 1.5 4.0 6.0 10.0 25.0 50.0 120.00 185.00 240.00 300-400
★ Pre-assembled insert should be ordered mounted in barrel. SERVICE VOLTAGE RATING
A = 240V, D = 600V
57
STAR-LINE®
Insert Configurations
4 Contacts front face of pin insert shown
Wire Service N 15o
Style Terminal Shell Insert Dash Catalog Qty. Size Voltage 01
Type Size Type Number Number AWG Rating
Mod I Solder C20 Pin 42P ZP-C20-42P 4 1/0 D 3 4
Socket 42S ZP-C20-42S
Mod I Pressure C20 Pin 42PR ZP-C20-42PR U® L
Socket 42SR ZP-C20-42SR 2
01 key 02 1
position not
available in 225o
pressure
termination
4 Contacts N 45o
Wire Service 2 01
Style Terminal Shell Insert Dash Catalog Qty. Size Voltage
Type Size Type Number Number AWG Rating 3
Mod I Solder 24 Pin 83P ZP-24-83P 4 4/0 D
Socket 83S ZP-24-83S 1
4
4 Contacts N 15o
Wire Service 01
Style Terminal Shell Insert Dash Catalog Qty. Size Voltage 1
Type Size Type Number Number AWG Rating 2
Mod I Solder C24 Pin 26P ZP-C24-26P 4 4/0 D
Socket 26S ZP-C24-26S 4G
Mod I Pressure C24 Pin 26PR ZP-C24-26PR U® L
Socket 26SR ZP-C24-26SR 3
02
165o
4 Contacts 15o
Wire Service N
Style Terminal Shell Insert Dash Catalog Qty. Size Voltage 01
Type Size Type Number Number AWG Rating &
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