Sensor/Actuator Cabling and
Industrial Plug-in Connectors
2013 / 2014
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PCB connection technology and electronics housing
• PCB terminal blocks and plug-in connectors
• Electronics housing
Connection technology for field devices
• Plug-in connectors
• Cables and connectors
Modular terminal blocks
• Modular terminal blocks
Sensor/actuator cabling
and industrial plug-in connectors
Marking systems, tools, and mounting material
• Marking and labeling
• Tools
• Installation and mounting material
Surge protection and power supply units
• Lightning monitoring system
• Surge protection and interference filters
• Power supply units and UPS
• Protective devices
Interface technology and switching devices
• Electronic switching devices and motor control
• Measurement and control technology • Monitoring
• Relay modules • System cabling for controllers
Control technology, I/O systems and automation infrastructure
• Ethernet networks • Functional safety • HMIs and industrial PCs • I/O systems
• Industrial lighting and signaling • Industrial communication technology
• Fieldbus components and systems • Wireless data communication
• Process infrastructure • Software • Controllers
Table of contents
Connection technology from Phoenix Contact
Implement your individual connection for field cabling with the
expertise of Phoenix Contact
2
Product range overview
The illustrated table of contents will help you find the right product
more quickly.
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Sensor/actuator cabling
Sensor/actuator cables in M5 to M40, plugs and boxes in M5 to M12,
with SPEEDCON rapid interlock system as an option.
PLUSCON field
11
Data plug-in connectors and cables
Plug-in connectors, flush-type plug-in connectors, and cables for
fieldbuses and networks: M8, M12, 7/8", RJ45, SC-RJ, D-SUB,
and USB.
PLUSCON data
209
Installation system
Panel feed-throughs, cable connectors, plug-in connectors, and
distributors with QUICKON fast connection technology for easy
installation.
PLUSCON installation
375
Heavy-duty plug-in connectors
DUPLICON stackable plug-in connectors for flexible power
distribution. HEAVYCON heavy-duty plug-in connectors for signal
and power transmission.
PLUSCON heavy
395
Installation and mounting material
CES cable entry system for space-saving feed-through, plug assembly
frames, and service interfaces.
PLUSCON cabinet
603
Technical information
General information on the degree of protection, properties of
plastics, approvals, insulation coordination, etc.
626
Index
638
Sensor/actuator cabling and industrial plug-in connectors
Connection technology from Phoenix Contact
Screw connection
The screw connection is the most univer-
sal and globally accepted conductor connec-
tion technology. An important characteris-
tic is the maintenance-free conductor
contact. It is not necessary to tighten the
terminal screw again. All kinds of copper ca-
bles can be clamped without pretreatment,
thereby making gas-tight and reliable con-
tact. The wire protector, which protects the
individual litz wires from damage, is located
between the screw and the conductor. It
also performs a screw locking function to
prevent release due to vibrations and tem-
perature fluctuations. Splicing protection
can be implemented in the form of ferrules.
With a screw connection, several wires may
also be clamped under one screw. The cur-
rent-carrying parts of the screw connec-
tions are made of high-grade, strain-crack,
and corrosion-proof copper alloys.
Axial screw connection
With this method, the wire end to be
contacted is guided into the connection
area of the pin or socket contact. A cone-
shaped prong (part of the contact) is then
screwed into the stranded wire from the
front. The strands of the wire are radially
pressed against the contact wall. This re-
sults in a gas-tight connection with long-
term stability between the wire and con-
tact. It is important that the specified tight-
ening torque is observed. The prong is
pressed in using a hexagon key which is ap-
plied to the front of the contact. This con-
nection technology combines the advantag-
es of screw and crimp connection. It
requires very little space, is easy to execute,
and only requires a standard Allen key.
Crimp connection
The crimp connection impresses with its
small space requirements and its cost-effec-
tive creation in series production. For a re-
liable connection, it is essential that the
conductor cross section, the crimp contact,
and the crimping tool are compatible. Fur-
thermore, the crimping process must be
monitored during large-scale production as
the crimping tools are subject to a certain
degree of wear.
Crimp connections can be established
with the aid of crimping pliers or crimp ma-
chines through specific deformation of the
crimping ranges of the contact. The require-
ments for crimp connections are defined in
DIN EN 60352-2. Proof of the quality of a
crimp connection can be seen in the tensile
strength of the connection and crack-free
deformation of the crimp contact. Crimping
must not result in impermissible elongation
of crimp contacts, as this would prevent
them from latching correctly in the contact
carrier. The contact is released using a con-
tact removal tool. Assembly tools are also
available for very thin conductors.
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PHOENIX CONTACT
Sensor/actuator cabling and industrial plug-in connectors
Connection technology from Phoenix Contact
Spring-cage connection
The spring-cage connection contains a
steel spring which pushes the stripped con-
ductor against a power rail. The terminal
point is opened with a standard screwdriver.
After the conductor has been inserted into
the clamping space, the screwdriver is re-
moved and the conductor automatically
makes contact. The contact force is inde-
pendent of the user and a vibration-proof,
gas-tight connection with long-term stabili-
ty is established. The front connection pro-
vides an additional advantage. The conduc-
tor and screwdriver come in parallel from
the same direction and are always within the
user's field of vision. Contact inserts can
thereby also be connected or re-wired even
when mounted. All kinds of copper cables
can be clamped without pretreatment,
thereby making gas-tight and reliable con-
tact. Splicing protection can also be imple-
mented in the form of a ferrule.
Push-in connection
Stranded conductors with ferrules or sol-
id conductors can be quickly and easily in-
serted directly into the connection without
tools. The contact spring is formed in such
a way that it opens automatically when the
conductor is pushed in and thereby pro-
vides the required pressure force against
the current bar for a gas-tight, vibration and
shock-proof connection. With the aid of
the orange pusher, the terminal block can
be opened manually so that conductors
with smaller cross sections can also be se-
curely connected. To release the conductor,
the orange pusher features a confusion-free
and defined operating element. The con-
ductive metals are made from high-grade
copper alloys. All metal parts of the connec-
tion are made of corrosion-resistant mate-
rials.
QUICKON fast connection for
single wires
The QUICKON connection is equipped
with an IDC insulation displacement con-
tact. The term “IDC” stands for Insulation
Displacement Connection. With this con-
nection method, a non-stripped wire with
insulation is positioned in front of the gap of
the insulation displacement contact and
then pushed into the blade gap through in-
sulation displacement. In so doing, the wire
insulation is severed and a gas-tight contact
is made between the wire and the contact.
This can save at least 60% of connection
time.
The connection force is independent of
the user and completely reliable provided
the permitted conductor cross sections and
connection conditions are observed. Solid
and stranded conductors can be rewired up
to 10 times. However, the wire end should
be cut off before connecting again.
QUICKON connections have proven
themselves in numerous applications for
Phoenix Contact over recent years, such as
plug-in connectors, for COMBICON, and
modular terminal blocks to CEE plug-in
equipment from 0.14 to 6.0 mm2.
For additional information, visit www.phoenixcontact.net/products
PHOENIX CONTACT
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