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
STAR-LINE
®
Series
INDUSTRIAL
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
AVAILABLE – Consult
Amphenol Industrial Operations.
U
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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
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
Star-Line EX Connector with EX gland (EX-13-3 style shown)
from single-contact to 143 contacts.
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
AVAILABLE – Consult
Amphenol Industrial Operations
U
Star-Line EX Series connectors are certified for use in Zone
1-IIc hazardous environment
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Altera SoC
