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ITT POWERLOCK Operating Instructions Manual

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POWERLOCK Connector System
Operating Instructions POWERLOCK Rev. -
COMMERCIAL. RESTRICTED TO EMBARGOED COUNTRIES AND DENIED PARTIES.
PRINTED COPIES ARE NOT MAINTAINED TO LATEST REVISION.
TRANSLATION OF THE ORIGINAL
OPERATING INSTRUCTIONS
CAS25123E
POWERLOCK
Connector System
EXPORT CODE C
Page 1 von 48

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Summary of Contents for ITT POWERLOCK

  • Page 1 POWERLOCK Connector System TRANSLATION OF THE ORIGINAL OPERATING INSTRUCTIONS CAS25123E POWERLOCK Connector System Operating Instructions POWERLOCK Rev. - Page 1 von 48 EXPORT CODE C COMMERCIAL. RESTRICTED TO EMBARGOED COUNTRIES AND DENIED PARTIES. PRINTED COPIES ARE NOT MAINTAINED TO LATEST REVISION.

  • Page 2: Imprint

    All rights reserved INFORMATION! This publication is an integral part of the Technical Documen- tation for the “POWERLOCK Connector System” and is pro- tected by copyright. Any use beyond the limits of copyright law without written per- mission is forbidden and subject to penalty.

  • Page 3: Table Of Contents

    Declaration of conformity ................5 INFORMATION ABOUT THE document ............7 Intended use ....................8 Overview and description ................9 Introduction to the Powerlock System ............... 9 Description of the terms ................... 10 Technical specifications ..................12 Optional system accessories ................14 Overview of the individual connectors .............
  • Page 4 Disposal of the connectors ................44 List of Figures ....................45 Remarks and notes..................47 Page 4 von 48 Operating Instructions POWERLOCK Rev. - EXPORT CODE C COMMERCIAL. RESTRICTED TO EMBARGOED COUNTRIES AND DENIED PARTIES. PRINTED COPIES ARE NOT MAINTAINED TO LATEST REVISION.

  • Page 5: Declaration Of Conformity

    POWERLOCK Connector System DECLARATION OF CONFORMITY Operating Instructions POWERLOCK Rev. - Page 5 von 48 EXPORT CODE C COMMERCIAL. RESTRICTED TO EMBARGOED COUNTRIES AND DENIED PARTIES. PRINTED COPIES ARE NOT MAINTAINED TO LATEST REVISION.
  • Page 6 POWERLOCK Connector System Page 6 von 48 Operating Instructions POWERLOCK Rev. - EXPORT CODE C COMMERCIAL. RESTRICTED TO EMBARGOED COUNTRIES AND DENIED PARTIES. PRINTED COPIES ARE NOT MAINTAINED TO LATEST REVISION.

  • Page 7: Information About The Document

    (function), installation, operation and maintenance of the POWERLOCK type connectors. This document is part of the technical documentation for the POWERLOCK type connectors. Other applicable documents include the declaration of conformity, risk assessment, drawings and circuit diagrams.

  • Page 8: Intended Use

    INTENDED USE The POWERLOCK connector system described herein is a single-pole connector system for high-current applications up to 660 amps. The POWERLOCK connectors are color coded to suit the requirements of three-phase electrical systems. Typical fields of application for this product are ...

  • Page 9: Overview And Description

    POWERLOCK Connector System OVERVIEW AND DESCRIPTION INTRODUCTION TO THE POWERLOCK SYSTEM The POWERLOCK connector system consists of single-pole connectors in insulated plastic housings. They are used in high-current applications up to 660 amps in sin- gle-phase or multi-phase power distribution systems.

  • Page 10: Description Of The Terms

    M12 threaded hole for fixing with a bolt. The POWERLOCK connector system allows following connection and mounting variants: ...

  • Page 11: Figure 1: Connection Usage

    Line Source Line Drain Panel Source Panel Drain Figure 2: Connection styles Operating Instructions POWERLOCK Rev. - Page 11 von 48 EXPORT CODE C COMMERCIAL. RESTRICTED TO EMBARGOED COUNTRIES AND DENIED PARTIES. PRINTED COPIES ARE NOT MAINTAINED TO LATEST REVISION.

  • Page 12: Technical Specifications

    Cable jacket diameter ø15mm up to ø38mm Vibration range 10-2000 Hz / 15 g Page 12 von 48 Operating Instructions POWERLOCK Rev. - EXPORT CODE C COMMERCIAL. RESTRICTED TO EMBARGOED COUNTRIES AND DENIED PARTIES. PRINTED COPIES ARE NOT MAINTAINED TO LATEST REVISION.
  • Page 13 VDE Reg.No. D042 VDE tested and certified Certificate with production control no. 40030523 Operating Instructions POWERLOCK Rev. - Page 13 von 48 EXPORT CODE C COMMERCIAL. RESTRICTED TO EMBARGOED COUNTRIES AND DENIED PARTIES. PRINTED COPIES ARE NOT MAINTAINED TO LATEST REVISION.

  • Page 14: Optional System Accessories

    Caps not only offer protection against ingress of moisture and dirt into the inter- face of the PowerLock connector, they also offer a degree of protection against mechanical damage that can be caused when connectors on cables are being han- dled and transported.

  • Page 15: Figure 5: Accessories Powerlock-Box

    POWERLOCK Connector System POWERLOCK-BOX: A connection unit in 19” format with 5 inputs for the power supply of a three-phase network. It guarantees sequential plugging and unplug- ging of connectors in correct order (PE, N, L1, L2, L3). An interlock protects the sequential connection against unauthorized disconnection.

  • Page 16: Overview Of The Individual Connectors

    POWERLOCK Connector System OVERVIEW OF THE INDIVIDUAL CONNECTORS This section describes the currently available POWERLOCK connectors and shows them in figures and technical drawings.  Connector POWERLOCK  Connector POWERLOCK ”  Connector POWERLOCK ”  Connector POWERLOCK ” ...

  • Page 17: Connector Powerlock "Nls

    For a quick release of the secondary locking, the connector can optionally be or- dered with a sliding collar “SC”. This section describes the currently available POWERLOCK connectors and shows them in figures and technical drawings. Figure 6: NLS connector Operating Instructions POWERLOCK Rev.

  • Page 18: Figure 7: Nls Connector: Components

    Contact body Cable gland Figure 8: Connector NLS: Label or marking 400/660A Page 18 von 48 Operating Instructions POWERLOCK Rev. - EXPORT CODE C COMMERCIAL. RESTRICTED TO EMBARGOED COUNTRIES AND DENIED PARTIES. PRINTED COPIES ARE NOT MAINTAINED TO LATEST REVISION.

  • Page 19: Figure 9: Connector Nls: Dimensions In Mm (In)

    Figure 9: Connector NLS: Dimensions in mm (in) Further dimensions of connector housing, contact body and cable gland are shown on drawing SR1841 and are available on request. Operating Instructions POWERLOCK Rev. - Page 19 von 48 EXPORT CODE C COMMERCIAL.

  • Page 20: Connector Powerlock "Nldft

    For better handling the connector can optionally be ordered with a rubber hand grip (Hand Grip “HG”). See also “Introduction to the POWERLOCK System” and “Description of terms” for more information. Figure 10: NLDFT connector Page 20 von 48 Operating Instructions POWERLOCK Rev.

  • Page 21: Figure 11: Nldft Connector: Components

    Cotter pin Contact body Cable gland Figure 12: NLDFT connector: Label or marking 400/660A Operating Instructions POWERLOCK Rev. - Page 21 von 48 EXPORT CODE C COMMERCIAL. RESTRICTED TO EMBARGOED COUNTRIES AND DENIED PARTIES. PRINTED COPIES ARE NOT MAINTAINED TO LATEST REVISION.

  • Page 22: Figure 13: Nldft Plug Connector: Dimensions In Mm (In)

    Further dimensions to plug housing, contact connection and cable gland are shown on drawing SR1840 and available on request. Page 22 von 48 Operating Instructions POWERLOCK Rev. - EXPORT CODE C COMMERCIAL. RESTRICTED TO EMBARGOED COUNTRIES AND DENIED PARTIES. PRINTED COPIES ARE NOT MAINTAINED TO LATEST REVISION.

  • Page 23: Connector Powerlock "Nps

    The four mounting holes in the flange can optionally be provided with threaded inserts to shorten the assembly time. See also “Introduction to the POWERLOCK System” and “Description of terms” for further information. Figure 14: NPS connector with T4/T6 contact Operating Instructions POWERLOCK Rev.

  • Page 24: Figure 15: Nps Connector With H6 Contact

    Pos. Designation Pos. Designation Connector housing Cotter pin Contact body O-ring (sealing) Page 24 von 48 Operating Instructions POWERLOCK Rev. - EXPORT CODE C COMMERCIAL. RESTRICTED TO EMBARGOED COUNTRIES AND DENIED PARTIES. PRINTED COPIES ARE NOT MAINTAINED TO LATEST REVISION.

  • Page 25: Figure 17: Nps H6 Plug Connector: Components

    Cotter pin Contact body O-ring (sealing) Figure 18: Plug connector NPS: Label or marking 400/660A Operating Instructions POWERLOCK Rev. - Page 25 von 48 EXPORT CODE C COMMERCIAL. RESTRICTED TO EMBARGOED COUNTRIES AND DENIED PARTIES. PRINTED COPIES ARE NOT MAINTAINED TO LATEST REVISION.

  • Page 26: Figure 19: Plug Connector Nps T4/T6: Dimensions In Mm (In)

    SR1843 (NPS T4/T6) and SR1848 (NPS H6) and are availa- ble on request. Page 26 von 48 Operating Instructions POWERLOCK Rev. - EXPORT CODE C COMMERCIAL. RESTRICTED TO EMBARGOED COUNTRIES AND DENIED PARTIES. PRINTED COPIES ARE NOT MAINTAINED TO LATEST REVISION.

  • Page 27: Connector Powerlock "Npdft

    The 4 mounting holes in the flange can optionally be provided with threaded in- serts to shorten the mounting time. See also “Introduction to the POWERLOCK System” and “Description of terms” for further information. Figure 20: NPDFT connector: with T4/T6 contact Operating Instructions POWERLOCK Rev.

  • Page 28: Figure 21: Npdft T4/T6 Plug Connector: Components

    Contact body O-ring (sealing) Figure 22: NPDFT connector: label or marking 400/660A Page 28 von 48 Operating Instructions POWERLOCK Rev. - EXPORT CODE C COMMERCIAL. RESTRICTED TO EMBARGOED COUNTRIES AND DENIED PARTIES. PRINTED COPIES ARE NOT MAINTAINED TO LATEST REVISION.

  • Page 29: Figure 23: Npdft T4/T6 Plug Connector: Dimensions In Mm (In)

    Figure 23: NPDFT T4/T6 plug connector: dimensions in mm (in) Further dimensions to plug housing, contact connection and cable gland are avail- able on drawing SR1842 and on request. Operating Instructions POWERLOCK Rev. - Page 29 von 48 EXPORT CODE C COMMERCIAL.

  • Page 30: Connector Powerlock "Npdft Skpp

    POWERLOCK Connector System CONNECTOR POWERLOCK “NPDFT SKPP” The connector POWERLOCK NPDFT SKPP is a combination of the NLDFT connector and the NPDFT connector. In terms of contacting, it is similar to the NLDFT connector: The current conductor is connected via a crimped connection or alternatively with the Set-Screw contact.

  • Page 31: Figure 25: Npdft Skpp Plug Connector: Components

    Flange gasket Cable gland Contact body Figure 26: NPDFT SKPP plug connector: Label or marking 400/660A Operating Instructions POWERLOCK Rev. - Page 31 von 48 EXPORT CODE C COMMERCIAL. RESTRICTED TO EMBARGOED COUNTRIES AND DENIED PARTIES. PRINTED COPIES ARE NOT MAINTAINED TO LATEST REVISION.

  • Page 32: Figure 27: Npdft Skpp Plug Connector: Dimensions In Mm (In)

    Further dimensions for connector housing, contact connection and cable gland are shown on drawing SR1844 and are available on request. Page 32 von 48 Operating Instructions POWERLOCK Rev. - EXPORT CODE C COMMERCIAL. RESTRICTED TO EMBARGOED COUNTRIES AND DENIED PARTIES.

  • Page 33: Transportation And Storage

    (if possible). Immediately report any missing parts and/or damage to the delivery as a result of poor packaging or due to transportation to the manufacturer or distributor. Operating Instructions POWERLOCK Rev. - Page 33 von 48 EXPORT CODE C COMMERCIAL.

  • Page 34: Transportation

    The type of packaging may vary depending on the component, weight and selected shipping route. Page 34 von 48 Operating Instructions POWERLOCK Rev. - EXPORT CODE C COMMERCIAL. RESTRICTED TO EMBARGOED COUNTRIES AND DENIED PARTIES. PRINTED COPIES ARE NOT MAINTAINED TO LATEST REVISION.

  • Page 35: Installation/Commisioning

    (also areas sup- plied by external sources) are de-energized and secured against accidental switch-on! Modifications (of any kind) of the POWERLOCK type connect- ors are strictly forbidden! Operating Instructions POWERLOCK Rev. - Page 35 von 48 EXPORT CODE C COMMERCIAL.

  • Page 36: Coupling Of The Connectors

    POWERLOCK Connector System COUPLING OF THE CONNECTORS The “POWERLOCK” system connectors have a bayonet locking mechanism with a safety pin for secondary locking. Figure 28: Connector coupling  Align the slot (pos. 1) and the groove (pos. 2) on the two connectors.

  • Page 37: Figure 29: Locking Of The Connector

    The spring-loaded locking pin (pos. 3) must fully engage in the groove of the mating connector in order to lock the bayonet lock. Result: The plug connection is coupled and locked. Operating Instructions POWERLOCK Rev. - Page 37 von 48 EXPORT CODE C COMMERCIAL.

  • Page 38: Uncoupling Of The Connectors

    Use the unlocking key to push back the locking pin (pos. 2) and unlock the connector counterclockwise. Result: The plug connection is unlocked and disconnected. Page 38 von 48 Operating Instructions POWERLOCK Rev. - EXPORT CODE C COMMERCIAL. RESTRICTED TO EMBARGOED COUNTRIES AND DENIED PARTIES. PRINTED COPIES ARE NOT MAINTAINED TO LATEST REVISION.

  • Page 39: Figure 31: Optional Sliding Sleeve „Sc

    (SC). This allows a connector pair to be separated without the use of a separate release key. Figure 31: Optional sliding sleeve „SC“ Operating Instructions POWERLOCK Rev. - Page 39 von 48 EXPORT CODE C COMMERCIAL. RESTRICTED TO EMBARGOED COUNTRIES AND DENIED PARTIES.

  • Page 40: Cable Connection To Connector

    Instructed personnel with specific training in mechatronics or electrical engineering may only carry out the activities! For the “POWERLOCK” connector system to function properly, it is essential that the cable is connected correctly by means of crimping. Only the recommended crimping pliers and die should be used for cable connection.
  • Page 41 Only insulating bodies, contact bodies and add-on parts from the original manufacturer ITT may be used; under no circum- stances, competitor parts may be used or mixed! The specified maximum current load of 660A or 400A presup- poses that the cross-section of the connected power conduc- tor has also been designed at least for this.
  • Page 42 (also areas sup- plied by external sources) are de-energized and secured against accidental switch-on. Modifications (of any kind) of the POWERLOCK type connect- ors are strictly forbidden! Page 42 von 48 Operating Instructions POWERLOCK Rev. - EXPORT CODE C COMMERCIAL.

  • Page 43: Maintenance

    CONTROL OF THE COMPONENTS At regular intervals (at least once a year), a visual inspection of all components of the “POWERLOCK” connector system for damage and an assessment of their functionality must be carried out. The visual inspection must include the following components: ...

  • Page 44: Disposal Of The Connectors

    Transfer possibly arising residual materials to a certified waste disposal company. Page 44 von 48 Operating Instructions POWERLOCK Rev. - EXPORT CODE C COMMERCIAL. RESTRICTED TO EMBARGOED COUNTRIES AND DENIED PARTIES. PRINTED COPIES ARE NOT MAINTAINED TO LATEST REVISION.

  • Page 45: List Of Figures

    Figure 3: Accessories unlocking key ............... 14 Figure 4: Accessories protective cap IP53 (left) and protective cap IP67 (right) ... 14 Figure 5: Accessories POWERLOCK-Box ..............15 Figure 6: NLS connector ..................17 Figure 7: NLS connector: components ..............18 Figure 8: Connector NLS: Label or marking 400/660A ...........
  • Page 46 Figure 30: Unlocking of the connector ..............38 Figure 31: Optional sliding sleeve „SC“ ..............39 Page 46 von 48 Operating Instructions POWERLOCK Rev. - EXPORT CODE C COMMERCIAL. RESTRICTED TO EMBARGOED COUNTRIES AND DENIED PARTIES. PRINTED COPIES ARE NOT MAINTAINED TO LATEST REVISION.

  • Page 47: Remarks And Notes

    ………………………………………………………………………………………………………………………………………………………………. ………………………………………………………………………………………………………………………………………………………………. ………………………………………………………………………………………………………………………………………………………………. ………………………………………………………………………………………………………………………………………………………………. ………………………………………………………………………………………………………………………………………………………………. ………………………………………………………………………………………………………………………………………………………………. ………………………………………………………………………………………………………………………………………………………………. ………………………………………………………………………………………………………………………………………………………………. ………………………………………………………………………………………………………………………………………………………………. ………………………………………………………………………………………………………………………………………………………………. ………………………………………………………………………………………………………………………………………………………………. ………………………………………………………………………………………………………………………………………………………………. Operating Instructions POWERLOCK Rev. - Page 47 von 48 EXPORT CODE C COMMERCIAL. RESTRICTED TO EMBARGOED COUNTRIES AND DENIED PARTIES. PRINTED COPIES ARE NOT MAINTAINED TO LATEST REVISION.
  • Page 48 Cannonstraße 1 D-71384 Weinstadt www.ittcannon.com 2021 © ITT Cannon GmbH All rights reserved Page 48 von 48 Operating Instructions POWERLOCK Rev. - EXPORT CODE C COMMERCIAL. RESTRICTED TO EMBARGOED COUNTRIES AND DENIED PARTIES. PRINTED COPIES ARE NOT MAINTAINED TO LATEST REVISION.

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