IEC 60309 – Industrial connectors

In addition to a comprehensive range of international power cords, Morvan Trading also supply industrial IEC 60309 plugs and connectors.  These are circular connectors with cylindrical pins arranged in a circle, come in different sizes and pin configurations depending on the application, and can be supplied as rewireable connectors and/or assembled into power cables.

IEC 60309 (formerly known as BS 4343 in the UK, IEC 309, and CEE 17) and CENELEC EN 60309 is a standards issued for “plugs, socket outlets and connectors for industrial uses”.  The IEC60309-1 document specifies general functional and safety requirements, while IEC60309-2 contains manufacturing specifications for standard connectors.  They are designed to be used in a nominal ambient temperature range of −25°C to 40°C; there are no special high temperature connectors. These are also called Pin and Sleeve plugs, Commando plugs, CeeForm, and CEE plugs.

Aside from industrial use at currents and voltages different from domestic power, commando sockets are also found in workshops, agriculture, camping and caravanning, yachting and marinas.  They are also used to prevent domestic appliances being plugged in where they shouldn’t.  As an internationally-recognised standard, these can also be used anywhere in the world.

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IEC 60309: voltage colour-coding

IEC60309 couplers are colour-coded by voltage. Extra low voltage is 20-25V and violet in colour. Low voltage is 40-50V and white. 100-130V is colour yellow, and often used for building site equipment and power tools, along with North American domestic voltage (110-125V); these are called pin and sleeve connectors. 200-250V is blue, and used for European domestic voltages (220-240V). 380-480V is red and usually used for three-phase applications. 500-1000V is colour black, and used in marine and shipboard settings. See table below for more details.

IEC 60309 aviation connectors

We can also supply high-frequency green connectors rated up to 500 Hertz for defence and aviation use, usually connecting the terrestrial power supply to the aeroplane’s AGPU (Aircraft Ground Power Unit) through a voltage and frequency convertor. Aircraft voltages are generally 14V DC, 28V DC, or 115V AC 400Hz, depending on the size of the plane. Operating at a much higher frequency, 400 Hz rather than 50 or 60 Hz for land power, means less energy is stored in the transformer per cycle, allowing the use of fewer copper coils, which translates as less weight which is highly desirable in aircraft design. 400 Hz also allows for a smoother conversion between AC and DC, and was first standardised by the U.S. Air Force in 1959. The downside of high frequencies is greater transmission losses over distance, but this is not a problem as aircraft are of a finite size.

Voltage keying in commando plugs

In addition to the colour-coding, a keying system exists to prevent plugs and sockets of different current voltages being incorrectly connected.  A mating key and keyway on the outer plastic barrels means that plugs and sockets can only be connected one way round, and the pins are rotated for different voltages.  With the keyway at the bottom (or 6 o’clock on an imaged clock face) position of a socket, the larger earth contact aperture of a 3 pole 110V yellow socket is at 4 o’clock, which stops it being used with 240V blue plugs (6 o’clock earth) or 415V red plugs (9 o’clock earth).

The keying and location of the pins makes all IEC 60309 plugs and sockets polarised.

 Comparison of International (Series I) and North American (Series II) current ratings

IEC 60309 IP ratings

IEC 60309 are rated IP44 splashproof as minimum, making them ideal for outdoor or wet environments.  They can also be rated IP67 waterproof for harsher environments; the two rating systems are interchangeable.

The IP rating stands for International Protection and is set out in IEC 60529 document (EN 60529 in Europe), and is sometimes also called the ingress protection rating.  ‘IP’ is followed by two digits, the first being a number from 0 (none) to 6 (dust-tight) for solid particle protection, and the second digit a number from 0 (none) to 8 (water jet) for liquid ingress protection.  The letter ‘X’ is used if insufficient data was available at testing.

Sockets have a sprung lid to protect the live contacts when not in use, and when open the lid also locks onto the male connector, preventing inadvertant disconnection.  IP66/67 adds a a thread to the lid to screw it shut against a rubber gasket. Wall mount and panel mount inlets and outlets are mounted facing downwards for added protection.  The pins on the plug are shrouded by the sleeve to limit accidental contact, and contacts on the socket are recessed to make them more ‘finger-proof’.

The standard describes unearthed 2 pin (2P), and earthed 3 pin (2P+E), 4 pin (3P+E) and 5 pin (3P+N+E) connectors, plus a 7 pin non-standard connector available for delta 3 phase wiring.

Some larger plugs (63A and 125A) may have an optional extra pilot pin in the centre. At only 6mm in length, it breaks contact first, before the current-carrying pins, and is used to switch off the current and avoid potentially dangerous arcing between the pins and socket contact when disconnecting.

Commando plug approvals

Industrial plugs and socket do not seem to be as highly regulated as general purpose plugs and connectors. We usually supply a manufacturer certificate of conformity to the IEC 60309 standard, along with other regulatory requirements, e.g. RoHS compliance and CE declaration. Please advise in advance if independant approval is required so that this may be requested and provided in sufficient time.

For supply into North America, it is important to specify series II plugs and connectors to have the correct current ratings and wire sizes, and also the appropriate NRTL approval (e.g. UL). These are generally more expensive, although dual-rated connectors may reduce the need for stocking two similar product lines.

IEC 309 variations

IP rating
IP44 (splashproof)

IP66 / IP67 (waterproof)

Number of pins
2 pin (2P) for extra low voltage only

3 pin (2P+E or 2P3W) single phase and split phase

4 pin (3P+E or 3P4W) 3 phase without neutral, e.g. for electric motors

5 pin (3P+N+E or 4P5W) 3 phase

E or PE = protective earth, N = neutral, P = line L1, L2, L3, PP = pilot pin (optional, to prevent arcing)

Amperage
International: 16A, 32A, 63A, 125A, 250A, 400A, 630A, 800A

North America: 20A, 30A, 60A, 100A, 200A, 300A, 350A, 500A, 600A

Format
Plug (cable mount)

Connector or coupler (cable mount)

Socket (surface or panel mount)

Appliance inlet or appliance plug (surface or panel mount)

Conclusion

Morvan Trading can supply the whole range of IEC 309 connectors, as either rewireables or assembled power cables, along with intra-standard adaptors, e.g. 1x 32A plug to 2x 16A sockets.

Also possible are adaptors to and from domestic type plugs and sockets for the whole world, such as a UK plug to a 16A coupler. Otherwise, adaptors to/from other types of industrial plugs, e.g. European Perilex plugs, Swiss typ 15 & typ 25 plugs, various other 3-phase connectors, and the higher-rated American NEMA plugs and sockets.

Contact us for more information on any of these cable types, either in bulk or with plugs and connectors attached, and we can discuss options and provide quick quotations, call us on 01264 353489 or click here to contact us