Industrial Connector Selection Guide

When selecting an industrial connector, key parameters such as wire thickness, current size, operating environment, waterproof level, ease of plugging and unplugging, connection method, voltage requirements, and anti-interference ability should be considered comprehensively.

The IP protection level of industrial connectors ensures their environmental adaptability through a two-digit system: the first digit (0-6) represents dustproof capability, the second digit (0-9) represents waterproof performance, and "0" represents no corresponding protection. The highest level IP69 means complete dustproof (level 6) and can withstand continuous flushing of 80°C high-temperature and high-pressure water columns (80-100Bar), suitable for extreme cleaning scenarios; IP68 also achieves complete dustproof (level 6), and its waterproof capability supports immersion in 1.5 meters of water for 30 minutes, meeting the needs of long-term stable operation in deep water environments.

Of the two IP68-rated connectors launched by Anderson Power Products, the Samtec ACR-16 uses a 10-pin design (rated current 11.6A), while the SBSX-75A is equipped with dual power pins (135A high current load) and up to 4 signal pins. Both use differentiated locking mechanisms (ACR-16 is a push-pull buckle, SBSX-75A is threaded tightening) to achieve sealing protection for 30 minutes at 1.5 meters underwater, meeting the dual requirements of high waterproofness and electrical performance in industrial scenarios. (Figure 1).

Figure 1: The ACR-16 (left) and SBSX-75A (right) connectors have an IP68 environmental rating and locking mechanisms (not to scale).

Chemical and corrosion resistance

In response to the corrosion resistance requirements in hydrocarbon and solvent environments, the connector shell polycarbonate (PC) can resist dilute acids, greases, and detergents, while polybutylene terephthalate (PBT) can contain organic solvents, gasoline, and other compounds. The PC/PBT alloy material formed by the combination of the two further has the advantages of high chemical resistance, impact resistance, and weather resistance.

The SB connector series from Anderson Power Products offers chemically resistant housings using a PC/PBT mixture. These connectors have a rated current of up to 280 A, an extended operating temperature range from -40 °C to 105 °C, and an environmental rating of IP64 (Figure 2).

Figure 2: The housing of this power connector is made of a PC/PBT mixture and has high chemical resistance. (Image: Anderson Power Products)

Cold pluggable

High-voltage applications (1,500 V+) are usually more concerned with operator safety than system uptime. In these cases, service plugs can be used for cold-pluggability to manually disconnect the power and protect the operator from high voltage.

The Hirose EM30MSD service plug includes power terminals rated at 1,500 V and 200 A and signal lines rated at 250 V and 1 A. These signal lines are interrupted to prevent hot pluggability when the bayonet locking mechanism is rotated to disconnect. When mated, the locking system also provides shock resistance to minimize the possibility of accidental disconnection (Figure 3).

Figure 3: When the EM30MSD cold-pluggable connector is unplugged, both the power and signal lines are opened to protect the operator. (Image: Hirose)

The EM30MSD service plug adopts a multi-point contact design to reduce resistance.

The PBT shell is corrosion-resistant and has an IP68 protection level when plugged in. When unplugged, the socket has an IPX2 anti-finger protection function, which can block objects with a diameter greater than 12.5mm from entering. It is suitable for all kinds of harsh environments.