Difference between revisions of "Connectors"

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(Anderson Powerpole)
(Suggested Connectors: Cleanup ;))
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=== [https://en.wikipedia.org/wiki/MC4_connector Multi-Contact 4] ===
 
=== [https://en.wikipedia.org/wiki/MC4_connector Multi-Contact 4] ===
 +
[https://ec.staubli.com/AcroFiles/Technical%20Info/PV_SOL-LVDC_(en).pdf datasheet]
  
 
Technical Specifications:
 
Technical Specifications:
* Max Amps: 20A
+
* Max Amps: 39~104A (depends on cable)
* Max Volts: 600V
+
* Max Volts: 600~1500V (12kV surge)
 +
* Mating cycles: 100x
 +
* Number contacts: 1
 +
* Ingress: IP65
  
 
Pros:
 
Pros:
* Waterproof
+
* Approved for high voltage DC applications (IEC, TUV, UL)
* Fairly cheap
+
* Waterproof IP65
 +
* Availability / Fairly cheap
 
* Difficult to disconnect by accident
 
* Difficult to disconnect by accident
 
* While not recommended, designed to stop potential arcing on disconnect (an advantage over the [https://en.wikipedia.org/wiki/MC3_connector MC3 connectors])
 
* While not recommended, designed to stop potential arcing on disconnect (an advantage over the [https://en.wikipedia.org/wiki/MC3_connector MC3 connectors])
 +
* Extension cords are possible
 +
 
Cons:
 
Cons:
* + and - connectors are separate cables.
+
* PE, + and - connectors are separate cables.
* Can be difficult to disconnect without tools
+
* Should not be disconnected under load
* Low (~200) mating cycles
+
* Difficult to disconnect without tools (can break)
 +
* Low mating cycle count
  
 
=== [https://m.youtube.com/watch?v=qEdysiZAYZ4 XT60] ===
 
=== [https://m.youtube.com/watch?v=qEdysiZAYZ4 XT60] ===
 +
[https://media.digikey.com/pdf/Data%20Sheets/DFRobot%20PDFs/FIT0587_Web.pdf datasheet]
  
 
Technical Specifications:
 
Technical Specifications:
* Max Amps: 60A
+
* Max Amps: 30A (60A peak)
* Max Volts:  
+
* Max Volts: 500VDC
 
+
* Mating cycles: 1000x
Suggested by [https://wiki.munichmakerlab.de/wiki/DC_Microgrid Munich Maker Lab] during camp
+
* Number contacts: 2
Page creator has no experience with this type of connector.
+
* Ingress: IP00
  
 
Pros:
 
Pros:
* Cheap
+
* Availability / Cheap
* Small
+
* Small size
* one connector does both + and - wires
+
* 2 pole, one connector does both + and - wires
 +
* Extension cords are possible
  
 
Cons:
 
Cons:
* No waterproof variant has been found
+
* Unsafe, contacts open when disconnected and possibly when connected
 +
* Should not be disconnected under load
 +
* Not waterproof / outdoor
 +
* No 3 pin version with PE
 +
 
 +
Suggested by [https://wiki.munichmakerlab.de/wiki/DC_Microgrid Munich Maker Lab] during camp
 +
Page creator has no experience with this type of connector.
  
 
=== [https://en.m.wikipedia.org/wiki/Speakon_connector Speakon] / [https://en.m.wikipedia.org/wiki/PowerCon PowerCon] ===
 
=== [https://en.m.wikipedia.org/wiki/Speakon_connector Speakon] / [https://en.m.wikipedia.org/wiki/PowerCon PowerCon] ===
 +
[https://www.neutrik.com/media/10094/download/product-guide---section-loundspeaker-connectors.pdf?v=1 datasheet]
  
 
Technical Specifications:
 
Technical Specifications:
* Max Amps: 20A
+
* Max Amps: 20A (40A AC continuous)
* Max Volts: 250V
+
* Max Volts: 250V (4kV surge)
 +
* Mating cycles: >5000x
 +
* Number contacts: 4 or 8
 +
* Ingress: IP54 (IP20 disconnected)
  
 
Pros:
 
Pros:
 +
* Availability / Reasonable price
 +
* Outdoor design UL/CSA approved (IP54 when connected)
 +
* 4 or 8 pin versions
 +
* Disconnect under load
 +
* Locking
 +
* High mating cycle count
  
 
Cons:
 
Cons:
 +
* Designed/approved for AC
 +
* No female plug (chassis/coupler only)
 
* Used for all sorts of stuff. Mistakes are more likely.
 
* Used for all sorts of stuff. Mistakes are more likely.
 +
* Most cables only have 2 wires
  
=== [https://en.wikipedia.org/wiki/XLR_connector#Four-pin_(XLR4) XLR-4] ===
+
=== [https://en.wikipedia.org/wiki/XLR_connector XLR] ===
 +
[https://www.neutrik.com/media/10098/download/product-guide---section-xlr.pdf?v=1 datasheet]
  
 
Technical Specifications:
 
Technical Specifications:
* Max Amps: 10A per contact
+
* Max Amps: 16A 3p / 10A 4p / 7,5A 5~6p / 5A 7p
* Max Volts: 50V
+
* Max Volts: 50V (1,5 kV surge)
 +
* Mating cycles: >1000x
 +
* Number contacts: 3~7 or 8+2 (Ethernet+power)
 +
* Ingress: IP20 Female
  
 
Pros:
 
Pros:
* Extra wires could be used for signalling
+
* Availability
 +
* Number of contacts (PE, data)
 +
* Outdoor (IP40 or IP65)
 +
* Extension cords are possible
 +
 
 
Cons:
 
Cons:
* Could be confused with stage equipment already in use at festivals
+
* Low voltage / metal case
 +
* Varying quality (fakes)
 +
* Often used for small signals and stage equipment (audio / dmx etc.)
  
=== [https://m.reichelt.de/index.html?ACTION=7&LA=3&OPEN=0&INDEX=0&FILENAME=C152%2FRST16I2_B1_DB_DE.pdf RST16i2] ===
+
=== [https://www.wieland-electric.com/en-gb/products/circular-connector-system-industry Wieland Gesis RST series] ===
 +
[https://eshop.wieland-electric.com/categorie/en/circular-connector-system-in-raised-degree-of-protection-ip6x-gesis-rst/1000008683 specifications]
  
 
Technical Specifications:
 
Technical Specifications:
* Max Amps: 16A
+
* Max Amps: 16A (20A and 50A versions available)
* Max Volts: 250V
+
* Max Volts: 250V (4kV surge)
 +
* Mating cycles: 50~100x
 +
* Number contacts: 3~5
 +
* Ingress: IP68 (IP20 disconnected)
  
 
Pros:
 
Pros:
* Seems uncommon enough so mistakes are less likely
+
* Waterproof (IP66/68)
 +
* Multiple contacts available (PE, data)
 +
* Not commonly used (only 3p is sometimes used for 230VAC)
 +
* Lots of accessories available (male / female / chassis / splitters etc.)
 +
* Locking
 +
* Extension cords are possible
 +
 
 
Cons:
 
Cons:
 +
* Availability, proprietary in Germany
 +
* Not cheap
 +
* Low mating cycle count
 +
* No disconnect under load
  
 
=== [http://www.hirschmann.de/en/Hirschmann_Produkte/Industrial_Connectors/Power_Connectors/CA_Series/index.phtml Hirschmann CA Series] ===
 
=== [http://www.hirschmann.de/en/Hirschmann_Produkte/Industrial_Connectors/Power_Connectors/CA_Series/index.phtml Hirschmann CA Series] ===
 +
[https://catalog.belden.com//prodimgs/AllAssets-approved/EN/39/86/PDF_183986.pdf datasheet]
  
 
[[File:Hirschmann CA-Series.png|thumb]]
 
[[File:Hirschmann CA-Series.png|thumb]]
  
 
Technical Specifications:
 
Technical Specifications:
 +
* Max Amps: 10A
 +
* Max Volts: 230V (6kV surge)
 +
* Mating cycles: 100~500x
 +
* Number contacts: 3 or 6
 +
* Ingress: IP67 (IP20 Disconnected Female)
  
Protection: IP65, IP67
+
Pros:
 
+
* Waterproof (IP65, IP67)
4 pole
+
* Multiple connectors
* Max Amps: 16 A AC/10 A DC
+
* Not commonly used
* Max Volts: 400 V AC/230 V DC
+
* Locking
7 pole
 
* Max Amps: 230 V AC/DC
 
* Max Volts: 10 A AC/DC
 
  
Pros:
 
* Extra wires could be used for signalling
 
 
Cons:
 
Cons:
* Costly? (7€ plug, 3€ socket for 4 pole, 10€ plug, 7€ socket)
+
* Availability, proprietary in Germany
 +
* Not cheap (7€ plug, 3€ socket for 4 pole, 10€ plug, 7€ socket)
 +
* No disconnect under load
 +
* Extension and connection cords are different
  
 
=== [https://www.breve.pl/pliki/2016/01/SELV-EN.pdf SELV Connectors] ===
 
=== [https://www.breve.pl/pliki/2016/01/SELV-EN.pdf SELV Connectors] ===
Line 117: Line 174:
 
Technical Specifications:
 
Technical Specifications:
 
* Max Amps: 16A
 
* Max Amps: 16A
* Max Volts: 48V
+
* Max Volts: 50V
 +
* Mating cycles: Unknown
 +
* Number contacts: 2
 +
* Ingress: IP20 Female
  
 
Pros:
 
Pros:
* Made specifically for low voltage AC/DC power connections
+
* 48V version specific for this purpose
* Keying for different voltage levels
+
 
 
Cons:
 
Cons:
* hard to get
+
* Only 2 pins
* only 2 pins
+
* Extremely rare
 +
* Not water proof
 +
* No female plug
  
 
=== [https://en.wikipedia.org/wiki/Anderson_Powerpole Anderson Powerpole] ===
 
=== [https://en.wikipedia.org/wiki/Anderson_Powerpole Anderson Powerpole] ===
 +
[http://www.farnell.com/datasheets/1922225.pdf datasheet]
 +
 +
Technical Specifications:
 +
* Max Amps: 45A(55A) / 75A(120A) / 120A(240A) / 180A(350A)
 +
* Max Volts: 600V (2200V dielectric)
 +
* Mating cycles: >250x under load (>5000x probably)
 +
* Number contacts: stackable in 2 dimensions
 +
* Ingress: IP20 up to 45A version
 +
 +
Pros:
 +
* Availability (Ubiquitous worldwide, lot's of clones)
 +
* Low price
 +
* Disconnect under load
 +
* Number of contacts, virtually unlimited
 +
* Genderless, no male/female or direction exist
 +
* Lots of versions (cable, chassis, pcb, rubber shroud, T-splitter)
 +
* Colors available
 +
* Pretty much touch-proof on both sides (rated IP20 up to 45A version)
 +
 +
Cons:
 +
* Not waterproof (except the shrouded premade connectors)
 +
* Not touch-safe bigger versions
 +
* Often used for 12 Volt DC (Amateur radio)
 +
 +
 +
=== [https://en.wikipedia.org/wiki/Anderson_Powerpole Anderson Multipole SBE] ===
 +
[http://www.farnell.com/datasheets/1922225.pdf datasheet]
  
 
Technical Specifications:
 
Technical Specifications:
* 15/30/45/180 Amp variants available (different sizes)
+
* Max Amps: 70A+20A / 175A+20A / 350A+20A
* 600V rating, dielectric withstanding voltage of 2200V
+
* Max Volts: 600V+200V (2200V dielectric)
* 250 mating cycles under full load, a few hundred thousand mating cycles without load
+
* Mating cycles: >250x under load (>5000x probably)
 +
* Number contacts: 2x Power and 2x PowerPole 20A or 2x PPMX (4x 5A pins)
 +
* Ingress: IP20
  
 
Pros:
 
Pros:
* Easy to get
+
* Often used in electric vehicles (durable)
* Cheap
+
* Disconnect under load
* Extremely modular (you can build your connectors to spec using single pole assemblies in different colors and there are even pcb-mount variants, housings with locking, ...)
+
* High power
* Pretty much touch-proof (you'll have to try really hard with something like a screwdriver to touch a contact)
+
* Number of contacts, 8 data pins possible
* Unisex (optionally, one can add a blind pin to make it non-unisex)
+
* Genderless, no male/female or direction exist
 +
* Lots of versions (cable, chassis, pcb, rubber shroud, T-splitter)
 +
* Colors available
 +
* Touch-proof on both sides (rated IP20)
  
 
Cons:
 
Cons:
* without one of the modular housings, it's not waterproof
+
* Not waterproof
 +
* Not cheap

Revision as of 04:02, 22 September 2019

One current problem we need to address is to choose a capable standard connector so that everyone can participate and prepare equipment before the next camp so that time is not wasted trying to connect everything together.

The discussion tab can be used to debate the various types of connectors.

It would be worth listing the connectors that have been tried but are not suitable with reasons too, for example, car cigarette connectors. Although rated for 10A, this happened at 30V@5A.

Connector requirements

We have some requirements on our connectors which need to be met with varying importance. Key Words according to rfc2119. Please expand this list. :

High Voltage Connectors

  • Must have at least 3 Pins (PE, GND, V+)
  • Must be lockable to prevent unplugging when loaded or alternatively this must be prevented by a different measure.
  • Must be able to handle the load and voltages
  • Should not be commonly used for different applications in a Camp context. If this cant be prevented damage to the different application and ours must not occur when connected with each other.
  • Should be Waterproof
  • May have added pins for communication. <- This may change to a "must have" depending on our implementation of load sharing.
  • Must prevent touchable live connections. This may be implemented by a different measures.

Low Voltage (< 50VDC) Connectors

  • Should have at least 3 Pins (PE, GND, V+)
  • Must be lockable to prevent unplugging when loaded or alternatively this must be prevented by a different measure.
  • Must be able to handle the load and voltages
  • Should not be commonly used for different applications in a Camp context. If this cant be prevented damage to the different application and ours must not occur when connected with each other.
  • May have added pins for communication. <- This may change to a "must have" depending on our implementation of load sharing.
  • Should prevent touchable live connections. This may be implemented by different measures

Suggested Connectors

Multi-Contact 4

datasheet

Technical Specifications:

  • Max Amps: 39~104A (depends on cable)
  • Max Volts: 600~1500V (12kV surge)
  • Mating cycles: 100x
  • Number contacts: 1
  • Ingress: IP65

Pros:

  • Approved for high voltage DC applications (IEC, TUV, UL)
  • Waterproof IP65
  • Availability / Fairly cheap
  • Difficult to disconnect by accident
  • While not recommended, designed to stop potential arcing on disconnect (an advantage over the MC3 connectors)
  • Extension cords are possible

Cons:

  • PE, + and - connectors are separate cables.
  • Should not be disconnected under load
  • Difficult to disconnect without tools (can break)
  • Low mating cycle count

XT60

datasheet

Technical Specifications:

  • Max Amps: 30A (60A peak)
  • Max Volts: 500VDC
  • Mating cycles: 1000x
  • Number contacts: 2
  • Ingress: IP00

Pros:

  • Availability / Cheap
  • Small size
  • 2 pole, one connector does both + and - wires
  • Extension cords are possible

Cons:

  • Unsafe, contacts open when disconnected and possibly when connected
  • Should not be disconnected under load
  • Not waterproof / outdoor
  • No 3 pin version with PE

Suggested by Munich Maker Lab during camp Page creator has no experience with this type of connector.

Speakon / PowerCon

datasheet

Technical Specifications:

  • Max Amps: 20A (40A AC continuous)
  • Max Volts: 250V (4kV surge)
  • Mating cycles: >5000x
  • Number contacts: 4 or 8
  • Ingress: IP54 (IP20 disconnected)

Pros:

  • Availability / Reasonable price
  • Outdoor design UL/CSA approved (IP54 when connected)
  • 4 or 8 pin versions
  • Disconnect under load
  • Locking
  • High mating cycle count

Cons:

  • Designed/approved for AC
  • No female plug (chassis/coupler only)
  • Used for all sorts of stuff. Mistakes are more likely.
  • Most cables only have 2 wires

XLR

datasheet

Technical Specifications:

  • Max Amps: 16A 3p / 10A 4p / 7,5A 5~6p / 5A 7p
  • Max Volts: 50V (1,5 kV surge)
  • Mating cycles: >1000x
  • Number contacts: 3~7 or 8+2 (Ethernet+power)
  • Ingress: IP20 Female

Pros:

  • Availability
  • Number of contacts (PE, data)
  • Outdoor (IP40 or IP65)
  • Extension cords are possible

Cons:

  • Low voltage / metal case
  • Varying quality (fakes)
  • Often used for small signals and stage equipment (audio / dmx etc.)

Wieland Gesis RST series

specifications

Technical Specifications:

  • Max Amps: 16A (20A and 50A versions available)
  • Max Volts: 250V (4kV surge)
  • Mating cycles: 50~100x
  • Number contacts: 3~5
  • Ingress: IP68 (IP20 disconnected)

Pros:

  • Waterproof (IP66/68)
  • Multiple contacts available (PE, data)
  • Not commonly used (only 3p is sometimes used for 230VAC)
  • Lots of accessories available (male / female / chassis / splitters etc.)
  • Locking
  • Extension cords are possible

Cons:

  • Availability, proprietary in Germany
  • Not cheap
  • Low mating cycle count
  • No disconnect under load

Hirschmann CA Series

datasheet

Hirschmann CA-Series.png

Technical Specifications:

  • Max Amps: 10A
  • Max Volts: 230V (6kV surge)
  • Mating cycles: 100~500x
  • Number contacts: 3 or 6
  • Ingress: IP67 (IP20 Disconnected Female)

Pros:

  • Waterproof (IP65, IP67)
  • Multiple connectors
  • Not commonly used
  • Locking

Cons:

  • Availability, proprietary in Germany
  • Not cheap (7€ plug, 3€ socket for 4 pole, 10€ plug, 7€ socket)
  • No disconnect under load
  • Extension and connection cords are different

SELV Connectors

Details on the specs

Technical Specifications:

  • Max Amps: 16A
  • Max Volts: 50V
  • Mating cycles: Unknown
  • Number contacts: 2
  • Ingress: IP20 Female

Pros:

  • 48V version specific for this purpose

Cons:

  • Only 2 pins
  • Extremely rare
  • Not water proof
  • No female plug

Anderson Powerpole

datasheet

Technical Specifications:

  • Max Amps: 45A(55A) / 75A(120A) / 120A(240A) / 180A(350A)
  • Max Volts: 600V (2200V dielectric)
  • Mating cycles: >250x under load (>5000x probably)
  • Number contacts: stackable in 2 dimensions
  • Ingress: IP20 up to 45A version

Pros:

  • Availability (Ubiquitous worldwide, lot's of clones)
  • Low price
  • Disconnect under load
  • Number of contacts, virtually unlimited
  • Genderless, no male/female or direction exist
  • Lots of versions (cable, chassis, pcb, rubber shroud, T-splitter)
  • Colors available
  • Pretty much touch-proof on both sides (rated IP20 up to 45A version)

Cons:

  • Not waterproof (except the shrouded premade connectors)
  • Not touch-safe bigger versions
  • Often used for 12 Volt DC (Amateur radio)


Anderson Multipole SBE

datasheet

Technical Specifications:

  • Max Amps: 70A+20A / 175A+20A / 350A+20A
  • Max Volts: 600V+200V (2200V dielectric)
  • Mating cycles: >250x under load (>5000x probably)
  • Number contacts: 2x Power and 2x PowerPole 20A or 2x PPMX (4x 5A pins)
  • Ingress: IP20

Pros:

  • Often used in electric vehicles (durable)
  • Disconnect under load
  • High power
  • Number of contacts, 8 data pins possible
  • Genderless, no male/female or direction exist
  • Lots of versions (cable, chassis, pcb, rubber shroud, T-splitter)
  • Colors available
  • Touch-proof on both sides (rated IP20)

Cons:

  • Not waterproof
  • Not cheap