Difference between revisions of "Connectors"

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(Suggested Connectors: Availability)
(XLR)
 
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* Max Volts: 50V (1,5 kV surge)
 
* Max Volts: 50V (1,5 kV surge)
 
* Mating cycles: >1000x
 
* Mating cycles: >1000x
* Number contacts: 3~7 or 8+2 (Ethernet+power)
+
* Number contacts: 3~7 or 8+2 (Ethernet+power) -> 4-pin version used for DC applications
 
* Ingress: IP20 Female
 
* Ingress: IP20 Female
  

Latest revision as of 07:15, 23 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

Name Amps Volts Mating Contacts Lockable Water proof Finger safe 3 Pin Data Not Confusing Extendable Available
MC4 104 1500 100 1 + ++ ++ O - + + ++
XT60 30 500 1000 2 O -- -- - - O + +
Speakon 20 250 5000 8 ++ + ++ + + -- O ++
XLR 10 50 1000 7 ++ O + + + -- + ++
Wieland RST 50 250 100 5 ++ ++ ++ ++ + + + -
Hirschmann CA 10 230 500 6 + ++ + + + + O O
SELV 16 50 250 2 O - + - - ++ - --
Anderson PP 180 600 5000 10 + - + + + ++ ++ +
Anderson MP 350 600 5000 2 + - + O ++ ++ ++ -


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) -> 4-pin version used for DC applications
  • 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