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Connector
Connectors - All the information, models and pin numbers at a glance
In industry, machines, equipment or switch cabinets are connected together with heavy-duty connectors (as shown in the picture on the right), power connectors, signal connectors, valve connectors or sensor connectors. Depending on the device and application, the connectors must be designed for low or high currents and voltages. Our guide provides information about what a connector must be capable of, what application is suitable for and what connector types are available.
Table of contents:
- How does a connector work?
- What is a connector and how is it made?
- What are the areas of application of connectors?
- What IP protection classes are there for connectors?
- What connection technologies do connectors use?
- What types of connectors are there?
- Who are the connector manufacturers?
- What numbers of pins do connectors have?
How do connectors work?
As components of electrical connection technology, connectors connect electrical or signal-carrying wires.
Electronic connectors and industrial connectors exist for this in a housing, in which one or more electrical contacts are housed. Depending on the area of application, connectors must be robust and insensitive to temperature fluctuations, as well as resistant to penetrating moisture and dust. Some Amphenol connectors, Harting connectors or Phoenix Contact connectors for industrial use also have an integrated lock. This prevents unintentional disconnection of the connection during operation.
What is a connector and how is it made?
No matter whether M8 connectors, M12 signal connectors or RD 24 connectors: in principle a connector comprises two parts:
- one is described as a female part with an opening directed inwards for the contacts. This part serves as a counter piece for the actual connector. If this part is at the end of a cable, it is called a coupling. If it is permanently fitted in a housing or in the wall, it is called a socket. (See image, top right)
- A male part with contact pins pointing outwards. It is called a jack if this part is fitted at the end of a cable, a connector if it is permanently integrated into a housing. See image bottom right)
All connections have one thing in common, the current or signal-carrying parts of both connectors are oriented precisely and positively to each other. It is also important that the coupling and the jack have the same number of pins and thus the same arrangement.
Components of a Harting connector are the bottom part, also called the mounting housing or socket housing. A coupling connection is also treated as a bottom section. Heavy-duty connectors from Harting can be identified from the seal. Top parts, also called grommets or hoods, mostly have a cable outlet with a PG or metric thread. Correspondingly matching connectors in, for example, M16 are screwed in there. There are also other designs without a connector. Depending on the connector type and manufacturer.
What is the task of a connector?
The task of a connector is to form a defined, easily separable interface between electrical components, systems or equipment. The influence of the relevant technical parameters compared to permanent cabling” should be as small as possible.
Important: The long-term, perfect function of the connection while retaining the mechanical and electrical properties.
- Long-term mechanical stability
- Constantly small losses of small contact resistance
- Permanent protection against environmental effects (IP, UV, EMC…etc.)
What are the areas of application of connectors?
Particularly long-lived, designed for high voltages and currents, protected against polarity reversal with bend protection or fitted with tension relief! Depending on the requirement, connectors must be safe, robust and easy to use. Hardly any economic areas today get by without connectors. They are essential both in production plants and testing laboratories, as well as in IT departments.
Connectors and the matching sockets are used in electronic devices for the internal and external connection of additional components. Further, external-facing connections are needed on a PC in order to connect peripherals to the computer by USB or monitors by HDMI, display port or D-Sub connectors. In short: there is barely an area of application that gets by without connectors.
Application areas for connectors at a glance:
- Machine and plant construction
- IT, communication and network technology
- vehicle manufacturing
- production, materials handling
- academic institutions
- testing technology
- event and audio technology
What IP protection classes are there for connectors?
Depending on the area of application, connectors must have touch protection, as well as being resistant to penetrating moisture and dust. The most common IP protection classes for connectors include:
- IP 44: All-round protection against spray water, contact with wires/foreign bodies (larger than 1 mm) and tools
- IP 67: Protection against a strong water jet and for temporary immersion. Resistant against penetrating dust, foreign bodies and contact.
All other IP protection classes for connectors can be looked up in the chart.
What approvals are there for connectors?
If connectors need to fulfil specific technical or safety-related requirements, under some circumstances they need an approval from an accredited testing institution. Only then does a connector system gain a test seal confirming its suitability for the respective area of application.
Moreover, connectors are also frequently awarded test seals from the following institutions:
- RoHS (EU Directive 2011/65/EU)
Connectors which are used in specific markets also need approval from the respective country where the machine is installed.
- UL (UL 969 “Standard for Marking and Labeling Systems) for the USA
- CCC (China Compulsory Certification) for the Chinese market
- CSA (Canadian Standards Association”) for the Canadian market
Electrical Data of Industrial Connectors
As per the definition according to DIN EN 61 984, the following electrical data exist for industrial connectors:
- Rated current - e.g. 16 A
- Rated voltage - e.g. 500 V
- Rated surge voltage - e.g. 6 kV
- Degree of contamination -e.g. 3
Crimp connection
The crimp connection is a mechanical fastening using plastic deformation. It is always sensible to crimp the connectors with a crimping tool whenever connections are made that must withstand a high tensile load. The areas of application include the mechanical engineering and automotive areas, as well as IT and network technology. Such as cabling for servers or when installing network switches. RJ45 network connectors are frequently crimped onto the network cables here.
Screw connection
The screw terminal allows quick and easy connection of electricity or signal-carrying wires with the connector using screw terminals. Circular connectors with integrated screw locks are also referred to as screw terminals. This design allows the secure connection of cable connectors and cable sockets by integrated thread on the connector housing. Accidental loosening of the connection to a device or technical system is almost ruled out completely when in operation.
Solder connection
The solder terminal is specifically used for board connectors or signal connectors.
Axial screw connection
The axial screw terminal combines the advantages of a screw terminal with the low space requirement of crimped contacts. These connectors are suitable both for thin cable strands and for wires with a large cross-section.
Cage clamp terminal and double cage clamp terminal
These terminal types facilitate tool-less wire connections. The integrated spring mechanism locks the inserted cable strands up to a cross-section of 2.5 mm2 and guarantees a vibration- and impact-proof connection.
Quick-Lock terminal
The quick-lock terminal is very popular in Harting connectors. This type of terminal is characterised by their limited required space, easy handling and fast connection of wires without additional specific tools.
Insulation displacement connector
The insulation displacement connector is optimal for fast cabling of solid conductors. This connector type facilitates a connection that does not require soldering, screws or stripping. The wire is inserted into the housing and the integrated insulation displacement connector connects the cable with the conductive contact in one work step.
Quick Connect screwless spring clamp technology
Quick Connect is connection type for connectors that correspond to standard IEC 60309 and which are used in industrial and multi-phase connectors, e.g. CEE connectors. The wires are connected using a screwless spring clamp, which is mechanically highly durable and simplifies the production of the cable with connectors, sockets and couplings.
Electronic connectors / D-Sub connectors
As a replacement for a defective D-Sub connector or additional D-Sub socket for installation in a housing. Electronic connectors from Harting are available in almost every shape and with up to 50 pins, made either from metal or plastic. The right accessories, such as threaded bolts, knurled screws and socket inserts (F/M), guarantee a high level of precision and easy assembly of all components.
D-Sub connectors are standardised internationally according to Guideline IEC 807-2 and typically have 9 to 50 pins. The pins, arranged as a trapezoid in two or three rows, are secured against twisting. D-Sub connectors are used for signal transmission, inter alia in the IT branch and when connecting industrial systems.
Circular connectors
Circular connectors are frequently used in measuring and control technology and for signal and electricity transmission. Depending on the type, they differ in terms of design, shape and terminal technology.
Circular connectors at a glance:
- Circular connectors, power connectors: suitable for power applications, they are designed for up to 630V and a rated current of up to 150A.
- Signal connectors are circular connectors for industrial areas where sensors are read or actuators controlled.
- RD 24 connectors are used for voltage supply in machine and plant engineering and are typically approved according to VDE and UL.
- Cable connectors are circular connectors with threaded screws of M12 to a maximum of M58 and 3, 5, 8, 12 or 17 terminal pins. Designed for rated voltages between 125V and 630V. Designs of cable connectors at a glance:
- Cable connectors straight: Straight connectors and sockets
- Angled cable connectors: suitable for installation positions with little available space.
CEE connectors
CEE connectors are characterised by their cage clamp technology for screwless cabling. CEE connectors in RAL Ton 5015 are designed for rated operating voltages of 200V to 250V, while the connectors in RAL 3000 are suitable for voltages between 380V and 480V.
Sensor connectors
Sensor connectors are EMC-shielded connectors for signal transmission for automation applications. Single sensor connectors in thread sizes M5, M8 or M12 or directly produced with cables as a ready-made sensor wire up to 10m long
- M8 connectors: Sensor connector with M8 threaded terminal and 3 or 4 pins. Suitable for solder connection or fitted with insulation displacement technology (IDC contacts).
- M12 connectors: Sensor connector with M12 threaded terminal and 3, 4, 5, 8 or 12 pins. Suitable for crimp terminals, solder connection, screw terminal or fitted with insulation displacement technology (IDC contacts).
Network connectors
Network connectors RJ45, Ethernet, Quintax or Profibus: These connectors with insert or screw terminal are suitable for industrial Ethernet, use in server rooms or for domestic networks.
Valve connectors
Valve connectors for connecting electromagnetic, pneumatic or hydraulic actuators. They are robust connectors for connecting valves, for all assembly types. They are used wherever dust, spray water or water jets are expected. Such as in conveyor systems, mechanical engineering, in industry, oil platforms or in construction machinery. General manufacturer systems simplify the planning for controlling valves in pneumatic, electromagnetic or hydraulic applications across different interfaces.
What connector manufacturers are there?
There are as many manufacturers as there are types of connector. The range extends from large manufacturers such as Harting, which offer a large number of different connectors, to small specialist manufacturers. Here is a small selection of the best known manufacturers and their products.
Connectors from Harting
Harting connectors are extremely reliable and highly durable. Harting connectors are suitable both for use in switch cabinets and in the workshop and vehicle area. Thanks to their easy handling, long service life and a very good price-performance ratio, they are also used in industry. The Harting range is rounded off with a comprehensive accessories program and special solutions such as the optional Han housings.
Connectors from Amphenol
Amphenol connectors are ideal for data and signal transmission, or heavy-duty connectors for high-voltage application. Robust, industry-quality connectors from Amphenol are suitable for use in almost every area. Depending on the design, they are designed for currents of up to 100A per contact. The housings, available in rectangular or circular form, are all protected against penetrating water.
Connectors from Phoenix Contact
The wide range from Phoenix Contact provides all connectors that are needed in connection and automation technology. Circular connectors or sensor connectors - Phoenix Contact has the right connector for almost every application..
What pin numbers are there for connectors?
Connectors are available with many different pin numbers. In the following table, we have sorted our connectors for you by pin number. Consequently, you can directly see which connectors are available for which pin number. In the smaller pin numbers there are many connector types to choose from. However, if you need a higher-pole connector, there is really no way around the Harting connectors.
| Number of pins | Connectors Type |
|---|---|
| 1-pin connectors | Harting connectors |
| 2-pin connectors | Harting connectors, Amphenol AT connectors, Amphenol ATM connectors, Amphenol ATP connectors |
| 3-pin connectors | Harting connectors, Amphenol AT connectors, Amphenol ATM connectors, Signal connectors, Appliance connectors, Cable connectors, CEE plug 16A, Sensor connectors, Valve connectors |
| 4-pin connectors | Harting connectors, Amphenol ecomate connectors, Amphenol AT connectors, Amphenol ATM connectors, Amphenol ATP connectors, Power connectors, Equipment connectors, Coupling connectors, RD24 connectors, CEE plug 16A, Sensor connectors, Network connectors |
| 5-pin connectors | Harting connectors, Signal connectors, Power connectors, Equipment connectors, Cable connectors, CEE plug 16A, CEE plug 32A, CEE plug 63A, Sensor connectors, Network connectors |
| 6-pin connectors | Harting connectors, Amphenol AT connectors, Amphenol ATM connectors, Signal connectors, Coupling connectors, Appliance connectors |
| 7-pin connectors | Harting connectors, Amphenol ecomate connectors, Signal connectors, Coupling connectors, RD24 connectors |
| 8-pin connectors | Harting connectors, Amphenol AT connectors, Amphenol ATM connectors, signal connectors, device connectors, coupling connectors, cable connectors, sensor connectors, network connectors |
| 9-pin connectors | signal connectors, coupling connectors, D-Sub connectors, electronic connectors |
| 10-pin connectors | Harting connectors |
| 12-pin connectors | Harting connectors, Amphenol AT connectors, Amphenol ATM connectors, Signal connectors, Panel connectors, Cable connectors, Sensor connectors |
| 15-pin connectors | Harting connectors, D-Sub connectors, Electronic connectors |
| 16-pin connectorsr | Harting connectors, Signal connectors |
| 17-pin connectors | Signal connectors, Panel connectors, Cable connectors |
| 18-pin connectors | Harting connectors |
| 19-pin connectors | Signal connectors |
| 21-pin connectors | Harting connectors |
| 24-pin connectors | Harting connectors |
| 25-pin connectors | Harting connectors, D-Sub connectors, Electronic connectors |
| 26-pin connectors | D-Sub connectors, Electronic connectors |
| 28-pin connectors | Harting connectors/td> |
| 32-pin connectors | Harting connectors |
| 37-pin connectors | D-Sub connectors, Electronic connectors |
| 40-pin connectors | Harting connectors |
| 42-pin connectors | Harting connectors |
| 46-pin connectors | Harting connectors |
| 48-pin connectors | Harting connectors |
| 50-pin connectors | Harting connectors, D-Sub connectors, electronic connectors |
| 55-pin connectors | Harting connectors |
| 64-pin connectors | Harting connectors |
| 72-pin connectors | Harting connectors |
| 75-pin connectors | Harting connectors |
| 80-pin connectors | Harting connectors |
| 92-pin connectors | Harting connectors |
| 107-pin connectors | Harting connectors |
| 108-pin connectors | Harting connectors |
| 128-pin connectors | Harting connectors |
| 144-pin connectors | Harting connectors |
| 216-pin connectors | Harting connectors |