It takes the right electrical components, connectors and cable glands (also known as strain relief or cord grips) to ensure flawless operation of systems and machines in harsh environments where dust and moisture are part of daily operations. Whether connectors and cable glands are operating in high-dust paper mills or in chemical plants exposed to hazardous substances, electronic connectors and cable glands must be designed to deliver secure, long-lasting performance, providing the strongest ingress protection link in these systems by meeting stringent IP ratings.
Understanding IP ratings is the first step in choosing the right connectors and cable glands for every sector and application. Those tasked with specifying and procuring these components must make the right choice every time.
Each sector has entire systems, services, workflows, products, and processes relying on connectors. Those tasked with specifying these components must make the right choice every time.
Defining that right choice requires a detailed understanding of several factors, including:
This starts by understanding what IP ratings are and how they drive those right decisions.
The International Electrotechnical Commission (IEC) defines Ingress Protection (IP) under standard IEC 60529. These IP rating standards measure how well enclosures (like connectors and cable glands) protect against solid objects like dust and liquids like water and caustic chemicals.
Each IP rating code comprises two digits.
This IP ratings chart shows how much protection each rating offers and what type of protection.
|
IP Rating |
Solid Protection |
Liquid Protection |
|
IP40 |
Objects >1mm |
No protection from liquids |
|
IP54 |
Limited dust |
Splashing water from any direction |
|
IP65 |
Dust-tight |
Low-pressure water jets |
|
IP67 |
Dust-tight |
Temporary immersion (up to 1m) |
|
IP68 |
Dust-tight |
Continuous immersion (depth specified) |
|
IP69K |
Dust-tight |
High-pressure, high-temp spray cleaning |
IP65 is often the minimum requirement in demanding sectors. Going lower can mean poor performance and premature failure.
The wrong choice of IP-rated connector will lead to a failed seal, unplanned downtime, and other associated costs.
This can include safety risks, regulatory violations, ruined product batches, slowed supply chains, and much more. Which of these costs will occur and how many will happen in combination depends on the sector, connector, system, environment, and processes they affect.
Even small amounts of moisture, which can just be present in the air as humidity, can trigger corrosion or a short if it infiltrates a connector. This makes waterproof connectors and cable glands vital to different industries. Even the smallest amount of dust can break signal continuity in today's critical electrical and digital systems.
Regulated industries must never let compromised enclosures into the system, service, and production workflows. This could lead to failed inspections, product contamination, or major product or process safety violations.
A closer look at several industries shows how the right connector and IP rating are essential to avoiding these disasters.
Choosing the right IP-rated connector protects not just the cable but the integrity of the entire system it supports.
Here are some of the broader sectors where an ingress protection rating plays a critical role.
The food and beverage sector has tight sanitation rules demanding frequent wash downs with high-pressure, high-temperature water and caustic cleaners. This sector turns to hygienic stainless steel circular connectors and cable glands rated IP69K with stainless steel housings and silicone seals for liquid ingress protection. Packaging machines, bottling lines, and conveyors use these connectors to maintain hygienic operation.
Panel-mount connectors and housings rated IP68 are used for secure cabinet access where cabling must remain sealed during clean-in-place (CIP) procedures. These connectors and cable glands must endure high-pressure, high-temperature spray cleaning without risk of shorting or microbial contamination. An inferior connector with an insufficient IP rating could cause water intrusion, machine stoppage, and product recalls.
In production plants, environmental stressors like vibration, oil, and flying particulates are constant. Process automation actuators, programmable logic controllers (PLCs), and sensors commonly use M12 and M8 circular connectors rated IP67/IP68.
Many of these processes require panel-mount connectors with IP66/IP68 ratings mounted into enclosures for seamless integration. Without proper IP sealing, signal instability and equipment wear can cause cascading failures in automation lines.
Salt spray, water immersion, and fluctuating temperatures make weatherproof connector and cable gland integrity non-negotiable. Control boxes, lighting systems, and communication cables on docks, coastal installations and vessels, and offshore platforms require IP68 connectors.
These connectors provide liquid ingress protection, which prevents corrosion and failure.
Preferred materials for these connectors in these environments include nickel-plated brass or corrosion-resistant polymer housings. Marine-grade RJ45 connectors and sealed panel-mount enclosures keep vital signals flowing, even during immersion. These and other IP-rated connectors can save entire systems from failure risk in environments that are expensive and dangerous to service.
Outdoor 5G towers, remote base stations, and rooftop enclosures require RJ45 and fiber connectors that are IP67/IP68 rated. Dust, rain, and UV exposure can wreak havoc on data integrity if not properly sealed. Waterproof RJ45 connectors and IP69K-rated panel mount housing receptacles help safeguard critical links in smart cities, public safety networks, and enterprise-grade wireless systems.
Field sensors, irrigation controllers, and automated feeders often sit out in the elements, exposed to mud, water, and dust. Circular M12 connectors rated IP67 and above offer robust sealing for these setups. Rugged panel-mount connectors also make it easy to tie equipment back to control cabinets in livestock, greenhouse, or pump sheds.
Without IP-rated connectors, equipment failures can endanger livestock and crop health.
In retail point-of-sales systems, digital signage, and public kiosks, connectors must survive spills, humidity, inclement weather and cleaning. IP66/67 panel-mount connectors protect digital displays in transportation hubs or stadiums, while waterproof Ethernet connections support outdoor surveillance and access systems.
Equipment failures can have a major bottom-line impact with lack of consumer trust, site safety and process flow.
Vehicles, tactical equipment, and communication devices face shock, dust, and water exposure. M12 locking connectors with IP67/IP68 ratings can withstand these extreme conditions. Public, private, and military sectors often rely on IP67+ circular connectors with locking mechanisms and sealed back shells in these settings. Electrical equipment connectors in panel-mount versions housed in sealed enclosures deliver stable power and signal transmission across aircraft, rail, or defense-grade mobile systems.
Selecting the right electrical equipment connector and ingress protection rating requires a complete understanding of where and how they will be installed, used, cleaned, and maintained. The following IP rating chart provides a general breakdown for contract manufacturing manufacturers, product/system design engineers, and procurement managers.
Materials are part of the selection process, so having access to a distributor supplying circular connectors in nylon, metal, and stainless-steel housings with IP-rated seals is vital. The person ordering and providing specifications/designs for any system must understand all these aspects. This enables them to match the IP rating and connector material to the chemical, UV, or temperature exposure expected in the field.
Every project has a tight timeline and budget, so the best connector available at the right time, quantity, and prices requires a distributor with inventory depth and competitive pricing.
Working with an experienced distributor offers the advantage of in-house experts who can help you find the right connectors for your needs and save money on component sourcing.
To find the right IP rated connector in the style and quantity you need from thousands of in-stock options from trusted manufacturers, explore our selection or contact us to learn more about how we can help.