Explanation of Damaged DC Connector Case

Explanation of Damaged DC Connector Case


In the cases where happened a melted connector(s), it is almost always due to

either of two reasons:

1. Incompatible connector types been used together.

2. Faulty crimping of DC cable.

When the connection is not secure, there is a resistance across the connection, which causes heat. As DC power is constant, the heat builds up and will cause the connection to oxidise even more,

causing more resistance. Eventually the heat builds up and melts the plug casing. In rare cases, it can catch fire.



Example of a burnt connectors

IEC 62548 IEC 62109-1 IEC 62109-2 specifies that the DC connector and socket must be the same manufacturer and type. If different brands of plugs and sockets are used, the connection may not be

made properly. Or, the inner sleeve may be pushed back into the plug body and not connect properly.

In case of faulty workmanship, the plug insert may not be properly crimped or terninated into the cable. Below is a correctly crimped termination. Note, the correct tool must be used.


 Must be solid and tight

 
 The cross sections showing that they have been crimped by correct tool

 
 The ones that they have been crimped by improper tools
  

How do we know it was caused by the bad connection?

It’s easy to know that the damage will be concentrated at the point of maximum heat.

In the below example, we can clearly see that the areas just above and below are not

heat damaged.So, the heat is exactly where the connection iss
​

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