21/01/2022

Which M12 Termination Method Should You Choose?

In many automation applications, the importance of “the connector” is often underestimated, including in industrial automation. From the production processes in consumer packaged goods (CPG) to the cloud, connectors impact performance at every level of an automation network.

IIoT environments demand smart devices—PLCs, IPCs, human-machine interfaces (HMIs), robots, cameras, sensors, and more. All of these devices need to connect to the network. If it’s a wired connection, then the device will also need a connector. This connector acts as an essential link between network nodes.

Reliability

Although M12 connectors were originally designed for sensor signal processing, they have become vital in industrial power and data transmission applications. They are used to connect components like sensors, actuators, switches, PLCs, and I/O-boxes.

This connectivity technology is crucial for capturing, processing, and transmitting data from increasingly intelligent machines. These systems support automated, responsive decision-making in production processes. Data must be transmitted through highly reliable, high-speed connections that can withstand elements like dust, noise, extreme temperatures, and vibrations. The M12 connector provides the speed, reliability, and robustness needed in today’s automation environments and offers connectivity that supports:

Lower maintenance costs

Increased safety

Enhanced efficiency

Reduced downtime (In CPG environments, reducing downtime is essential, as even a few minutes of lost production can lead to significant raw material waste.)

M12 Termination Methods and Their Importance

Field-attachable connectors are ideal for applications where cable lengths can’t be predetermined. This type of connector allows for on-site cable cutting to the required length before attaching the connector.

There are three classic M12 termination methods for connecting cables to M12 connectors in the field. Whichever option you choose, the first step is always to prepare the cable for connection. Begin by sliding the gland, handle, and housing over the cable to secure it after stripping.

The termination method can affect connector performance and the amount of repair work required by maintenance teams. Here’s an overview of these three classic termination methods:

1. Insulation Displacement Contact (IDC) Termination

IDC termination, also known as self-locking, allows for a quick, easy installation and is the most popular termination method in industrial and harsh environments.

To complete the termination process, strip the cable after threading the hex nut over a cable with a typical diameter of 6–8 mm (22 AWG to 26 AWG). For shielded cables, fold back the braid and wrap the drain wire around it. The cable is then ready for wire management according to TIA color codes for Cat 5e, Cat 6, Cat 6A, etc.

After inserting the wires into the wire manager, trim any excess wire beyond the load bar/wire manager, then insert the load bar into the IDC portion of the plug. The grounding wire should connect to the grounding path, either via a grounding wire on the connector housing or by connecting to the hex nut. This choice depends on the grounding design of the connector.

Next, slide and tighten the coupling nut onto the plug housing. Based on installation guidelines, a wrench may be required to fully tighten it.

Since this method doesn’t require a punch-down tool, IDC termination is a cost-effective and relatively easy installation process.

Available IDC Products: Hirschmann and Lumberg Automation offer IDC products in D- and X-coded variants, such as BRSCCS, BSCIS, RSCIS, and 0986 EMC 600. RJ45 versions with M12 round strain relief are also available.

2. Screw Termination

The screw termination method is a classic technique that has been used for several years.

The process begins with preparing the cable for assembly. After stripping the cable jacket, individual wires must be stripped to ensure reliable contact. Stripped wires require additional ferrules, which must be crimped before inserting them into the contact holes of the cable socket or plug.

Ensure the necessary insulation for pin 5. Insert the wires to the bottom of the contact holes and tighten the contact screws (clockwise to tighten, counterclockwise to loosen). Assembly is now complete.

Attention to detail is crucial in the final assembly step, as this is one of the most important stages to maintain the integrity of the sealing system.

Available Screw Termination Products: Hirschmann and Lumberg Automation offer M12 and M8 screw termination product lines in a wide variety. Shielded and unshielded versions, straight and angled, as well as brass and stainless steel options, are available. A-, B- of D-coded options are available with 3, 4, 5, or 8 pins, with or without LEDs.

Choosing the Right M12 Termination Method for the CPG Market

In most industrial automation environments, including the CPG sector, selecting the right termination method means balancing cost, reliability, and installation time. Here are some guiding questions:

What are the maintenance requirements?
How often will connectors need to be replaced?
Do I need to meet a specific IP rating?
What are the vibration levels in my environment?
How much time do we have for installation at each node?
What is our budget for connectors?

Different nodes within the same application may have entirely different requirements. For this reason, the CPG market demands unique connectivity solutions and M12 termination methods tailored to location-specific needs. Lumberg Nederland supports these needs through our customization program.