In the world of industrial automation, the details matter. Understanding the difference between a UL-listed and a CE-marked component, or knowing why you need an IP69K-rated connector, can be the key to a successful, reliable project.
We’ve created this no-nonsense glossary to demystify the key terms you’ll encounter when specifying, buying, and installing high-performance connectivity solutions.
For Field Installers & System Integrators
These are the terms that matter when you’re on-site, getting the job done right the first time.
| Term | A Simple Definition | Why It Matters for Your Project |
| Bend Radius | The minimum radius a cable can be safely bent without damaging the conductors or shielding inside. | Respecting the bend radius is crucial. Forcing a cable into a tighter bend than it’s designed for can cause signal loss, data errors, and premature failure, leading to callbacks. |
| Strain Relief | A component, usually part of a cable gland or clamp, that absorbs pulling and bending forces at the connection point. | Without proper strain relief, vibrations and accidental tugs will put all the stress directly on the delicate wire terminations inside the connector, which is a primary cause of connection failure. |
| IP69K Rating | The highest Ingress Protection rating. It certifies that a component is completely dust-tight and can withstand high-pressure, high-temperature water jets. | This is essential for equipment in food & beverage or pharmaceutical plants that undergo intense daily wash-downs. An IP69K-rated connector ensures zero water ingress, preventing corrosion and short circuits. |
| Cable Gland | A fitting used to securely attach and seal a cable as it enters a piece of equipment or an enclosure. | A high-quality cable gland is your first line of defence. It provides strain relief, creates an environmental seal (IP rating), and in the case of EMC glands, grounds the cable shield. |
| Shield Termination | The process of connecting the cable’s metallic shield (braid or foil) to ground, providing a 360° low-impedance path for electrical noise to escape. | Doing this correctly is critical for preventing EMI. An improper shield termination renders the best shielded cable useless, leading to phantom errors and system instability. |
| Crimping | Using a specialized tool to mechanically bond a terminal or contact to a wire, creating a secure and gas-tight connection. | A good crimp is electrically and mechanically sound. A bad crimp (made with the wrong tool) can lead to high resistance, overheating, or the wire pulling out under vibration. |
| M12 / M8 Connectors | Rugged, circular connectors that are the industry standard for connecting sensors, actuators, and fieldbus devices in industrial automation. | Knowing the different codes (e.g., A-code for sensors, D-code for Ethernet) is key to a fast and error-free installation. Using these standardized connectors ensures compatibility and reliability on the factory floor. |
For Technical Buyers & Procurement
These are the terms you’ll find on spec sheets and compliance documents that ensure you’re sourcing the right, compliant products for your project.
| Term | A Simple Definition | Why It Matters for Your Project |
| UL Listed | A certification mark from Underwriters Laboratories (UL) indicating that a product meets recognized safety standards for North America. | If your machinery is being exported to the US or Canada, having UL-listed components is often a mandatory requirement for customs clearance and site acceptance. |
| IP Rating | (Ingress Protection) A two-digit code that classifies how well a product is sealed against solids (first digit) and liquids (second digit). | This is not negotiable. You must match the IP rating to the environment. Specifying an IP67-rated connector for a wet or dusty area prevents premature failure and costly downtime. |
| CPR Classification | (Construction Products Regulation) A European standard (Euroclass) that rates cables on their reaction to fire (e.g., flame spread, smoke, etc.). | For projects that require high fire safety standards, such as public buildings or critical infrastructure, specifying a cable with a Cca or B2ca rating ensures you meet modern safety codes. |
| LSZH | (Low-Smoke, Zero-Halogen) A type of cable jacketing material that produces very little smoke and no toxic halogen gases when it burns. | In enclosed spaces like tunnels, ships, or office buildings, LSZH cables are critical for safety. They improve visibility during an evacuation and don’t release corrosive gases that can damage sensitive electronics. |
| ATEX Certified | A certification for equipment intended for use in potentially explosive atmospheres (e.g., oil & gas facilities, chemical plants). | Sourcing ATEX-certified components is a legal requirement in hazardous zones. It ensures the component will not create a spark that could ignite flammable gases or dust. |
| AWG vs. mm² | Two different systems for measuring wire size. AWG (American Wire Gauge) is common in North America, while mm² is the standard in Europe and Asia. | You need to be able to cross-reference these when specifying products. A mismatch could lead to ordering the wrong size cable or connector for the required current capacity. |
| Total Cost of Ownership (TCO) | A financial calculation that includes the purchase price of an asset plus the direct and indirect costs of operation over its entire lifespan. | A premium component might have a higher initial price, but it results in a lower TCO by reducing costs associated with downtime, maintenance, and replacement. |
For Design Engineers & Specifiers
These are the advanced technical concepts that ensure a system is designed for maximum performance and reliability from the start.
| Term | A Simple Definition | Why It Matters for Your Project |
| Class 2 Copper Strands | A coarser stranding of copper conductors, typically found in cables designed for fixed installation or occasional flexing (e.g., in building wiring). | While cost-effective for stationary applications, Class 2 strands are not designed for repeated motion. Using them in cable chains or robotics will lead to early conductor breakage. |
| Class 5 Copper Strands | Finer, more flexible stranding of copper conductors used in cables designed for frequent flexing and movement (e.g., in drag chains). | Cables with Class 5 stranding are significantly more durable in dynamic applications, resisting fatigue and breakage from constant bending. Essential for reliable motion. |
| E-Beam (Electron Beam) Crosslinking | A process where cable insulation material is exposed to electron beams, which improves its mechanical strength, temperature resistance, and chemical resistance. | This advanced manufacturing technique makes cable jackets and insulations tougher, allowing them to withstand higher temperatures, harsher chemicals, and more abrasion without degrading. It enhances long-term reliability in extreme environments. |
| Drag Chain Cable | A cable specifically designed with high-flexibility conductors and abrasion-resistant jackets to survive millions of bending cycles inside a moving cable chain. | Using a standard cable in a drag chain is a guaranteed failure point. A true drag chain cable is essential for the reliability of any ASRS, gantry robot, or moving machine. |
| Torsion-rated Cable | A cable engineered to withstand repeated twisting along its axis (e.g., ±180°/m), which is common in robotic arms and wind turbine loops. | Standard cables will fail quickly under torsional stress as the internal conductors bunch up and break. A torsion-rated cable ensures the long-term reliability of rotating machine parts. |
| Hybrid Cable | A composite cable that combines different types of components—such as power, data, and even fibre optics—within a single, rugged jacket. | In complex robotics and moving machinery, a hybrid cable saves a huge amount of space, reduces installation time, and simplifies cable management compared to running multiple separate cables. |
| Single Pair Ethernet (SPE) | A new technology that transmits Ethernet data and power over a single twisted pair of wires, ideal for connecting sensors and actuators in IIoT systems. | SPE allows you to extend the reach of your Ethernet network deep into the field with simpler, lighter, and more cost-effective cabling, breaking down old fieldbus communication barriers. |
| EMC | (Electromagnetic Compatibility) The ability of a system to function correctly in its electromagnetic environment without generating or being affected by electrical noise. | Achieving good EMC is a system-level goal. It requires a combination of shielded cables, proper grounding, and EMC-rated glands and connectors to prevent interference and ensure reliable operation. |
| MICE Rating | A system for classifying the harshness of an industrial environment based on four factors: Mechanical, Ingress, Climatic/Chemical, and Electromagnetic. | Using the MICE framework helps you specify the exact level of robustness needed for your cables and connectors, ensuring you don’t over-engineer (and overpay) or under-engineer (and risk failure). |
For Facility & Maintenance Managers
These are the terms focused on long-term reliability, safety, and keeping the plant running smoothly after installation.
| Term | A Simple Definition | Why It Matters for Your Project |
| Insulation Resistance Test | A preventive maintenance test where a high DC voltage (“Megger test”) is applied to a cable to measure the integrity of its insulation. | A low reading indicates that a cable’s insulation is degrading, possibly due to moisture or physical damage. This test helps you find and replace failing cables before they cause a short circuit or a safety hazard. |
| Thermal Imaging | (Thermography) The use of an infrared camera to scan electrical panels, motors, and connections to find abnormally hot spots. | A hot spot is a clear sign of a problem, such as a loose connection or an overloaded circuit. Regular thermal scans are a powerful, non-invasive way to predict failures before they happen. |