IP68 certification for waterproof electrical connectors

Various regulations and standards govern the use of IP68 connectors, depending on the industry and specific application. It’s important to note that the “IP68” designation itself isn’t a certification, but a degree of protection defined by the IEC 60529 (EN 60529) standard, also known as the “IP Code.” This international standard classifies the degree of protection offered by an enclosure against the ingress of solid objects and liquids.

IEC 60529 defines the IP68 degree of protection. However, depending on the industry and application, other regulations and standards may apply. It is essential to verify industry-specific requirements and local regulations, as well as consult the manufacturer’s specifications, to ensure the correct selection and use of IP68 connectors. Careful consideration of these aspects is crucial to ensuring the safety, reliability, and regulatory compliance of the installation.

Generally, the higher the number associated with the IP rating, the greater the device’s ability to resist dust and liquids. The maximum achievable level of protection is IP69, although for consumer electronics, such as smartphones and similar devices, the most common ratings are IP67 and IP68.

An important detail to consider is the presence of an X in place of one of the numbers: this indicates that the manufacturer has not provided data relating to that type of protection. For example, an IPX7 certified device will have level 7 protection against liquids, but will not be certified against dust.

Below is an overview of the various levels of protection defined by the International Protection standard (IEC 60529).

The first number in the IP acronym indicates the level of resistance to solid objects or dust. The higher the number (0 to 6), the greater the protection. Here are the defined levels:

• 0: No protection.
• 1: Protection against solid objects with a diameter greater than 50 mm.
• 2: Protection against solid objects with a diameter greater than 12 mm.
• 3: Protection against solid objects with a diameter greater than 2.5 mm.
• 4: Protection against solid objects with a diameter greater than 1 mm.
• 5: Partial protection against dust (not enough to impair the operation of the device).
• 6: Complete protection against dust (no infiltration).

The second number of the IP acronym specifies the device’s resistance to liquids, with protection levels ranging from 0 to 9:

• 0: No protection.
• 1: Protection against vertically falling drops of water.
• 2: Protection against falling drops of water at a maximum inclination of 15° from the vertical.
• 3: Protection against rain or water jets at an angle of up to 60° from the vertical.
• 4: Protection against splashes of water from any direction.
• 5: Protection against low pressure jets of water directed from any direction.
• 6: Protection against high pressure water jets or waves.
• 7: Protection against temporary immersion in water (depth between 15 cm and 1 m, for up to 30 minutes).
• 8: Protection against permanent immersion in water (depth and duration specifications defined by the manufacturer, generally up to 3 m for 1 hour).
• 9: Protection against permanent immersion in water and against high-pressure, high-temperature water jets (e.g. high-pressure washing).

Additional notes

• To correctly interpret the degrees of protection, it is advisable to refer to the official tables of the IEC 60529 standard, which has international value.
• It is essential to consult the manufacturer’s technical specifications, as IP rating tests may include specific conditions (e.g., duration of immersion, pressure, temperature, etc.).
• In critical applications, be sure to choose devices with the appropriate degree of protection for the operating environment.

Specific tests are performed to ensure the quality and compliance of IP68 connectors with the IEC 60529 standard. These tests verify the connector’s resistance to dust and liquid penetration, simulating the conditions the connector may encounter in its operating environment.

Here are some of the most common tests:

Fine dust test: The connector is placed in a sealed chamber containing fine talcum powder for a specified period of time. After the test, it is verified that no dust has entered the connector in sufficient quantities to compromise its functionality.

• Submersion test: The connector is immersed in water to a depth and for a duration specified by the manufacturer. The depth and duration of immersion may vary depending on product specifications. After the test, it is verified that no water has penetrated the connector in sufficient quantity to compromise its functionality.
• Pressure Test: In some cases, the connector is subjected to hydrostatic pressure to simulate immersion at greater depths. This test verifies the integrity of the connector’s watertight seal under high pressure conditions.
• Water jet tests: For some IP ratings lower than IPX8, but still relevant for assessing water resistance, water jet tests are used at various pressures and angles. While not specific to IP68, they can provide useful information about the connector’s water resistance under various conditions.

In addition to the specific IP protection tests, other tests can be performed to evaluate the quality and performance of the connector, such as:

• Mechanical resistance tests: These test the connector’s resistance to shock, vibration and bending.
• Thermal Resistance Tests: These test the connector’s ability to function properly under extreme temperatures.
• Electrical resistance tests: They check the connector’s ability to conduct electrical current efficiently and safely.
• Durability tests: They simulate the use of the connector over time, verifying its resistance to wear and corrosion.

It’s important to note that tests must be performed according to standardized procedures and by accredited laboratories to ensure the validity of the results. Manufacturers of quality IP68 connectors typically provide documentation certifying their products’ compliance with regulations and quality tests. Verifying the presence of these certifications is essential to ensure the safety and reliability of the installation.

In addition to IEC 60529, other regulations and standards may be relevant for the use of IP68 connectors:

• Industry-specific standards: For example, in the automotive industry, there are specific standards that define the requirements for connectors used in vehicles. Similarly, in the medical or military sectors, specific regulations govern the use of connectors.
• National regulations: Some countries may have additional regulations or specific interpretations of international standards. It is important to check local regulations before using an IP68 connector in a particular country.
• Product certifications: In addition to the IP rating, connectors may have other product certifications that attest to their compliance with specific safety and performance requirements. For example, the CE marking indicates the product’s compliance with European regulations.
• Manufacturer Specifications: Connector manufacturers can provide detailed technical specifications for their products, including test conditions for IP68 certification (submersion depth and duration). It is essential to consult the manufacturer’s specifications to ensure the connector is suitable for your specific application.