Too many cordset options? Start here.

Connector types, pin counts, cable lengths, jacket materials, shielding options and environmental ratings all influence cordset selection.

With so many variables involved, narrowing down the options can quickly become frustrating.

A structured approach can make the process much easier.

Why there are so many cordset options

Cordsets support signal transmission, power distribution and industrial Ethernet communications across automation systems.

They may also need to operate in environments where moisture, washdown, abrasion, movement or electrical noise are present.

As a result, manufacturers offer a wide range of connector styles, cable constructions and configurations designed for different operating conditions and installation requirements.

Start with the application

One of the quickest ways to reduce the number of cordset options is to identify whether the application requires signal, power or data transmission.

Signal cordsets are commonly used to connect sensors, actuators and I/O devices to the control system.

Power cordsets distribute power to equipment such as motors, drives, lighting and field devices.

Data cordsets support communication between PLCs, I/O modules, drives and other networked devices across industrial Ethernet networks.

Starting with this distinction immediately eliminates large groups of unsuitable options and provides a clearer starting point for the selection process.

Narrow down the connection requirements

Once the application type has been identified, the next step is to narrow down the connection requirements.

Factors such as connector size, pin count, power requirements and communication protocols can quickly reduce the number of suitable options.

For example, a sensor connection may require a different connector style to an industrial Ethernet connection or a high-current power application.

Addressing these requirements early helps focus the search on cordsets designed for the intended purpose.

Consider the operating environment

After narrowing down the connection requirements, operating conditions can help refine the options further.

For example, a cordset used on a static machine inside a control cabinet may have very different requirements to one exposed to washdown conditions, continuous movement or high levels of electrical noise.

Factors such as moisture, abrasion, flexing and electromagnetic interference can influence cable construction, jacket material and shielding requirements.

Identifying these conditions early helps eliminate options that are unlikely to perform reliably in the intended environment.

This can significantly reduce the number of cordsets under consideration and make it easier to focus on products designed for the operating conditions at hand.

Standard or custom?

Many applications can be addressed using standard cordsets available in a range of connector types, pin counts and cable lengths.

In some situations, however, a standard option may not be the most practical solution.

Custom lengths can help reduce excess cable, while custom connector combinations, terminations and wiring configurations can simplify installation and reduce the number of individual components required.

For machine builders, this can create opportunities to simplify assembly and better align connectivity solutions with the requirements of the machine.

Determining whether a standard or custom solution is needed can further reduce the number of options and help focus the search.

Making the process easier

This is where selection tools can help.

Rather than searching through product catalogues or comparing part numbers individually, selection tools allow users to narrow the field by answering a series of practical questions.

Diagram above: Banner Engineering's cordset selection tool narrows options based on application requirements.

Banner Engineering's cordset selection tool follows this approach. Starting with the application type and then working through a small number of additional requirements helps reduce a large number of potential options to a smaller group of relevant solutions.

Each answer narrows the field further, making it easier to identify cordsets suited to the intended application.

Conclusion

Starting with a few simple questions about function, operating conditions and connectivity needs can quickly narrow the field and make the selection process more manageable.

A structured approach helps focus the search, reduce the number of options under consideration and identify suitable solutions faster.

Tools such as Banner Engineering's cordset selector are designed to support that process, helping engineers, OEMs and machine builders find relevant cordsets more efficiently.