Connectors for On-Board Electrical Systems and Vehicles – All Designs at a Glance
In on-board electrical systems, plug connections are the points where electricity has to cross a separation point – and this is precisely where most malfunctions occur. Moisture and salt spray attack contacts, corrosion increases contact resistance, and higher contact resistance means voltage drop and heat at precisely the worst spot. Then there's vibration: anything constantly moving on board in rough seas or in a vehicle on a poor road will work itself loose if the connection isn't locked and the cable isn't strain-relieved. Therefore, the reliability of a system is not determined by the price of a plug, but by selection based on four criteria: protection class at the installation site, current carrying capacity per contact, number of poles including protective conductor – and the consistent separation of AC shore power and DC on-board electrical system to prevent any confusion. In this category, you will find the designs for this, supplemented by selected assortment brands from philippi's own production in Germany.
Shore Connection (AC 230 V) CEE surface-mounted device plugs, coupler sockets, and pre-assembled connection cables are available for shore power connection. The CEE device plugs from Mennekes are available splash-proof with a sliding cover (CEE-GSS, CEE-GSK, IP X4, 2+PE, 230 V/50 Hz, 16 A) and in the waterproof version CEE-GS wd with IP X7 for exposed installation locations, along with matching coupler plugs and sockets. The MP series from Ratio covers surface-mounted device plugs and coupler sockets in 16 A, 32 A, and 50 A (MP 16-10, MPS 32-16, MP 50-10, MPS 50-110) and supplements them with CEE extension and Marinco adapter cables, a railing hook, and a carrying bag. For 230 V connections within the on-board electrical system itself, philippi offers the Series 692 as a 2+PE variant and the Series 694 as a 4+PE variant – the latter for AC 400 V.
Waterproof Circular Connectors Series 692 and 694 The core system for detachable cables on deck and on the vehicle body. The Series 692 is available in 2-, 4-, and 7-pole versions, has IP67 according to VDE 0470, a glass-fiber reinforced PBT housing, silver-plated contacts, and screw terminals; the 2-pole version carries 16 A per contact, the 7-pole version 10 A per contact with a 1.5 mm² connection cross-section. Typical applications include navigation lights (2- and 4-pole) and wind measuring systems (7-pole). The Series 694 goes up to 5-pole (4+PE), 13-pole, 24-pole, and a coaxial version, with IP65, 20 A per contact, and 400 V rated voltage according to VDE 0110. Both series are tested by Germanischer Lloyd and approved for watercraft. The screw locking mechanism keeps the connection closed even with vibration. Accessories include flange plugs and flange sockets for fixed mounting, coupler plugs and coupler sockets for connecting two cables, surface-mount housings and angled housings (692: L 56 x W 53 x H 36 mm) for deck mounting when a straight feed-through is not possible, triple surface-mount housings, flange rings, protective caps for unused connections, as well as protective covers and protective brackets. For pluggable data lines – such as wind measurement and fluxgate compass – there is the subminiature circular connector 720 with IP67, gold-plated contacts, snap-in locking, and 7 A (3-pole) or 5 A (5-pole) per contact.
DC High Current Connectors Where outboards, wind generators, hydro generators, solar modules, or electric drives are connected, the cable must remain detachable without loosening the wiring. The PC 65 Set from philippi transmits max. 65 A DC at 6–16 mm², is waterproof to IP68 when plugged in, is connected tool-free via spring force, and is locked against unintentional disconnection; positive and negative are color-coded. The LB 80 delivers 80 A at max. 96 V – thus also for 24 V and 48 V on-board electrical systems – with silver-plated E-Cu contacts, connection cross-section up to 25 mm², IP23, and a holder for vibration-proof mounting. Additionally, there is a 150 A high-current connector from EP-Technologies. The magnetic MagCode connection consisting of flange socket MCF and plug MCS for 12 V and 24 V is currentless when not plugged in, making it short-circuit proof.
DC Connectors 12/24 V Standard and universal plugs, couplers, twin couplers, adapter and extension cables from pro-car for everyday 12 and 24 V consumers (NS 12/24-15, USL 12/24-8 A, SUS and SWS cigarette plugs, KP 12/24, ZKP 12/24). Also, flush-mount and surface-mount sockets with covers (ESD 12/24, ASD 12/24, DSD 12/24) as well as the WSD 12/24 with screw cover, IP67, 6–24 V, max. 16 A, mounting hole Ø 18 mm and 30 cm potted connection cable. From philippi come flush-mount sockets with covers in round and square versions as well as the surface-mount socket AZS.
USB Charging Sockets Flush-mount, surface-mount, and dual charging sockets with USB-A and USB-C, with PD and QC, for 12 and 24 V on-board electrical systems – from pro-car (USC, USCC, USC 50, USC 60, USD 12/24 A, USF, CW), alfatronix (USD GW, USD FM) and Blue Sea Systems (USV). Matching covers and mounting plates keep contacts dust and moisture free when not charging.
Sockets and Switches For interior finishing, there are 230 V flush-mount sockets from the ND 230 series in versions for Germany, Great Britain, Switzerland and the USA, low-voltage sockets KD 12/24, cigarette lighter sockets ZD 12/24, rocker switches and rocker pushbuttons (ES 230, ET 230), media connections for TV, HDMI and coax, as well as frames, hinged covers, spacer rings, blanking plates and surface-mount housings for combination. For cable routing through the deck, there are deck glands DD 06 and DD 10 from philippi and DDK from Quick.
Are you unsure which design, number of poles or protection class is suitable for your on-board electrical system? Our team will advise you personally – from individual separation points to complete system planning.
FAQ
What protection class do I need on deck? For installation locations exposed to splash water, rain and overtopping water, you should opt for IP67 or higher – for example, Series 692 (IP67), the subminiature circular connector 720 (IP67) or the flush-mount socket WSD 12/24 (IP67). IP X4 is splash-proof and should be in protected areas. Indoors, lower protection classes are sufficient, as mechanical securing is more important there.
Why do consumers fail even though the battery is full? Very often the cause lies in a plug connection. Corroded or loose contacts increase the contact resistance, causing voltage to drop at the separation point instead of at the consumer, and the connection gets warm. First check the plug connections along the affected line before suspecting the battery or device.
How much current can I run through a connector? The crucial factor is the rated current per contact, not the total current of the plug. The Series 692 is designed for 16 A per contact in 2-pole versions and 10 A per contact in 7-pole versions, while Series 694 is designed for 20 A per contact. For higher currents, there are high-current connectors such as the PC 65 (max. 65 A DC) or the LB 80 (80 A).
What is the difference between a coupler and a flange? Coupler plugs and coupler sockets connect two cables together and sit freely in the line. Flange plugs and flange sockets are permanently installed in a wall, panel, or housing. For mounting a flange part on deck, there are surface-mount housings, and for confined spaces, the 90-degree angled housing.
Can I use the same connector for 230 V shore power as for 12 V? No. AC shore power and DC on-board electrical systems require different, non-interchangeable connectors with a protective conductor on the AC side. For 230 V, use CEE connectors or versions with PE – such as 2+PE of Series 692 or 4+PE of Series 694 for 400 V.
Do the connectors work on boats and in vehicles? Yes. The assortment is designed for marine and vehicle applications – philippi's waterproof circular connectors and high-current connectors are used on yachts as well as in motorhomes, campers, and expedition vehicles, and the category can therefore be found under both Marine and Offroad.
