WHITEPAPER
How to Specify High Voltage Connectors

J U LY

2020

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HOW TO MOST EFFECTIVELY SPECIFY HIGH VOLTAGE CONNECTORSFOR YOUR APPLICATION
Experienced insights for superior results
Specifying the right connector can have an enormous impact on the ultimate quality of your product or research equipment, both in the efficacy and longevity of its performance as well as theongoing safety of its operation. This is true, of course, with any connectors, but with high voltage
connectors the necessity is more urgent still. Indeed, the carrying of higher voltages and/or thetendency for more sensitive operations can not only bring with it increased safety concerns for
operators, patients, technicians, manufacturers, surrounding communities and other stakeholders, but also often presupposes the increasing threat of generating arcs or coronas, which canlead to reduced reliability and premature failure of the equipment.
While most equipment manufacturers understand that the engineering capabilities, advanced
materials knowledge and other experience needed to develop effective high voltage connectors
is far more extensive than that needed for their lower voltage cousins, and thus seek out provenexpertise accordingly, many do not realize the value of forming an informational alliance with
their selected high voltage connector partners. Indeed, optimum selection can involve much
more than merely selecting a part number; there can be numerous other aspects to understand,consider and discuss in order to benefit from optimum results for the long term. These might
include defining the impact of operating conditions, appreciating the various voltage levels that
may be involved, selection of safety mechanisms to be built in, and more.
If application specific information is not provided, it is incumbent upon the equipment manufacturer to at least determine and communicate the appropriate technical regulations and standards
that will impact the application. This will provide the experienced high voltage connector supplierwith valuable information for appropriate design specifications. Providing this information is avital first step, and you and your supplier can work together to communicate additional details
from there.
Regulations we often see, for example, originate from the International Electrotechnical Commission (IEC) and can include 60601-1, 60664-1 and 61010-1. Industry specific standards fromautomotive or medical organizations or specialized research institutes often impact operationand salability or legal usability and should also be identified and communicated. If the final product needs to meet Underwriters’ Laboratory (UL), Canadian Standardization Association (CSA)or International Organization for Standardization (ISO) testing requirements, this would be useful
information to impart as well.

Figure 1
IEC building based in Geneva
Switzerland

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In this white paper, LEMO engineers and designers specializing in high voltage connectors will
work to provide readers with an insider perspective, and take some of the mystery out of highvoltage connector specification. With this understanding, manufacturers and operators will beable to better specify the high voltage connector that will allow them to design equipment thatwill deliver maximum performance, optimum longevity, long-term reliability and ultimate safety
for all stakeholders.

WHAT IS “HIGH VOLTAGE” ANYWAY?
It is important to understand—and then not worry too much about—that there is no particularspecific voltage “number” at which the “high voltage” category begins. What constitutes “high”
varies by industry and application, and, more importantly, high voltage connectors in some cases
are vital in applications where there is, almost inarguably, fairly low voltages involved.
For example, there is an old rule of thumb amongst industrial manufacturers that anything above
50 volts can be potentially hazardous for humans to handle or to come into contact with undercertain circumstances, so over 50 volts might be considered “high” in that context. And, indeed
many manufacturers of medical devices that may go inside the body often specify high voltage
connectors—with the extra protections inherent to them—for their products even though the voltage involved may be even less. On the other hand, in an industry such as power transmission,
which is accustomed to handling extremely electrified equipment and infrastructure, the word“high” might not even be applied until 30,000 volts or more are involved.

Figure 2
Electrical arc, due to the flow of electric current through the air gap between two conductors,
causing plasma

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Experienced high voltage connector manufacturers find that for every extremely “high number” voltage application in medical and research-driven instrumentation such as supercolliders,
plasma technology, electron beams, nuclear physics, photolithography, x-ray imaging, neutron
microscopy and similar applications, there are always “low number” applications such in-bodyelectronics like LVAD (Left Ventricular Assist Device) devices and electrophysiology catheters, aswell as microelectronic and circuit board applications that demand the extra degree of protection
against arcs, coronas and other dangers and so use only high voltage connectors.
For some additional context, the IEC has a working rule of thumb setting the threshold of “highvoltage” at 1000 volts. We at LEMO, based on where we observe clusters of requests for “highvoltage” connectors from our customers, often think of the high voltage segment of the connector market as starting at equipment at about 500 volts.
However, the key message in this regard is that, while it is vital to correctly understand andquantify the voltage(s) relating to your product or piece of research or testing equipment, it is notthis number alone which should determine whether a “high voltage” connector is right for yourapplication. The ultimate designation should be based upon the function of the end product,
and, especially, the relative need to avoid the dangers of arcing or corona generation in use. Thisis a vital discussion which will be pursued later in this white paper, after some more fundamental
concepts are presented.

VOLTAGE IS NOT ONLY ONE NUMBER
When designing components for customers, experienced high voltage connector manufacturers
often think of the voltage requirements as at least three distinct numbers, not just one. This is
an important concept for product manufacturers to understand in order to get the most effective
connectors for their needs, and it should be food for discussions with their chosen high voltage
connector manufacturer partner. Certainly, the more the high voltage connector manufacturer
understands the specific real world needs of the application, the more on target their connector
design will be, and the more reliable and effective their customer’s product or equipment will be.
So, let’s look into this concept.
Often, the default meaning of voltage is operating voltage or working voltage—the typical voltage used when the equipment is new and operating under “optimum,” “pristine” conditions.
This is the number that, at a minimum, might be supplied by a product or equipment manufacturer to their high voltage connector partner when they are determining the requirements of a
new design.
Perhaps more useful—and practical—is the concept of test voltage. Test voltage assumes thedemand of the device under the theoretical poorest conditions. These detrimental conditions—sometime called pollutants—can include: Altitude
Air density is impacted by the lower pressures found at higher altitudes, so the elevation atwhich the product will be used can have significant impact on its voltage requirements.

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As a rule of thumb, requirements are assumed at sea level, but designs should be provided
with enough threshold to encompass up to 2000m above sea level. If, for example, a piece oftest equipment will be used in a mountainous area at an even higher altitude, this fact should
be shared with the high voltage connector manufacturer. Impacts on design to ensure efficacy
can be substantial; for example, usage at an elevation of 5000m requires an adjustment of
48% in a crucial design specification. The impact can be even more critical in aviation andaerospace applications—usage at 20,000 meters, for example, might demand a correction of
14x or more.
Altitude (m)Coefficient

2000

1.00

3000

1.14

4000

1.29

5000

1.48

Figure 3
Correction factor for high altitude
applications

Breakdown voltage (100%)

Test voltage (75%)
Safety factor

Operating voltage(recommended 1/3 of test voltage)

Figure 4
Illustration Breakdown voltage& test voltage

 Humidity
Usage in tropical areas with especially high humidity, use outdoors, or under conditions wherewide and frequent temperature fluctuations could create condensation, could impact the voltage needs of the connector.
 Grit/Dust
Equipment usage where there are commonly fine particles in the air—such as in a sawmill or
wheat mill or similar processing facility—create conditions that can allow an arc or corona
effect to be created inside or around the connector at lower voltages than would otherwise be
expected. The high voltage connector design needs to compensate accordingly.
 Temperature
All materials have temperature limits—limits that will be tested as the current passing throughit heats it significantly. If ambient temperatures are much higher than typical room temperatures—in an industrial environment in a tropical climate, for example—limits could be reachedat lower relative voltages and design would need to be modified accordingly.

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As a default, test voltage might be assumed to be 3x operating voltage to provide ample headroom; however, if the machinery will be used during especially challenging conditions—suchas those described above—then this fact should be shared with the connector manufacturer sothat even more headroom can be built in. These can sometimes be communicated in pollution
degrees, relative measures with “degree 1” meaning extremely low up to “degree 4” meaning
an extreme level of the particular pollutant. As suggested, the optimum span differences in eachcase could be significant.
Finally, responsive high voltage connector manufacturers will often test or extrapolate to determine breakdown voltage, the absolute limit voltage at which arcing or corona will occur and the
product will irrevocably fail. In the absence of specific information, the test voltage is assumed to
be 75% of the breakdown voltage. However, in some industries this can vary considerably. For
example, in some experimental work air is removed from the test environment and instruments
are operated at very low pressure. This can have great impact on breakdown voltage and should
be communicated to the high voltage connector manufacturer.

Figure 5
Corona effect visible between two electrical contacts at the surface of the connector insulator

In addition, determining these voltage numbers might be more complex still. Also important for
the high voltage connector manufacturer to know is if the voltage levels will be constant or intermittent, such as pulsing in short duration bursts of high power operation. Some applications,for example, require millisecond bursts of power. This type of duty cycle could impact designneeds as well.
Another potential pitfall that a product manufacturer might also fall into is not realizing—and notcommunicating to their high voltage connector manufacturer—that voltages might actually fluctuate substantially—albeit briefly—at start up.

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We have seen sensitive test equipment where voltage experienced can spike 2x, 3x or more for
an instant, and tax the limits of components and possibly cause failure. The potential for thisoperating characteristic should be communicated to the high voltage connector manufacturer sothat modifications can be made to avoid the threat of arcing and other damaging events.

THE DANGERS—ARCING AND CORONAS
Although the full extent of the complex physics involved may be beyond the scope of this white
paper, it is important for device manufacturers to at least have a basic working knowledge of thethreats facing high voltage and electronic equipment in use.
In general, the threats fall into two categories—arcs and coronas. Arcs are the most common
failure mode in this industry and what you will likely hear the most about. In simple terms, an
arc is basically a spark that forms and jumps between two pieces of metal or other conductive
materials due to a combination of “too high” voltage and “too close” proximity of the components relative to that voltage. When an arc occurs, it leaves a trace of carbon deposit—a burned,
ashed, charcoal-like material on the components, which significantly reduces their voltage handling capability at every level. With the breakdown voltage threshold now significantly lower, any
subsequent flow of electricity will likely cause immediate product failure.
A corona discharge is a phenomenon that occurs when electricity unintentionally flows off of thecomponents and into the surrounding air, especially under conditions of high frequency. As the
air becomes ionized, it heats up, creating a blue glow, often an audible buzz and an ozone smell,and can cause damage or failure to components around such as insulators.

THE INTRICACIES OF HIGH VOLTAGE CONNECTOR DESIGN
To help protect equipment manufacturers and their customers against the devastating effects
of arcing and coronas, high voltage connector manufacturers must develop an expertise in specialized engineering design as well as create and continually maintain a cutting edge portfolio ofadvanced materials to select from.
For example, depending upon the application, helping guard against the threat of a corona occurring often involves developing an expertise in creating components with smoothly roundededges rather than sharp, perpendicular, 90° edges. This is due to the fact that, like a car racing
around a track, sharp curves can, in layman’s terms, cause speeding electrons to veer off the
conductor or insulator and into the surrounding ambient air.
Another design concept that may be called upon is minimizing or eliminating the air surrounding
the connector components—such as replacing air gaps between conductors with additional
insulation material—so that coronas cannot form. Key in this regard is the ability to create a tighttolerance mating interface and the expert use of self-sealing materials such as fluorosilicone tohelp keep air out of the system. It is vital to let your high voltage connector manufacturer partner
know about the details of your application such as if high frequencies will be utilized so thatthese or other proper design precautions can be taken.

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When it comes to engineering in protections against the dangers of arcing, the main concept
becomes maximizing the distance between conductor pins and other metal parts inside theconnector. In fact, the distance between conductors in large part determines the voltage ratingof the connector, and the closer they are to each other the lower the voltage capabilities will be.
Since connectors are by nature relatively small components—and marketplace demands are
driving ever-smaller shell profiles—the engineering challenge becomes enlarging the distancesby artificial rather than spatial means.

Figure 6
Design with increased creepage distance between electrical contacts

This is done through engineering concepts such as creating insulative sleeves around components to create an artificially longer path and make the electrons “think” they are further apartthan they really are since they have to travel further distances to go from contact to contact.
These created distances are carefully constructed and precisely measured to ensure efficacy, and are usually reported in two ways. Creepage distance is the distance along surfaces
between the two conductors; air clearance is the distance in a straight line between them. It isthese specifications that are often codified by IEC and similar regulations to ensure adequate
voltage performance—and that’s why it is vital that your high voltage connector manufacturer
know what regulations are pertinent to the application. And, as suggested above, the distancesthat need to be created are determined not only by the different voltage demands, but also themitigating factors mentioned above such as the altitude, temperature, humidity and pollution
degree in the operating environments.

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Contact

Insulator

Air Clearance distance
Creepage distance

Figure 7
Creepage and clearance distance

Determining the best way to create the creepage distance and air clearance to optimize performance is predicated on possessing a working knowledge of the performance characteristics ofinsulative materials that have high dielectric strength such as polyoxymethylene (POM), Teflons,polyether ether ketones (PEEK), polyphenylene sulfides (PPS), fluorosilicones and silicones. In
addition, if high temperatures will also be involved in the application, then ceramics or even glass
will likely be specified as well. Many of these materials are not often utilized in the constructionof lower voltage connectors, and effective high voltage connector manufacturers must cultivate
ongoing partnerships with materials suppliers as well as understand and be able to effectively
deploy this more advanced esoteric knowledge and experience on behalf of their customers.
One such area of knowledge is understanding the concept and pertinence of the comparative
tracking index (CTI), a measurement of the electrical breakdown over the surface of an insulating material, measured in volts. Specifying materials with high CTIs helps improve creepage
distances; however all materials also have tradeoffs such as relative temperature performanceor resistance to radiation and steam sterilization, vital performance characteristics for medical
devices and other equipment. It is here where the strategic selection of advanced materials becomes both an art and a science.
It is also worth noting that there are a number of design subspecialty niches within the highvoltage connector specialty itself. These include high voltage hermetically sealed connectors
for environments that not only have the challenge of high voltage, but vacuum environments aswell. In these applications, additional engineering and materials knowledge is required to provide
effective connectors. For example, in LEMO’s case, these connectors make use of ceramic tometal construction with materials including alumina ceramic, moly-manganese and nickel plating. Further, knowledge of sealing techniques and their relation to ambient temperatures is vitalin the deployment of O-rings, welds or ultra-low leakage bonded ceramic or glass seals.
In addition, high voltage applications tend to be relatively low current, but some applications inhigh end research facilities and power generation facilities might require connectors that canoperate effectively in both high voltage and high current environments. This would call for “highpower” rather than “high voltage” connectors, a separate line that requires additional design
expertise still.

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As important as this knowledge and expertise is, perhaps the most important aspect of highvoltage connector manufacture has yet to be explored. This is another huge difference between
design criteria unique to high voltage connectors and can be literally the difference between lifeand death for users of the ultimate device. This is the safety engineering.

THE SPECIAL ENGINEERING OF SAFETY DEVICES IN HIGH VOLTAGE
CONNECTORS
Unlike standard connectors, high voltage connectors are built with additional safety protections
to help ensure that the connector will not be disconnected while it is live, protecting operators,
patients and other stakeholders from the risk of burns or electric shock.
High voltage connector manufacturers should be well versed on the engineering options available when selecting a strategy for a particular application. They include the addition of a safety
ring, a screw type mechanism which must be unloosened—disconnecting power—before theconnector can be unmated. Another strategy is the addition of a microswitch, which, similarly,
disables power with a flick before the connector can be decoupled. A simple Safety Interlock(SIL) strategy is to make one pin longer than the others, so the shorter ones disengage while thelonger one stays grounded, protecting the handler. Danger warning and directional stickers ortags are often affixed as well.

Figure 8
The safety ring (in red), a mechanical feature can prevent unmating when powered

In addition, special attention may be given to ensure that the connector is “scoop proof” to not
only protect the pin or pins, but also ensure that live pins are unlikely to be touched during mating
and unmating. Connectors are designed so that parts carrying current are further away from theopening, and openings are tapered so that fingers would be unlikely to be accidently inserted.

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ASSEMBLY AND REPAIR ISSUES AND FINAL WORDS
For all the added security and sophisticated engineering they deliver, most device manufacturers find that the modest additional investment that may be necessary in specifying high voltage
connectors over standard connectors represent high value and good business sense. Nevertheless, longevity of components—and their relationship to the efficacy of the overall system—
should be a concern for every manufacturer. Here again, selecting the right high voltage connector partner—and providing them with detailed, accurate information—can go a long way in thisregard.
For example, even though many device manufacturers have the high voltage connectors andcable produced separately and attached remotely, it behooves them to inform the connector
manufacturer of the type of cable that will be specified, with specifications provided such as inner and outer dimensions, insulation type and conductor interface. Better yet, provide a sample
if necessary. In the high voltage space, high quality manufacturers will often work to produce theconnector very close to the dimensions of the cable conductor in order to ensure that when they
are bonded together a very central fit can be readily achieved—even by a less-skilled assembler.
They can even suggest the best cable choices if it has not yet been specified. Sometimes thecable and connector can be produced in tandem to ensure a perfect match.
For high voltage connector manufacturers, precision is even more vital than with regular connectors. Small bits of metal or debris that may be harmless in a regular connector could increase thedanger of arcing or corona in a high voltage environment and must be cleaned out carefully andcompletely. For this reason, these parts are more often injection molded rather than machined;
indeed, residues of machining oils add impurities to the system that can impact performanceand must be carefully cleaned or eliminated. Assembly tolerances need to be even more precise;heat shrink might be added to confine metallic parts together or podding installed to isolate
wires to the electrical parts.
Customer-focused high voltage manufacturers will work to ensure maximum ease of assemblyin other ways as well—designing so that no special tools are required for example. In addition,
they might work to ensure that in the case of a failure of the cable, or wear of a pin or other single
component, the high voltage connector can be field repaired rather than need to be discarded
and replaced. LEMO connectors, for example, are often constructed in modular fashion, withreplaceable contacts and key components nutted and threaded rather than welded on, making
field disassembly possible to remove debris if needed.
Getting the most effective high voltage connectors produced is not difficult, but it does take ahigher level of communication than with many types of components, and it does take knowledge
and specialization that not every connector manufacturer can offer. By selecting an experienced
and proven high voltage connector partner, and working together with detailed application information every step of the way, manufacturers can ensure that their devices and equipment
operate effectively and safely from day one—and for many years to come.

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LEMO is the acknowledged leader in thedesign and manufacture of precision custom
connection and cable solutions.
LEMO’s high quality Push-Pull connectors arefound in a variety of challenging application
environments including medical, industrial
control, test and measurement, audio-video
and telecommunications.
LEMO has been designing precisionconnectors for seven decades. Offering
more than 75,000 combinations of productthat continue to grow through custom
specific designs, LEMO and its affiliatedsister companies REDEL, NORTHWIRE and
COELVER currently serve more than 100,000
customers in over 80 countries around theworld.

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