Ethercon - Professional Ruggedized Ethernet

Ethercon is Neutrik's ruggedized Ethernet connector system designed for live sound, broadcast, and touring applications where standard RJ45 connectors fail. It combines the familiarity of Cat 5e/6 Ethernet with XLR-style locking mechanics, dust/moisture resistance, and road-worthy durability. If you've ever had a network cable pull out during a show or corrode in outdoor weather, Ethercon solves those problems.

Why Standard RJ45 Fails in Pro Environments

1. No Locking Mechanism

• RJ45 uses a plastic tab that snaps into place
• Tabs break easily when stepped on or snagged
• Cable pulls out without warning—catastrophic in live production

2. Exposed Contacts

• Gold pins are open to dust, moisture, and corrosion
• Humidity shorts pins, causing intermittent dropouts
• Outdoor installations fail quickly without weatherproofing

3. Poor Strain Relief

• Standard RJ45 boot provides minimal cable grip
• Repeated plugging/unplugging fatigues cable jacket
• Internal wires break at connector, causing flaky connections

4. Not Field-Repairable

• Broken RJ45 connector requires crimping tool and skill
• Pre-terminated cables can't be easily repaired on-site
• Touring productions need field-serviceable connectors

How Ethercon Solves These Problems

Ethercon wraps a standard RJ45 jack inside a ruggedized XLR-style housing:

• Locking mechanism: Twist-lock like XLR audio connectors
• Dust cap: Spring-loaded shutter protects contacts when unplugged
• Metal shell: Grounded shield for EMI protection
• Gasket seal: O-ring creates weatherproof seal when mated
• Strain relief: Robust chuck clamps cable jacket

Backward compatible: Standard RJ45 plug fits into Ethercon receptacle (not vice versa—Ethercon plug too large for RJ45 jack).

Ethercon Connector Types

NE8FDP - Feedthrough Panel Jack

Use: Patch panel, stage box, rack gear

• Configuration: Female Ethercon on front, female RJ45 on back
• Mounting: Standard D-size cutout (XLR-compatible)
• Shield: Connected to metal housing for grounding

Example: Neutrik NE8FDP-B Ethercon Feedthrough (Black)↗

Typical installation:

• Front: Ethercon cable from stage
• Back: Standard RJ45 patch cable to switch

Ratings:

• IP65 (dust-tight, water-resistant) when mated with sealing cap
• Operating temp: -30°C to +80°C

NE8MC - Male Cable Connector

Use: Field-terminable cable connector

• Configuration: Male Ethercon housing, accepts standard RJ45 plug
• Assembly: Insert crimped RJ45 plug into housing, tighten strain relief

Example: Neutrik NE8MC-B Male Ethercon Cable Connector (Black)↗

Advantages:

• Use any Cat 5e/6 cable—terminate RJ45, insert into Ethercon shell
• Field-repairable—carry spare housings on tour
• Cost-effective—no need for pre-terminated Ethercon cables

NE8FDX-P6 - Duplex Panel Connector

Use: High-density patch panels (two Ethercons in one cutout)

• Configuration: Two female Ethercon jacks side-by-side
• Mounting: Single D-size cutout (saves panel space)

Example: Neutrik NE8FDX-P6 Duplex Ethercon Panel↗

Use case: Touring racks with limited panel space, FOH audio consoles.

NE8MC-B-TOP - Top-Entry Cable Connector

Use: Vertical cable routing (floor boxes, under-stage installations)

• Configuration: Cable exits from top of connector instead of rear
• Benefit: Prevents cable kinking in tight spaces

Pre-Terminated Ethercon Cables

If you don't want to field-terminate, buy pre-made Ethercon assemblies:

TecNec CAT6-EB Series

Shielded Cat 6 with Ethercon ends:

• Lengths: 10 ft to 250 ft
• Jacket: Durable polyurethane (touring-grade)
• Shield: S/FTP (foil per pair + braided overall shield)

Example: TecNec CAT6-EB-100 Ethercon Cable (100 ft)↗

Pros:

• ✅ Factory-terminated—guaranteed performance
• ✅ Tested and certified
• ✅ Professional appearance

Cons:

• ❌ Expensive ($3-$5 per foot)
• ❌ Fixed length (can't shorten without re-terminating)

Tactical Fiber Systems TFS Cat 6A

Armored cable for extreme environments:

• Construction: Kevlar braid + polyurethane jacket
• Temp range: -40°C to +75°C
• Rating: Repeated drive-over, crush-resistant

Example: TFS Cat 6A Tactical Ethercon Cable↗

Use case: Broadcast trucks, military field networks, outdoor festivals (drive-over cable crossings).

Ethercon vs Standard Ethernet

When to use Ethercon:

• ✅ Live sound (Dante, AES67 audio networks)
• ✅ Touring (repeated setup/teardown)
• ✅ Outdoor installations (moisture resistance)
• ✅ High-traffic areas (prevents accidental disconnection)

When standard RJ45 is fine:

• ✅ Office/home networks (low wear, climate-controlled)
• ✅ Permanent installations (cables not moved)
• ✅ Budget constraints

Common Ethercon Applications

1. Dante Audio Networks

Dante (Digital Audio Network over Ethernet) is the standard for professional audio:

• Carries 512+ channels of audio over Cat 5e/6
• Requires no packet loss—Ethercon's reliability critical
• Stage boxes connect to consoles via 100+ foot Ethercon runs

Example system:

• FOH console (Yamaha CL5) → 150 ft Ethercon → Stage box (Rio3224-D2) → Microphones

Why Ethercon matters:

• Band member stepping on cable = show-stopping dropout with RJ45
• Outdoor festival humidity = corrosion with standard connectors

2. Lighting Control (sACN, Art-Net)

DMX lighting protocols now run over Ethernet:

• sACN (Streaming ACN) and Art-Net multicast DMX data
• Ethercon connects lighting console to fixtures and dimmers

Example: ETC Ion Xe Lighting Console↗ with Ethercon ports.

3. Broadcast and OB Vans

Outside Broadcast (OB) trucks use Ethercon for:

• Camera CCU (Camera Control Unit) connections
• Intercom systems (RTS, Clear-Com over IP)
• Video routing (SDI over IP, SMPTE 2110)

Benefit: Armored Ethercon cables survive repeated drive-overs in cable crossings.

4. Outdoor Surveillance Networks

IP cameras in harsh environments:

• Ethercon weatherproofing extends cable life
• PoE+ (30W) powers PTZ cameras over Ethercon Cat 6

Example: Axis P5655-E PTZ Camera↗ with Ethercon wiring.

Installing Ethercon Systems

1. Panel-Mount Installation (NE8FDP)

Tools needed:

• 24mm chassis punch or D-hole punch
• Wrench for locking ring

Steps:

1. Cut D-size hole in panel (24mm diameter)
2. Insert NE8FDP from front
3. Tighten locking ring from rear
4. Connect RJ45 patch cable to rear jack
5. Test with cable tester

Grounding:

• Connect panel to equipment ground (safety wire or grounding strap)
• Ethercon metal shell bonds to panel via locking ring

2. Field-Terminating Cable Connectors (NE8MC)

Tools needed:

• RJ45 crimping tool
• Wire stripper
• Cable tester

Steps:

1. Strip Cat 5e/6 cable jacket (do not strip individual wires yet)
2. Crimp RJ45 plug onto cable (use T568B wiring standard)
3. Test crimped plug with cable tester
4. Disassemble NE8MC housing (unscrew rear cap)
5. Thread cable through rear cap and strain relief
6. Insert RJ45 plug fully into NE8MC housing
7. Tighten strain relief onto cable jacket
8. Screw rear cap back on

Common mistakes:

• ❌ Over-tightening strain relief (crushes cable)
• ❌ RJ45 plug not fully seated (intermittent connection)
• ❌ Cable jacket extends into RJ45 plug (causes crosstalk)

3. Weatherproofing Outdoor Connections

For permanent outdoor installations:

• Use NE8MC-1 with rubber boot for cable entry
• Apply dielectric grease to RJ45 contacts before mating
• Use heat shrink tubing over rear of connector
• Mount connector vertically (cable enters from bottom) to prevent water pooling

Ethercon Accessories

NE8FDY-A1-W - Terminating Cap

Use: Dust protection for unused Ethercon jacks

• Seals connector when not in use
• Prevents corrosion in storage

Example: Neutrik NE8FDY-A1-W Terminating Cap↗

NE8MC-1-WH - Colored Connector Housings

Use: Color-coding networks (e.g., white = Dante primary, red = Dante secondary)

• Available in black, white, blue, red, green, yellow

Example workflow:

• White Ethercon = Primary Dante network
• Red Ethercon = Redundant Dante network (automatic failover if primary drops)

SCE Dust Covers

Use: Protect unmated connectors during transport

• Slip-on rubber covers
• Prevents contact damage in road cases

Cost Analysis

Standard RJ45 System (100 ft run)

• Cat 6 cable: $20
• RJ45 plugs: $1
• Total: $21

Ethercon System (100 ft run)

• Cat 6 cable: $20
• 2× NE8MC housings: $30
• 2× RJ45 plugs: $1
• Total: $51

OR:

• Pre-terminated Ethercon cable (100 ft): $300-$400

Is Ethercon worth 2-4× cost?

• For touring: Absolutely—prevents show-stopping failures
• For fixed installations: Maybe—depends on environment (outdoor = yes, office = no)
• For home studio: No—standard RJ45 sufficient

Alternatives to Ethercon

Industrial M12 Connectors

• IP67 rated (waterproof)
• Smaller than Ethercon
• Common in factory automation

Downside: Proprietary—not compatible with RJ45 or Ethercon.

Ruggedized RJ45 (e.g., Amphenol RJF)

• RJ45 with metal housing and locking collar
• Cheaper than Ethercon (~$5 vs $15)
• Less common—harder to find cables and panel jacks

Fiber Optic (LC or SC Connectors)

• Immune to EMI (no metal conductors)
• Longer distances (multimode: 550m, singlemode: 10+ km)
• More fragile—fiber can't be bent tightly or driven over

Use fiber instead of Ethercon when:

• Distance exceeds 100 meters
• Extreme EMI (near radio transmitters, power substations)
• Lightning-prone areas (fiber is non-conductive)

Troubleshooting Ethercon Connections

"Link Won't Establish"

Causes:

1. RJ45 plug not fully seated in Ethercon housing
2. One or more pairs damaged
3. Cable exceeds 100-meter limit

Solution: Re-seat connector, test with cable certifier.

"Intermittent Dropouts"

Causes:

1. Strain relief too tight (crushes cable)
2. Moisture in connector (corrosion)
3. Shield grounded at both ends (ground loop)

Solution: Loosen strain relief, apply dielectric grease, ground shield at one end only.

"Slow Speeds (100 Mbps Instead of 1 Gbps)"

Causes:

1. Cable is Cat 5 (not Cat 5e)
2. Only 2 pairs connected (Gigabit requires all 4 pairs)
3. Crimped RJ45 plug has poor contact on orange or green pairs

Solution: Verify cable category, re-crimp RJ45 plug, test with multimeter.

Best Practices

1. Color-code your networks: Use different Ethercon housing colors for primary/redundant networks
2. Test before tour: Certify all cables with Fluke or similar tester
3. Carry spares: Bring extra NE8MC housings and RJ45 plugs for field repairs
4. Coil properly: Use over-under technique to prevent cable memory kinks
5. Label everything: Use Brady label maker or cable tags—critical when troubleshooting live

When to Upgrade from RJ45 to Ethercon

Signs you need Ethercon:

• ✅ You've had cables pull out during events
• ✅ Outdoor installations corrode within 6 months
• ✅ Touring—repeated setup/teardown fatigues standard connectors
• ✅ High-traffic areas where cables get stepped on
• ✅ Mission-critical networks (audio, lighting, broadcast) where downtime is unacceptable

RJ45 is still fine if:

• ✅ Fixed installation with no user access to connectors
• ✅ Climate-controlled environment (office, data center)
• ✅ Budget constraints (Ethercon is 4-10× cost of RJ45)

Ethercon is the professional choice when reliability matters more than cost—a $15 connector that prevents a $10,000 production failure is a bargain.