I found seven Ethernet ports on an operational polar icebreaker with badly deformed contacts. The pins appear bent out of their guides, and some also look corroded. The switch is not particularly old, and the equipment room is temperature- and humidity-controlled. What could cause this kind of repeated physical damage and corrosion?
3 Answers
The most likely explanation for the bent contacts is mechanical abuse: an RJ11 phone plug, a damaged RJ45 connector, or something else being forced into the port and then pulled out. A poor-quality plug with burrs or an incorrectly assembled cable can also catch and deform the contacts.
If the damage pattern is identical across several ports, check what was being plugged into them and whether someone used excessive force. A connector may have been inserted at an angle, or someone may have tried to straighten or retrieve a cable with a tool. With the switch fully powered down, individual contacts can sometimes be carefully moved back into the guide using a fine pick, but badly corroded or repeatedly damaged ports should be replaced.
The corrosion may be environmental rather than related to the original damage. Salt-laden air can reach conditioned equipment spaces on ships and gradually corrode exposed contacts. PoE ports can make the problem worse because different metals and energized contacts can encourage galvanic corrosion, especially in a marine environment.
Even with temperature and humidity control, outside air can still enter the space. Marine installations usually need appropriately sealed connectors, protected patching, and materials rated for salt exposure.