A full spectrum of custom cables
A full spectrum of custom cables
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A full spectrum of custom cables
Wilcoxon builds cables to your specifications and our exacting standards
Industrial process
Maritime
Predictive maintenance
Transportation
Condition based monitoring
Test and measurement
Military specifications
Underwater
Cables used with sensors are exposed to the chemicals, temperatures and hazards of the environment where the sensor
is located. Therefore, it is important to consider the application and the environment when wiring sensors.
A Wilcoxon customer sales and service representative will help you select the cable, protection level and connector
fittings to meet your individual needs. Custom cable orders are usually built in less than a week, some standard cables
ship the same day.
Cable design
Description
Application example
Multi-conductor
shielded
Shielded, twisted pair wire.
Permanent sensor installations most often use multi-conductor
shielded cable because it minimizes electrical noise, including RFI,
ESD, and EMI.
Coaxial
Carries power and signal on an
inner conductor. The shield acts as
the signal common.
Coaxial cable is used with BNC connectors; together they reduce the
connection time required for portable data collection.
Shielding
Description
Application example
Foil
Shielding made of aluminized mylar
with a drain wire for electrical
connection; reduces RFI.
Foil shielding attenuates RF signals by reducing the noise imposed
on cable by the surrounding equipment, as in a wind turbine.
Braided or spiral
Low frequency shielding is provided
by a braid made from many strands
of small gauge wire and wrapped
around the conductor(s) of a cable.
Braided shielding is used to decrease power line signal interference
like that often present around large electric motors.
Cable protection
Description
Application example
Spiral armored
jacket
Spiral wrap, interleaved band of metal
surrounds a cable to protect it from
heavy object impact.
The spiral armored jacket protects cable from damaging objects such
as those found in a hot roll steel mill.
Stainless overbraid
Braided electrical shield of stainless
steel wrapped along the outside of
a cable provides protection against
abrasion by foreign objects.
In the main intake pump at sewage treatment plant, a stainless overbraid
protects cable from objects underwater and does not trap water.
Environmental resistance
Description
Application example
Teflon®
Best temperature resistance,
excellent chemical resistance.
Usually the cable jacket choice for the connection to the sensor,
Teflon® cable jackets withstand up to 260˚C temperatures, making
Teflon® ideal for hot environments.
PVC
Moderate chemical resistance.
PVC provides a low cost alternative for dry air installations.
Enviroprene
Good chemical resistance in
non-abrasive environments.
Useful in most environments, a low-cost Enviroprene cable jacket
protects against common exposures, such as UV rays in an outdoor
cable tray installation
Tefzel®
Excellent chemical resistance, rated
for use in radiation environments.
Radiation resistance makes Tefzel® appropriate for use around
nuclear reactors.
Polyurethane
Low cost, waterproof material with
good abrasion resistance.
Polyurethane is often used in underwater applications because it can
be bonded to metals, creating a water-tight connection to the sensor.
Connectors
Description
Application example
MIL-style
Rugged, simple and cost-effective
connectors available in 2-pin, 3-pin,
and 6-pin configurations.
MIL-style connectors are the most common connectors used
with sensors. They are rugged and offer a wide variety of boots
and sealing methods for use in different environments, including
“splashproof” options.
Multi-conductor
MIL-style for 2 to 4 contacts. LEMO
and DIN-style for more than four
connections.
Multi-conductor connectors are often used on data collectors for the
sensor connection.
Coaxial
Designed for ease of connectivity in
instrumentation.
BNC and 10-32 Microdot connectors reduce the connection and
disconnection time required in portable date collection.
MaxFlex™ cables for data collectors
Compatible with data collectors made by SKF, Emerson (CSI), and Rockwell (Entek IRD)
Wilcoxon’s MaxFlex™ cables for data collectors are designed to exceed the harsh environmental requirements
of industrial applications. MaxFlex™ cables have reinforced cable joints at the sensor connector end - the most
common place that similar cables fail - to serve the needs of field data acquisition. They are rugged, reliable
and resistant to abuse.
Why MaxFlex™ is the best
Extended life
Reinforced for strength and maximum flexibility
Pull tested to over 100 pounds
Excellent EMI/RFI shielding
Wilcoxon connector tool kits
In addition to custom built cable assemblies, Wilcoxon also provides HTC and HTS Tool Kits for field assembly of the 6Q - series
of connectors. The High Temperature Crimp Kit is used to make a crimp connection to the socket, while the High Temperature
Solder Kit is used when the socket will be soldered to the wire. A similar field installation kit, the SP Kit, is available for the
6SL - series of connectors.
High temperature epoxy, 3 each
Epoxy nozzle,10 each
Epoxy applicator gun
Epoxy plunger, 4:1
Crimp frame tool and
Crimp positioner tool
Crimp tool
Exacto knife, 15 blades
Scissors
Wire stripper
Plastic socket insertion tool, 3 each
Metal socket insertion tool
A full spectrum of custom cables
Wilcoxon Research Inc
20511 Seneca Meadows Parkway
Germantown
Maryland 20876 USA
Tel: +1 301 330 8811
Fax: +1 301 330 8873
Email: sensors@wilcoxon.com
www.wilcoxon.com
www.meggitt.com
cmyk
Cable and connector selection
Wilcoxon’s extensive selection of cables and connectors offers a full spectrum of possibilities
Some of the most popular cables and connectors are pictured below. Want something you don’t see here?
Call your customer sales and service representative at 1-800-WILCOXON or send an email to sensors@wilcoxon.com
0
Description
Recommended cables
All
Blunt cut
1
IP
00
J1, J3, J4, J93
Microdot 10-32
1A
Microdot 10-32, right angle
J1, J3
2
BNC, plug, male
2F
BNC, female
2T
BNC, twinaxial
J1, J3, J4, J5A, J6, J9T,
J9T2, J9T2A, J9T3A,
J9T4, J10, J44, J51,
J61, J81, J93
J5A, J6, J9, J51, J61,
J93
J9
6
Amphenol, MIL-C-5015 style, 2 socket, metallic
50
50
50
50
50
J3, J4, J5A, J6, J9, J9T,
J9T2, J9T2A, J10, J51,
J61, J81, J93
50
MIL-C-5015 style, 3 socket, splash proof, premium
GSL: Electrical contact between shield and transducer housing
J9T3, J9T3A
66
6GQ/6GQI
MIL-C-5015 style, 3 socket, splash proof, premium
GSL: Electrical contact between shield and transducer housing
GSLI: Electrical isolation between shield and transducer
J9T3, J9T3A
66
6Q/6QI
MIL-C-5015 style, 2 socket, high temperature (200˚C / 392˚F)
Q: Electrical contact between shield and transducer housing
QI: Electrical isolation between shield and transducer housing
J5A, J9A, J9T, J9T2A,
J10, J51, J61
68
6QA/6QAI
MIL-C-5015 style, 2 socket, high temperature (200˚C / 392˚F)
Q: Electrical contact between shield and transducer housing
QI: Electrical isolation between shield and transducer housing
J9F
68
6SL/6SLI
MIL-C-5015 style, 2 socket, splash proof, premium
SL: Electrical contact between shield and transducer housing
SLI: Electrical isolation between shield and transducer housing
J5A, J9, J9T, J9T2,
J9T2A, J9T2AS, J9T3,
J9T3A, J9T4, J10, J51, J61
66
6W
MIL-C-5015 style, 2 socket, molded
J5A, J9T2A, J10
64
J9T2A, J10
64
Note: Electrical isolation between shield and transducer housing
6GSL/6GSLI
MIL-C-5015 style, right angle, molded
Common cables
Bendix, 4 socket, threaded, weatherproof
19SL/19SLI
MIL-C-5015 style, 6 socket
SL: Electrical contact between shield and transducer housing
SLI: Electrical isolation between shield and transducer housing
20
LEMO, 7 pin
Description
C˚ range
J9T2S, J9T4, J9T4A
50
J9T4, J9T4A
66
J9T, J9T2A, J10, J61
50
F˚ range
Diameter in.
pF/ft
-55 to 80
-67 to 176
0.088
30
Coaxial, low noise, orange PVC jacket
J3
Coaxial, low noise, high temperature, red Teflon jacket
-100 to 260
-148 to 500
0.085
30
J5A
Coaxial, RG 58, black PVC jacket
-40 to 105
-40 to 221
0.190
30
J9T
-80 to 150
-112 to 302
0.190
20
J9T2
Coaxial, RG 59, black Teflon® jacket
Twisted pair, shielded, white Tefzel® jacket
-80 to 150
-112 to 302
0.190
27
J9T2A
Twisted pair, shielded, yellow Teflon jacket
-80 to 200
-112 to 392
0.190
27
J9T2AS
Twisted pair, shielded, yellow Teflon jacket with stainless steel braid
-80 to 200
-112 to 392
0.210
27
J9T2S
Twisted pair, shielded, white Tefzel jacket with stainless steel braid
-80 to 150
-112 to 302
0.210
27
J9T3
Three conductor, shielded, white Tefzel jacket
Three conductor, shielded, yellow Teflon® jacket
-112 to 302
-112 to 392
0.190
0.190
27
J9T3A
-80 to 150
-80 to 200
J9T4
Four conductor, shielded, red Teflon jacket
-80 to 200
-112 to 392
0.190
30
J9T4A
Four conductor, shielded, yellow Teflon jacket
-80 to 200
-112 to 392
0.190
27
J10
Twisted pair, shielded, gray Enviroprene jacket
-50 to 125
-58 to 257
0.190
30
J88
Twisted pair, shielded, black Polyurethane jacket
-40 to 80
-40 to 176
0.175
J88C
Twisted pair, shielded, black Polyurethane jacket, coiled with 6” straight ends -40 to 80
-40 to 176
0.175
60
60
J95
Five conductor, shielded, black Polyurethane jacket
-20 to 90
-4 to 194
0.240
22
J96
Twisted pair, shielded, white Teflon® jacket
-80 to 150
-112 to 302
0.145
35
J9F
Twisted pair, foil shielded with drain wire, red Teflon jacket
-70 to 200
-94 to 392
0.125
51
®
®
®
®
®
®
®
MAXIMUM CABLE LENGTH vs. FREQUENCY
AND SUPPLY CURRENT
10,000
1000
100
10
1
6
10
600
100 khz
6,000 kcpm
Maximum frequency of interest
Note: Graph values assume cable capacitance of
IP ratings
J1
®
An accelerometer cable can be
run one hundred feet without
losing most signals. The exact
length can be determined
knowing the cable capacitance
(30 picoFarads per foot is
common) and the available
voltage swing (typically at least
5V peak to peak). Given these
values, the mazimum length
is a function of supply current
and highest frequency of
interest. The chart to the right
helps determine maximum
cable lengths.
represents current available to power the sensor.
Note: Electrical isolation between shield and transducer housing
9W
Cable length
30pF/ft and an available voltage swing of 5Vp-p. (I)
Note: Electrical isolation between shield and transducer housing
6WR
Tech tips
Cable length (ft)
Connectors
27
Splashproof connectors for sensors are categorized according to an Ingress
Protection or IP rating. IP ratings are industry standards that indicate how
connectors withstand invasion in harsh environments. In order to qualify the
level of sealing provided by a sensor connector, use the following chart:
Ingress protection ratings
First numeral
Protection against solid bodies
No protection – 0
Objects greater than 50mm – 1
Objects greater than 12.5mm – 2
Objects greater than 2.5mm – 3
Objects greater than 1.0mm – 4
Dust-protected – 5
Dust-tight – 6
Second numeral
Protection against liquid
0 – No protection
1 – Vertically dripping water
2 – Angled dripping water
3 – Sprayed water
4 – Splashed water
5 – Water jets
6 – Pressure jets
7 – Immersion to 1 meter
8 – Indefinite immersion
Wilcoxon’s 6SL connector has an IP rating of 66, making it dust tight and
protected against liquid from pressure jets. Even at this high rating, it is not
appropriate for temporary or permanent immersion in water.
Avoiding ground loops
In order to provide proper shielding and prevent ground loops, shield and
common grounding should be carefully considered. Ground loops are
developed when a common line (i.e. signal return/shield) is grounded at two
points of differing electrical potential.
For sensors with coaxial cable, the center conductor carries the signal and
power, while the outer braiding provides the shielding and signal return.
Normally the cable shield is electrically isolated from the sensor housing.
This isolates the shield from the mounting point of the machine and prevents
ground loops. If a non-isolated sensor is used, it is recommended that an
isolated mounting pad be used to break up possible ground loops.
For sensors using two conductor/shielded cable, the signal and power
are carried on one lead and the signal common on the other. The cable
shield serves to protect the signal from Electrostatic Discharge (ESD) and
Electromagnetic Interference (EMI). The shield should be grounded at only one
point, normally to the readout equipment.
In all cases, it is very important that the cable shield terminations be properly
grounded. Failure to do so in high ESD/EMI environments can result in damage
to the sensor electronics.
Data acquisition equipment
Sensor case
is grounded
Data acquisition equipment
Sensor case
is grounded
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