A full spectrum of custom cables

A full spectrum of custom cables

Wilcoxon Sensing Technologies builds cables to our exacting standards for a variety of applications:

>> Industrial process >> Maritime >> Paper machines

>> Predictive maintenance >> Transportation >> Machine tools
>> Condition monitoring >> Test and measurement >> High temperature or radiation
>> Military specifications >> Underwater >> Hazardous areas

Cables used with sensors are exposed to the chemicals, temperatures and hazards of the environment
where the sensor is mounted. It is important to consider the application and the environment when
selecting a cable to be used with a sensor.

A Wilcoxon sales and service representative can help you select the cable, protection level and
connector fittings that meet your specific needs. Custom cable orders are usually built in less than a
week, and some standard cables ship the next day. All cables are built with the care and precision you
have come to expect from Wilcoxon.

MaxFlex® cables
Compatible with data collectors made by SKF, Emerson (CSI), Rockwell (Entek/IRD)
and GE (Commtest)

MaxFlex® cables for data collectors are designed to excel in the harsh environments of route based
data collection. MaxFlex® cables have reinforced cable joints at the sensor connector end – the most
common place that similar cables fail to survive severe handling during data collection. The rugged
cable is reliable, durable, and resistant to wear and tear.

Why Maxflex is the best

>> Extended life
>> Reinforced for strencth and maximum flexibility
>> Pull tested to over 100 pounds
>> Excellent EMI/RFI shielding
Cable design
Description Application example
Permanent sensor installations most often use multi-conductor
Multi-conductor
Shielded, twisted pair wire shielded cable because it minimizes electrical noise, including RFI,
shielded
ESD and EMI.
Carries power and signal on an Coaxial cable is used with BNC connectors and charge output
Coaxial inner conductor. The shield acts as accelerometers. Low-noise mineral insulation cable minimizes
the signal common. triboelectric effects.

Shielding
Description Application example
Shielding made of aluminized
The foil blocks high levels of RF signal which are often found in
Foil mylar with a drain wire for
wind turbine nacelles or high speed turbines.
electrical connection
Shielding is provided by a braid
Braided shielding is considered more effective at minimizing power
made from many strands of small
Braided or spiral line frequencies found around electric motors. Tightly wound
gauge wire and wrapped around
braided shield also protects against RF interference.
the conductor(s) of a cable.

Cable protection
Description Application example
Spiral armored jacket protects the cable from heavy objects like
Spiral armored Spiral wrap, interleaved band of
those found in a hot roll steel mill, and provides chemical resistance
jacket metal surrounding a cable
since the cable is completely isolated from the atmosphere.
A stainless steel overbraid protects the cable from shart objects and
Braided electrical shield of
Stainless can also act as an additional signal shield. For underwater
stainless steel wrapped along the
overbraid applications the stainless braid protects the outer insulation from
outside of a cable
foreign objects and does not trap water.

Environmental resistance
Description Application example
The cable jacket of choice for most applications, Teflon® can
Best temperature resistance, withstand temperatures up to 260° C, ideal for hot environments.
Teflon®
excellent chemical resistance Teflon® is resistant to most chemicals and physically strong,
providing long cable life.
A low-cost alternative to Teflon®, Enviroprene is useful for most
Better chemical resistance in
Enviroprene environments and protects against common exposures, such as UV
non-abrasive environments
rays found in outdoor cable tray installations.
PVC is a low-cost solution for dry air installations but does not pro-
PVC Good chemical resistance
vide the same range of chemical resistances as Teflon.
Better chemical resistance, Radiation resistance makes Tefzel® appropriate for use in nuclear
Tefzel®
rated for use in areas with radiation environments.
Low-cost, waterproof material with Polyurethane is often used in underwater applications because it
Polyurethane
good abrasion resistance can be bonded to metals, creating a watertight seal to the sensor.

Connectors
Description Application example
MIL-style is the most common connector used with industrial sen-
Rugged, simple and cost-effective
sors. They are rugged and offer a wide variety of boots and sealing
MIL-style connectors available in a variety of
methods for use in different environments, including “splashproof”
pin configurations
options.
Multi-conductor connectors are used on data collectors, multi-axis
LEMO, Bendix, Turck, M12 and
Multi-conductor sensors and triaxial units. M12 connectors are commonly used in
other multi-conductor connections
process applications.
2 pin connectors for use with BNC and 10-32 Microdot connectors reduce the connection time as-
Coaxial
coaxial cables sociated with portable data connection.
 Durable connectors - built to last
The Wilcoxon 6Q boot used with a high quality Teflon® coated cable, such as J9T2A, has set the standard as a
ruggedized, submersible connector cable assembly. Rated at IP68 and tested up to 650 p.s.i., 6Q connectors are
usable in temperatures up to 200° C and underwater submersible to 230 feet. The design of the 6Q allows it to be
used in settings where the cable shield must be connected to the sensor body, or for industrial applications where
the shield must be isolated from the sensor (made possible by removing the grounding spring). The pairing the of
the new 6QN neoprene boot and J9T2 Tefzel® cable is an ideal configuration for nuclear environments.

Wilcoxon connector tool kits

Wilcoxon provides High Temperature Crimp (HTC) and High Temperature Solder (HTS) toolkits for field
assembly of the 6Q series of connectors. The HTC kit is used to make a crimp connection to a socket, while the
HTS kit is for applications where the socket will be soldered to the wire. Each kit comes with all the tools
necessary to prepare connectors and cables in the field, including high temperature epoxy to backfill the
connector, creating a sealed, potted backshell.

High temperature epoxy,

3 each
Epoxy nozzle,
10 each

Epoxy applicator gun

Epoxy plunger, 4:1

Crimp frame tool and
crimp positioner tool
(HTC kit only)

Crimp tool

Wire stripper

Exacto knife,
15 blades
Scissors
Plastic socket
Metal socket
insertion tool
insertion tool

Wilcoxon Sensing Technologies

20511 Seneca Meadows Parkway Tel: +1 (301) 330 8811
Germantown, MD 20876 [email protected]
USA www.wilcoxon.com
 Cable and connector selection

Connector Description Compatible cables IP Tech tips

1 Microdot 10-32 J1, J3, J4, J93 50 Cable length

An accelerometer cable can be run Maximum cable length vs Frequency and supply current
10,000 ft
1A Microdot 10-32, right angle J1, J3 50 100 feet without losing signal content. 3048 m
The exact length before signal
J1, J3, J4, J5A, J6, degradation begins can be determined
1,000 ft
2 BNC, plug, male J9T, J9T2, J9T2A, 50 using cable capacitance (30 pico- 304.8 m
J9T3A, J9T4, J10, J44, J51 Farads per foot is common) and

Cable length
available voltage swing (typically at
2F BNC, female J6, J9, J51, J61, J81, J93 50 least 5 V peak-to-peak). Using these 100 ft
values, the maximum length is a 30.5 m l=10 mA
l=8 mA
function of supply current and the l=6 mA
l=4 mA
2T BNC, twin-axial J9 50 highest frequency of interest. The
chart to the right helps determine 10 ft l=2 mA
3 m 1 10 100 kHz
J3, J4, J5A, J6, J9, maximum cable lengths. 6 600 6,000 kCPM
Amphenol, 2 socket, metallic
6 J9T, J9T2, J9T2A, 50 Maximum frequency of interest
Note: electrical isolation between shield and transducer housing Note: Graph values assume cable capacities of
J10, J51, J61, J81, J93 30 pF/ft and an available swing of 5 V p-p.
The current available is represented by l.
2 pin, suitable for use in Class I, Div 2 (Zone 2) areas,
6D2
factory assembled

2 socket, high temperature (200° C/392° F) IP ratings

J5A, J9T, J9T2A, J10,
6Q/6QI Q: Electrical contact between shield and transducer housing 68
J51, J61, J91
QI: Electrical isolation between shield and transducer housing Splashproof connectors used with sensors are categorized by Ingress Protection or
2 socket, high temperature (200° C/392° F) IP rating. IP ratings are industry standards that indicate how connectors withstand
6QA/6QAI QA: Electrical contact between shield and transducer housing J9F 67 invasion in harsh environments. In order to understand the level of sealing provided
QI: Electrical isolation between shield and transducer housing by a sensor connector, use the following chart:
2 socket, radiation resistant, Neoprene boot/Tefzel® insert
6QN/6QNI QN Electrical contact between shield and transducer housing 68 Protection against solids Protection against liquid
QNI: Electrical isolation between shield and transducer housing No protection 0 0 No protection
3 socket, premium Objects >50 mm 1 1 Vertically dripping water
MIL-C-5015 style

6GQ/6GQI GQ: Electrical contact between shield and transducer housing J9T3, J9T3A 68 Objects >12.5 mm 2 2 Angled dripping water
GQI: Electrical isolation between shield and transducer housing Objects >2.5 mm 3 3 Sprayed water
Objects >1.0 mm 4 4 Splashed water
3 pin, suitable for use in Class I, Div 2 (Zone 2) areas, Dust-protected 5 5 Water jets
6GD2 67
factory assembled Dust-tight 6 6 Pressure jets
2 socket J5A, J9, J9T, J9T2, J9T2A, 7 Immersion to 1 meter
6SL/6SLI SL: Electrical contact between shield and transducer housing J9T2AS, J9T3, J9T3A, 66 8 Indefinite immersion
SLI: Electrical isolation between shield and transducer housing J9T4, J10, J51, J61
Example: Wilcoxon 6SL connectors are rated at IP66, meaning they are dust-tight and protected against liquid
3 socket from pressure jets. Even though it is rated highly, the connector is not appropriate for temporary or
6GSL/6GSLI GSL: Electrical contact between shield and transducer housing J9T3, J9T3A 66 permanent immersion in water.
GSLI: Electrical isolation between shield and transducer housing

2 socket, molded connector

6W
Note: electrical isolation between shield and transducer housing
J5A, J9T2A, J10 67 Avoiding ground loops

2 socket, right angle, molded connector In order to provide proper shielding and prevent ground loops, shield and com-
6WR J9T2A, J10 67 mon grounding should be carefully considered. Ground loops are developed when
Note: electrical isolation between shield and transducer housing
a common line (i.e. signal return/shield) is grounded at two points of differing
6 socket electrical potential.
19SL/19SLI SL: Electrical contact between shield and transducer housing J9T4, J9T4A 66
SLI: Electrical isolation between shield and transducer housing For sensors with coaxial cable, the center conductor carries the signal and power,
while the outer braid provides the shielding and signal return. Normally the cable
9W Bendix, 4 socket, threaded, weatherproof J9T2S, J9T4, J9T4A 50 shield is electrically isolated from the sensor housing. This isolates the shield from
the mounting point at 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
20 LEMO, 7 pin J9T, J9T2A, J10, J61 50 possible ground loops.

For sensors using 2 conductor/shielded cable, the signal and power are car-
Molded M12 5 socket connector ried on one lead and the signal common on the other. The cable shield serves to
M12 J10 68
Note: for 4 conductor applications please contact us
protect the signal from Electrostatic Discharge (ESD) and Electromagnetic Inter-
ference (EMI). The shield should be grounded at only one point, normally at the
readout equipment.
Max temp Diameter
Cable Description pF/ft In all cases it is very important that the cable shield terminations be properly
F C inch cm grounded. Failure to do so in high ESD/EMI environments can result in damage to
J1 Low noise, orange PVC jacket 176° 80° 0.088 0.224 30 sensor electronics. Choosing a single point for your ground also greatly increases
the ability of the shield to protect against RF interference.
J3 Low noise, high temp, red Teflon® jacket 500° 260° 0.085 0.216 30 Data acquisition equipment
Coaxial

power/signal
J5A RG58, black PVC jacket 221° 105° 0.190 0.483 30 common
ground
J9T RG59, black Teflon® jacket 302° 150° 0.190 0.483 20
Sensor electronics
inside a faraday shield
J93 RG316/U, high temp, clear Teflon jacket
®
392° 200° 0.098 0.249 29 Sensor case
is grounded
J88 Black Polyurethane jacket 176° 80° 0.175 0.445 60

J88C Black Polyurethane jacket, coiled with 6’ straight ends 176° 80° 0.175 0.445 60

J9 Grey PVC jacket 176° 80° 0.231 0.587 32

J9A Brown PVC jacket 221° 105° 0.190 0.483 28

Twisted pair, shielded

J9T2 White Tefzel® jacket, radiation resistant 302° 150° 0.190 0.483 27
How to order
J9T2A Yellow Teflon jacket
®
392° 200° 0.190 0.483 27
Ra-b-c-xx-d is the numbering system for custom cable assemblies.
J9T2AS Yellow Teflon® jacket with stainless steel braid 392° 200° 0.210 0.533 27
c b
a
J9T2B Blue Teflon jacket
®
392° 200° 0.210 0.533 27 xx
J9T2S White Tefzel® jacket with stainless steel braid 302° 150° 0.210 0.533 27 a Connector that will mate to sensor
b Cable termination connector
J96 White Teflon® jacket 302° 150° 0.145 0.368 35
c Compatible cable type
J10 Gray Enviroprene jacket 257° 125° 0.190 0.483 30 xx Desired cable length (ft/m), including connectors (standard lengths: 3, 5, 10 ft)
J9F Foil shield with drain wire, red Teflon® jacket 392° 200° 0.125 0.318 51 d Optional: armor (A), stainless steel braid (S), safety connector (SC)
Note: R signfies cable assembly
J9T3 3 conductor, white Tefzel® jacket 302° 150° 0.190 0.483 27 Example: R6Q-0-J9T2A-16 (16 ft yellow Teflon® cable, 2 pin IP68 connector to blunt cut)
multi-conductor

J9T3A 3 conductor, yellow Teflon® jacket 392° 200° 0.190 0.483 27

Shielded,

J9T4 4 conductor, red Teflon® jacket 392° 200° 0.190 0.483 30 To place an order, contact us via email at [email protected]
J9T4A 4 conductor, yellow Teflon® jacket 392° 200° 0.190 0.483 27
or by phone at +1 (301) 330 8811.

J95 5 conductor, black Polyurethane jacket 194° 90° 0.240 0.610 22 To view our selection of cables and connectors, visit www.wilcoxon.com.