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which option is best for you?connectors and lead wiresprovide the electrical connection between the coils of an lvdt position sensorand signal conditioning electronics. below are some helpful tips to guide youin deciding whether to specify a connector or lead wires for your next sensor.

wire leads

lvdt sensors are mostcommonly specified with lead wires as they are generally less expensive thanconnectors and easy to use, providing a simple connection to signalconditioning electronics for bench-top testing. in some cases, lead wires canoffer expanded operating ranges in both temperature and pressure. for example,lead wires are the preferred electrical connection for sensors used in highpressure, in-cylinder hydraulic applications or when operating temperaturesexceed 400°f.

lead wire sensitivity,however, is a potential drawback to its use as the wire can break if nothandled carefully during installation. long runs of leads also can becumbersome and complicated to install. in addition, lead wires are susceptibleto picking up noise that can affect interpretation of signals by theconditioning equipment, ultimately reducing the accuracy of the sensor output.

connectors

independent of wiring,sensors with connectors are easier to install and uninstall. when reinstallinga sensor, connectors can simply be unplugged or plugged into while lead wiresmust be broken and often repaired. connectors also can be specified withshielded cable assemblies to create longer distances between the lvdt linear positionsensor and electronics, which is especially important when sensors must performin harsh environments, as cabling has lower resistance and shielding thatprotects against interference from outside sources.

if wires are broken or pulledon the cable assembly, only the cable assembly has to be replaced as the lvdtsensor will otherwise remain in working order. breaking or stripping a leadwire by pulling on it too hard makes the sensor non-repairable, requiring thepurchase of a replacement sensor. through the use of connectors, lvdt sensorscan be hermetically sealed, offering ingress protection ratings to ip-68.

on the downside, connectorscan be bulky and difficult to fit into tight spaces or on lvdts with smallpackage size requirements.

application-specific examples

industrial, dirty, and subseaenvironments

glass-sealed connectors arerecommended as a way to make the electrical connection while maintaining thehermetic seal. this protects the lvdt from dust, dirt, jetting, or submersion.applications that require a hermetically sealed ip-67 or ip-68 lvdt willgenerally have a connector.

industrial and oemapplications

where a single piece ofequipment can use various sensors, cable assemblies can save time bycentralizing wiring to a cable harness. and by using connectors with longercable assemblies, ac-operated lvdts can operate under hostile conditions whileelectronics are located in a more benign environment. cables connect the linearposition sensors with remotely located electronics that power the sensors,amplify and demodulate their output.

hydraulic in-cylinderapplications

where pressures can reach20,000 psi and higher, using leads on vented lvdts allow for equalized pressureon all components of the sensor. for indoor test and measurement applicationsin ambient environments, leads also offer a simple connection from the lvdt toassociated electronics.

environment-specific examples

in determining the bestelectrical connection for an lvdt sensor, gather facts on the environment wherethe sensor will be placed as different elements can effect performance.

·        temperatures in excess of 400°f: leads may be better suited highpressure: in conductive fluids like water: require a connector; in fluids thatare not electrically conductive like hydraulic fluid, leads can be used

·        dust/humidity: glass-sealed connectors offer betterenvironmental protection against heavy dust, humidity and submersion

·        vibrations: if the sensor will be exposed toconstant shock and vibration over a long period of time, leads or a screw-onconnector offer the best options

table 1: recommended applicationsfor wire leads vs. connectors. note that application requirements should alwaysbe checked along with lvdt performance specifications.

applications

lead wire

connector

simple  bench-top setup

x


frequent  in-field replacement


x

clean/dry  environments

x


heavy  dust/dirt/humidity


x

light  dust/dirt

x


high pressure  hydraulic oil

x


freshwater/seawater  submersion


x


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