ELPRO LEPENIK presents complete kits with connectors, cables, plugs and extension leads to facilitate use in industrial environments and to ensure reliable and efficient operation of measurement systems.
Connector connections are most common in portable instrumentation applications, but less common in fixed installations and automated control and measurement systems.
When we have a process that requires:
the sensors must be removed (dismantled) and then reconnected (reinstalled) to the measurement system.
In such situations, it is wise to consider a connector connection somewhere between the sensor and the system, maybe on/near the sensor, maybe on the connecting cables, or even at the device or electrical control box (e.g. built-in connectors). This simple and economical intervention saves a lot of maintenance time later on, often allowing the operator to change the sensors himself or at least saving a lot of time when the process is standing still for the maintenance team to do their work.
To optimise performance, we standardise sensors as much as possible, introduce a minimum stock and train operators to change them themselves.
Faster sensor replacement: connectors built into the measuring systems allow easy and quick sensor replacement. This reduces downtime, thus reducing production downtime and maintenance costs.
Reduced downtime during repairs: using connectors reduces the time needed for repairs and maintenance, as there is no need for soldering or other time-consuming and technically difficult sensor connection procedures.
Replaceable by the machine operator: when the industrial sensor has a connector connection instead of a fixed connection, the machine operator can replace the sensor independently. This increases operational flexibility and efficiency.
Preventing incorrect connection: connectors allow sensors to be connected precisely and correctly, eliminating the possibility of connection errors such as Pt100 4-cable sensor connection errors or polarity reversal in thermocouples (TC connectors have different pin thicknesses, so reversal is physically impossible).
Ensuring correct measurements: correct connection and reliable communication between sensors and measuring devices ensure accurate and reliable measurements and prevent possible errors in the measurement results.
Increased safety: fused connectors prevent potential hazards such as short circuits that could damage equipment or cause interruptions in the production process.
Connectors are versatile. They are found in many industrial applications where they play a key role in providing reliable connections between sensors and devices.
Their use is wide-ranging and includes the following applications:
Resistive sensors: connectors such as M12, LEMO and 3-pin models are often used to connect resistive temperature sensors such as RTD temperature sensors (Pt 100, Pt 1000 …) and humidity sensors.
Thermocouples : when connecting thermocouples, we use so-called flat connectors, miniature or standard, in different versions (economy, industry, high temperature, lock …). The most important feature of thermocouple connectors is their metal composition – the pins must be of the same thermocouple type as the temperature sensor. Here the untrained user is “at risk” of connecting the wrong connector, so users should strictly follow the rules of the colour scales in the IEC 584 standards (example: K-type is green-white combination, cable sheaths are green or with green filament in case of metal sheaths, connectors are green (same colour throughout the measuring system)). Confusion can arise because thermocouples in different standards have different colour codes (K type is green according to IEC and yellow according to ANSI). If we have equipment from a non-EU manufacturer we need to pay attention to this part and do our part of the installation in a suitable thermocouple pair, otherwise the measurement will be wrong.
Pressure switches: M12 connectors are most commonly used to connect pressure switches that measure pressure in industrial systems.
Level switches (WIKA, JOLA and MOLLET): connectors are essential for connecting level switches that measure the level of liquids or materials in vessels or tanks. M12 connectors are also popular for this application.
☏ Call us: +386 2 62 96 720
They are always available for opinions and explanations:
Aleksandra Lepenik, expert in temperature measurements
Measurement expert Zoran Lepenik
By Mojca Kugler and Zoran Lepenik, October 2023