Looking for 120V-rated, weather-resistant M+F plugs for sensors

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RyanMP1011

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Texas, United States
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Industrial Electrician
Hi everybody,

I'm an industrial electrician that services multiple rock crushing sites. One of our remote sites is about 90 miles away from my typical area.

We use stop-switches on some conveyors, mounted to the tail bearing by magnet, and they occasionally go bad. When these units go bad, it leaves the plant down for several hours until me, or someone else, can drive out there to replace the failed sensor.

These are the two types of sensors we use:

4B Whirligig - Universal Shaft Sensor Mount

www.go4b.com www.go4b.com


What I am looking to do is to install a female cord-plug or bulkhead connector, and a matching male plug on the sensors.

This way, if a sensor goes bad, one of the plant guys can quickly plug a new one in and get back to running. I would of course make up a few sensors with these connectors and leave them at the site, so that they would be ready to simply unplug and plug in.

It would have to be something non-standard, something that couldn't be accidentally mixed up with something else.

You guys got any solutions?

Thanks in advance.

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I have used Brad Harrison corded plugs and receptacle for some industrial instrumentation that we want to have a local disconnect or for items that are often interchanged. There are multiple combinations of wire sizes and number of conductors.
www.zoro.com

Brad Harrison Cordset, 2 Pin, Receptacle, Female 102000A01F060 | Zoro

Order Brad Harrison Cordset, 2 Pin, Receptacle, Female, 102000A01F060 at Zoro.com. Great prices & free shipping on orders over $50 when you sign in or sign up for an account.
www.zoro.com www.zoro.com
 
I used many of the ones Don references, originally Brad Harrison micro connect, but now different numbering as they are combined with DIN style. I would use a 1/2” npt 3pole male with 12” leads on a c conduit body for a solenoid valve, connect with a 3 pole female cord
Hardest part is the catalog number. Find a rep and call
 
You might also look at Deutsch Connectors. There come in all shapes and sizes, and all have silicone "O-Rings" to seal the mating halves. You can also install sealing plugs for the back side of each mating connector to seal the wire entry. Very common in automotive applications, you might have seen some under your car's hood.

Just Google Deutsch connectors.

1692710024336.png
 
LarryFine said:
How many conductors, what voltage, what current?
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Larry, sorry I did not fully specify

These sensors all operate at 120V, and they have either two or three wires.

One hot, one return, and sometimes a ground. I've seen these come with and without a ground wire.

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MD Automation said:
You might also look at Deutsch Connectors. There come in all shapes and sizes, and all have silicone "O-Rings" to seal the mating halves. You can also install sealing plugs for the back side of each mating connector to seal the wire entry. Very common in automotive applications, you might have seen some under your car's hood.

Just Google Deutsch connectors.

View attachment 2567088
Click to expand...
Our heavy equipment mechanics keep some of these types of connectors around, but I didn't know if they would be voltage-rated or identified/listed for such use, like with alternating current.

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RyanMP1011 said:
Our heavy equipment mechanics keep some of these types of connectors around, but I didn't know if they would be voltage-rated or identified/listed for such use, like with alternating current.

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Click to expand...
I am pretty sure 120VAC would not be a problem for those connectors. See the snip below...

1692727388330.png
 
Todd0x1 said:
OP wanted weatherproof, those arent (and the weatherproof ones are pretty expensive)
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The price doesn't bother me too much, considering it'd only be a fraction of the sensor price, but mainly because those twist-locks could *theoretically* be mixed up with a 120V twist-lock power outlet, and someone could *theoretically* plug the sensor into it, potentially damaging the sensor. And I guess they could also wrongly plug a power tool into it, thinking that it's a power receptacle, but that wouldn't cause any damage.

While I doubt that would happen, still we are asked to make things 100% fool-proof when possible. So it shouldn't be something they can just grab off the shelf at the big orange store, because I also don't want the plant guys to make these plug connections up themselves.

It doesn't even need to have a high ampacity, since it's only powering a relay or starter coil, protected by a 1 amp fuse most of the time.

Those Deutsch connectors look like they'll be perfect for what I need, and it looks like there's even some panel mounted options as well.

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RyanMP1011 said:
. . . we are asked to make things 100% fool-proof when possible.
Click to expand...
rofl1.gif
 
RyanMP1011 said:
Those Deutsch connectors look like they'll be perfect for what I need, and it looks like there's even some panel mounted options as well.
Click to expand...

Yes, they come in a variety of styles and sizes. Current rating from ~7.5 amps to 100 amps. Likely your sensor application would be a small, lower power style, if you are protecting the circuit with a 1A fuse.

As far as voltage ratings, there was some discussion above about if they were suitable. Unless I am reading the specs wrong, they can handle an order of magnitude more than your 120 VAC. So there should be no worry there.

I have used these in the past on some custom made projects we were building. I was always impressed with how they were built, when you go to connect them up, you can "feel" the silicone rings sealing up as you push the mating halves together. Then the "click" as they lock. Also, as I mentioned above, you can get them with silicone seals (and plugs) for the back half (wire entry) of each connector. It's a nicely designed system.

Good luck with whatever solution you choose !
 
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