EA402 913-402-000-012 Extension Cable

The EA402 913-402-000-012 is a precision-engineered extension cable designed specifically for use with the Vibro‑Meter TQ402 and TQ412 series proximity transducers, forming an integral part of the Vibro‑Meter proximity measurement system that includes the IQS 450 signal conditioner. This extension cable provides the necessary electrical connection between the transducer’s integral cable and the signal conditioner, allowing flexible system layout while maintaining the critical impedance matching and electrical trimming required for accurate, repeatable measurements. The EA402 913-402-000-012 is a standard‑configuration extension cable, featuring a 1‑metre total system length contribution, and is intended for use in non‑hazardous (safe area) installations.

The EA402 913-402-000-012 is a coaxial cable assembly with a 70 Ω characteristic impedance, matching the transducer’s integral cable to ensure signal integrity across the entire system. It is terminated with a miniature coaxial female connector on one end (to mate with the transducer’s male AMP connector) and a miniature coaxial male connector on the other end (to connect to the IQS 450 conditioner or to another extension cable in a daisy‑chain configuration). The cable is constructed with FEP (fluorinated ethylene propylene) insulation, providing excellent dielectric properties, low signal attenuation, and resistance to high temperatures and chemicals. The cable’s outer diameter is 3.6 mm, identical to the transducer’s integral cable, ensuring consistent handling and bending characteristics.

The EA402 913-402-000-012 is part of a calibrated, interchangeable proximity system. Each extension cable is electrically trimmed at the factory to compensate for its specific length, ensuring that the total system length (TSL) meets the required electrical characteristics for optimal performance. The system’s interchangeability feature allows any component (transducer, extension cable, or conditioner) to be replaced without recalibration, provided the total system length remains unchanged. This significantly simplifies maintenance and reduces spare parts inventory.

The primary function of the EA402 913-402-000-012 is to extend the reach of the transducer while preserving the high‑frequency signal quality essential for both static (position) and dynamic (vibration) measurements up to 20 kHz. The cable’s robust construction, combined with its flexibility and temperature resistance, makes it suitable for routing through machinery enclosures, junction boxes, and control panels in demanding industrial environments, including power generation, oil and gas, petrochemical, and marine applications.

This product introduction provides a comprehensive technical overview of the EA402 913-402-000-012, covering its design, electrical and mechanical specifications, environmental ratings, system integration, installation best practices, and ordering information. All data are derived from the official Vibro‑Meter datasheet (TQ 402 & TQ 412 / EA 402 / IQS 450, document 265‑062, version 3).

Construction and Design Features

The EA402 913-402-000-012 is a high‑quality coaxial extension cable assembly with the following key structural components:

• Conductor: A stranded or solid tinned copper centre conductor (typical for 70 Ω coaxial cables) that ensures low DC resistance and excellent signal transmission.

• Dielectric: FEP (fluorinated ethylene propylene) insulation, which provides a stable dielectric constant over a wide temperature range (–100°C to +200°C), low loss, and resistance to moisture and chemicals.

• Shield: A tinned copper braid or foil shield (typical for coaxial cables) that provides electromagnetic interference (EMI) protection and maintains the characteristic impedance.

• Outer Jacket: FEP outer sheath, which is tough, flexible, and resistant to abrasion, oils, and solvents. The jacket has a nominal outer diameter of 3.6 mm and is colour‑coded for easy identification.

• Connectors: The cable is terminated with a miniature coaxial female connector (type AMP 1‑330 723‑0 mating with the transducer’s male connector) on one end, and a miniature coaxial male connector (type AMP 1‑330 723‑0) on the other end. Both connectors are gold‑plated to ensure low contact resistance and corrosion resistance. The connectors are designed for hand‑tightening only – no tools should be used to avoid damaging the delicate centre pin or outer shell.

• Cable Length: The EA402 913-402-000-012 is configured with a nominal length that contributes to a total system length of 1 metre. The exact physical length is trimmed at the factory to meet the electrical trimming requirements (see Total System Length section). The cable length tolerance is such that the total system length (TSL) is at least 0.9 metre for a 1‑metre system, as per the datasheet.

• Marking: Each cable is marked with its part number and electrical trimming code to ensure correct pairing with other system components.

The EA402 913-402-000-012 is designed to be used in conjunction with the TQ402 or TQ412 transducer’s integral cable. The sum of the integral cable length and the extension cable length equals the total system length (TSL). For this specific model, the extension cable length is chosen so that the total TSL is 1 metre, ensuring compatibility with the factory calibration of the IQS 450 conditioner.

Operating Principle and System Integration

The EA402 913-402-000-012 is a passive coaxial cable that carries the high‑frequency carrier signal from the IQS 450 conditioner to the transducer, and the modulated signal back to the conditioner. The cable’s impedance (70 Ω) is matched to the transducer and conditioner to minimise reflections and signal loss, which is critical for maintaining the linearity and accuracy of the eddy‑current measurement.

The system operates as follows:

1. The IQS 450 conditioner generates a high‑frequency oscillator signal (typically in the megahertz range) and sends it through the extension cable to the transducer.

2. The transducer’s coil generates an electromagnetic field that induces eddy currents in the metallic target. The coil’s impedance changes with the gap.

3. The reflected signal (which varies with impedance) travels back through the same cable to the conditioner.

4. The conditioner demodulates the signal to produce a DC voltage or current proportional to the gap.

The EA402 913-402-000-012 is an essential link in this chain. Its length affects the phase and amplitude of the signal; therefore, each cable is electrically trimmed at the factory to compensate for its specific length. This trimming ensures that any cable of the same length is interchangeable with another, maintaining system accuracy without recalibration.

The system is calibrated at +23°C ±5°C using a VCL 140 steel target. The total system length (TSL) must be within the specified tolerances for the interchangeability to hold. For a 1‑metre system, the TSL must be at least 0.9 metre, and the actual trimmed length is set at the factory to achieve the optimal electrical performance.

Intended Applications

The EA402 913-402-000-012 is used in all applications where Vibro‑Meter proximity transducers (TQ402/TQ412) are deployed, particularly when the transducer’s integral cable is not long enough to reach the signal conditioner. Typical applications include:

• Turbomachinery Monitoring: Steam, gas, and hydraulic turbines – connecting transducers mounted in bearing housings to remotely located conditioners in control panels.

• Compressors and Pumps: Turbo‑compressors, centrifugal pumps, and fans – extending the transducer cable through conduit or cable trays.

• Generators and Alternators: Monitoring shaft vibration and axial position in power generation plants.

• Marine and Offshore: Main propulsion engines, shaft lines, and auxiliary machinery on ships and offshore platforms.

• Industrial Machinery: Paper mills, steel mills, mining equipment – where the transducer must be installed in hard‑to‑reach locations and the conditioner is placed in a safe, accessible area.

• **Any installation where the total system length must be precisely controlled to maintain interchangeability and factory calibration.

The EA402 913-402-000-012 is particularly suited for systems requiring a total length of 1 metre, which is common in retrofit applications where the existing cable run is short, or when the conditioner is mounted close to the transducer.

Installation and Handling Recommendations

Proper installation and handling of the EA402 913-402-000-012 are essential to maintain system accuracy and reliability. The following guidelines should be observed:

• Cable Routing: The cable should be routed with a minimum bend radius of 20 mm. Avoid sharp bends, kinks, or crushing. Use cable ties or clamps to secure the cable at regular intervals, but do not over‑tighten as this can deform the jacket.

• Connector Mating: Connectors must be aligned carefully and pushed together until they click. Hand‑tighten only – use of pliers or wrenches can damage the centre pin or the outer shell. If a connector feels tight, clean the threads and mating surfaces; do not force.

• Strain Relief: Provide adequate strain relief at both ends to prevent mechanical stress on the cable‑to‑connector joints. Use cable glands or grommets if passing through panels.

• Environmental Protection: Although the cable is rated IP64 at the connector junction when mated, it is advisable to use the optional heat‑shrinkable sleeve (available as an accessory) to provide additional splash‑proofing, especially in humid or wet areas. For outdoor or exposed installations, consider a flexible protection tube.

• Cable Separation: Keep the extension cable away from high‑voltage power cables to avoid electromagnetic interference. Maintain at least 100 mm separation from AC power cables, and cross them at right angles if necessary.

• Length Verification: The total system length (integral + extension) must match the factory‑trimmed value. If replacing a cable, ensure the new cable has the same trimmed length code to preserve interchangeability. Mixing cables of different lengths will shift the calibration.

• Temperature Considerations: While the cable can withstand up to +200°C, the connectors are limited to +85°C. Ensure the connectors are not exposed to temperatures exceeding this limit. If the cable passes through a high‑temperature zone, use a heat‑resistant conduit.

• Cleaning: Clean connectors with a lint‑free cloth and isopropyl alcohol if contamination is suspected. Do not use abrasive cleaners.

System Interchangeability and Total System Length (TSL) – Detailed

The EA402 913-402-000-012 is part of a system where interchangeability is guaranteed by factory trimming. The trimming process involves adjusting the cable’s electrical length (not physical length) to achieve a consistent phase and amplitude response. This is done by measuring the cable’s capacitance and inductance and then selecting a precise physical length that yields the correct electrical characteristics.

For a 1‑metre system, the TSL must be at least 0.9 metre. The actual cable lengths (integral and extension) are chosen such that their sum falls within the acceptable range. The EA402 913-402-000-012 is trimmed to work with a specific integral cable length (e.g., 0.5 metre integral plus 0.5 metre extension, or 1.0 metre integral with no extension, etc.). The exact combination is specified at the time of order.

When replacing any component, the new component’s trimmed length code must match the original to ensure the system remains within calibration. The IQS 450 conditioner is calibrated for a specific TSL; altering the TSL will shift the output and require recalibration.

Compliance and Certifications

The EA402 913-402-000-012 (standard version) does not carry ATEX or CSA hazardous area certifications, as it is intended for use in safe areas. However, the cable family is available with Ex i (intrinsic safety) and Ex nA (non‑sparking) options for use in Zone 1, 2, and Class I Division 1/2 areas – those are ordered with different environment codes.

The standard version still meets general industrial EMC requirements as part of the complete system. The cable itself is passive and does not generate emissions; it is designed to maintain signal integrity in industrial electromagnetic environments.

RoHS compliance is assumed, as Vibro‑Meter products typically conform to European directives.

Accessories and Complementary Products

To complete the installation, the following accessories may be ordered separately:

For the EA402 913-402-000-012, no additional protection is included; if required, order a variant with a protection code (e.g., F=1) or add aftermarket protection.

Maintenance and Troubleshooting

The EA402 913-402-000-012 is a maintenance‑free passive component, but periodic inspection is recommended:

• Visual Inspection: Check the cable jacket for cuts, abrasions, or signs of thermal degradation (discolouration, hardening). Examine connectors for bent pins, corrosion, or loose connections.

• Continuity Check: Use a multimeter to verify that the centre conductor and shield have continuity and that there is no short between them.

• Connector Cleaning: If connectors become dirty, clean with a contact cleaner and a soft brush.

• Length Verification: If system performance drifts, verify that the total system length matches the original specification. An incorrectly matched extension cable will cause measurement errors.

Common issues and solutions:

• Intermittent signal: Check connector tightness and cleanliness; inspect cable for intermittent breaks.

• No signal: Check continuity; ensure the connector is fully engaged; test with a known good cable to isolate the fault.

• Output drift: Ensure the cable is not exposed to extreme temperatures beyond its rating; verify the target material and gap.