The EA403 extension cable is a key component of VM product line, specifically designed for the TQ403 proximity measurement system. It serves to extend the connection between the sensor and signal conditioner, working in conjunction with the TQ403 non-contact sensor and IQS450 signal conditioner to form a complete, interchangeable proximity measurement system. Manufactured with high-quality materials and precision engineering, the EA403 extension cable ensures stable signal transmission and mechanical reliability in harsh industrial environments.
The design of the EA403 extension cable addresses various industrial requirements, including long-distance transmission, high-temperature operation, mechanical stress protection, and explosion-proof capabilities. Its flexible configuration options and multiple protection measures make it an indispensable component in rotating machinery vibration and position monitoring systems.
Working Principle
As a critical part of the TQ403 proximity measurement system, the EA403 extension cable operates based on high-frequency signal transmission and impedance matching technology to ensure signal integrity between the sensor and signal conditioner. Below is a detailed explanation of its working principle:
1. High-Frequency Signal Transmission Mechanism
The EA403 extension cable is a 70 Ω coaxial cable using fluorinated ethylene propylene (FEP) as insulation and sheathing material. The coaxial structure includes an inner conductor, insulation layer, shielding layer, and outer sheath, effectively reducing electromagnetic interference and signal attenuation during transmission. When the weak high-frequency signal generated by the TQ403 sensor is transmitted through the cable, the impedance characteristics of the cable must match those of the sensor and signal conditioner to prevent signal distortion due to reflection or loss.
2. Impedance Matching and Signal Integrity
Impedance matching is crucial for ensuring system performance. The EA403 extension cable is designed with 70 Ω impedance, matching the input and output impedance of both the TQ403 sensor and IQS450 signal conditioner. This matching reduces signal reflection during transmission, preventing standing waves and signal attenuation, thereby ensuring accurate and stable measurement results. The cable length and electrical characteristics are precisely calculated and optimized to minimize signal delay and phase distortion.
3. Shielding and Anti-Interference Design
Industrial environments contain numerous sources of electromagnetic interference, such as motors, frequency converters, and high-voltage equipment. The EA403 extension cable effectively suppresses external electromagnetic interference (EMI) and radio frequency interference (RFI) through a multi-layer shielding design, including metal braided shielding and FEP insulation. Additionally, the cable's low capacitance and inductance characteristics further reduce noise and crosstalk during signal transmission, ensuring the purity of high-frequency signals.
4. Electrical Trimming and System Optimization
Due to slight variations in the electrical characteristics of coaxial cables with length, the EA403 extension cable supports "electrical trimming" functionality. By adjusting the electrical length of the cable, the system can optimize overall performance, ensuring that sensor interchangeability is not affected by cable length. For example, the minimum total system length (TSL) for a 5-meter measurement chain is 4.4 meters, while for a 10-meter chain, it is 8.8 meters. This trimming mechanism ensures optimal performance across different configurations.
5. Environmental Adaptability Design
The EA403 extension cable operates reliably in extreme environments, with a temperature range from -40°C to +200°C (including connectors and optional protection layers). The FEP material offers excellent chemical stability, low permeability, and mechanical toughness, resisting oil, moisture, corrosive gases, and liquids. Additionally, the cable provides various optional protection measures, such as stainless steel flexible hoses and FEP sheaths, further enhancing its durability in harsh environments.
6. Explosion-Proof and Safety Design
The EA403 extension cable is available in multiple explosion-proof certified versions, including Ex ia (intrinsically safe) and Ex nA (non-sparking) types, suitable for Zone 0/1/2 or Zone 2 hazardous areas. The cable's connectors feature a self-locking miniature coaxial design, ensuring secure connections that remain stable under vibration. In explosion-proof applications, the combination of the cable, sensor, and signal conditioner must comply with relevant certification requirements to ensure safe operation in potentially explosive atmospheres.
Features
The EA403 extension cable offers advanced functionalities to meet the high standards of industrial measurement systems. Its main features include:
1. High-Frequency Signal Transmission with Low Loss
Designed for high-frequency signal transmission, the EA403 extension cable ensures signal integrity with its low-loss characteristics. The cable's attenuation coefficient is optimized to maintain signal strength and stability even over long distances (up to 10 meters).
2. Flexible Length Configurations
The EA403 extension cable is available in multiple standard lengths, including 4.0 meters, 5.0 meters, and 9.0 meters (with tolerances of ±400 mm to ±900 mm). Users can select the appropriate cable length based on application requirements and combine it with the TQ403 sensor's integral cable (1.0 meters, 5.0 meters, or 10.0 meters) to form a 5-meter or 10-meter measurement chain.
3. Multiple Protection Options
The cable supports various mechanical and environmental protection options:
Stainless Steel Flexible Hose: Provides additional mechanical protection against crushing, abrasion, or cutting. With a minimum bend radius of 50 mm, it is suitable for high-vibration environments.
FEP Sheath: Offers excellent chemical resistance and low permeability, ideal for applications exposed to oil, solvents, or moisture.
IP172 Interconnection Protector: Ensures mechanical sealing and environmental protection at cable connection points, safeguarding against external factors.
4. Wide Operating Temperature Range
The EA403 extension cable operates reliably in temperatures from -40°C to +200°C, making it suitable for high-temperature industrial environments (e.g., inside turbines or compressors). Its material and structural design ensure consistent performance under extreme temperatures.
5. Explosion-Proof Certification and Safety Compliance
The cable is available in multiple explosion-proof certified versions, meeting international standards such as ATEX, IECEx, and cCSAus. For hazardous environments, users can select Ex ia or Ex nA versions to ensure compliance with safety regulations.
6. Plug-and-Play and Interchangeability
The EA403 extension cable features self-locking miniature coaxial connectors for easy installation and reliable connections. All components (sensor, cable, conditioner) are fully interchangeable without recalibration, significantly reducing maintenance costs and downtime.
7. Environmental Durability
The cable's FEP material offers excellent aging resistance, UV resistance, and abrasion resistance, maintaining performance over long-term use. Its extended design life makes it ideal for high-reliability industrial applications.
Technical Specifications Summary
| Item | Specification |
|---|
| Cable Type | 70 Ω Coaxial Cable, FEP Insulation and Sheath |
| Standard Lengths | 4.0 m ±400 mm, 5.0 m ±500 mm, 9.0 m ±900 mm |
| Total System Length | 5 m or 10 m (combined with TQ403 integral cable) |
| Connectors | Self-Locking Miniature Coaxial Connectors (Male and Female) |
| Temperature Range | -40°C to +200°C |
| Minimum Bend Radius | 20 mm (cable itself), 50 mm (with stainless steel hose) |
| Protection Rating | Depends on optional protections (e.g., stainless steel hose, FEP sheath) |
| Explosion-Proof Certification | Ex ia / Ex nA (optional) |
| Electrical Trimming Requirements | Min. TSL 4.4 m for 5 m chain, Min. TSL 8.8 m for 10 m chain |
Application Areas
The EA403 extension cable is widely used in the following industrial scenarios:
Turbomachinery: Vibration and position monitoring systems for steam turbines, gas turbines, and hydraulic turbines.
Power Generation Equipment: Extending sensor signal transmission distances in generators and exciters.
Compressor Sets: Mechanical health monitoring for centrifugal and axial compressors.
Pump Equipment: Supporting vibration measurement chain extensions for high-speed and multi-stage pumps.
Other Rotating Machinery: Condition monitoring systems for fans, gearboxes, and motors.
With its high performance and reliability, the EA403 extension cable provides critical signal transmission support for the monitoring and protection of industrial rotating machinery.
