Protection for vulnerable sensor cables

Recognise the problem? Damaged cables at the sensor output due to mechanical stress.

In a digital world sensors are indispensable. They monitor processes and conditions to ensure that everything runs smoothly and safely. It is therefore very important to ensure that sensors continue to function properly as failure can have far-reaching consequences such as system downtime, security issues and additional cost.

Most sensors are installed to operate in static non-critical environments where the probability of damage to a sensor cable is relatively low. There are, however, situations where sensitive sensor cables are exposed to severe and harsh operating conditions which can result in them becoming compromised and having to be prematurely replaced. In addition to mechanical loads, sensitive cables that are left unprotected and are exposed to aggressive chemicals, high temperatures, dynamic movement and other demanding conditions are more likely to be damaged resulting in system failure. With this in mind the R&D teams of Pepperl+Fuchs and Anamet Europe put their heads together to develop a robust sensor cable protection system that is capable of handling the most demanding operating conditions while providing data transfer continuity and uncompromised system security. When connected, the robust 4 part system consisting of sensor, sensor adapter, flexible metal conduit and cable hose fitting combine to ensure a fully integrated, high integrity sensor cable protection system.

Depending on application requirements, the flexible metal conduit can be supplied in either a stainless-steel version without cover (type UI) with IP40 rating or a galvanized steel version with PU cover (type HFX) with IP 67/IP66 rating which offers additional cable protection against oils, greases and chemicals etc. The choice of sensor adapter depends upon the thread size of the sensor. Two options are available: the standard version is made of nickel plated brass while a stainless steel version is available on demand. The sensor adapter acts as an interface connecting the conduit to the cylindrical sensor while the cable hose fitting guarantees an IP 68 sealing at the enclosure side.

The sensor adapter is available in sizes M8x1mm, M12x1mm, M14x1mm, M18x1mm and M30x1,5mm and is used to connect the sensor to the flexible conduit. The required nickel-plated brass cable-hose fitting is used to connect the flexible metal conduit to the terminal (junction) box or enclosure. The internal clamping seal of the cable-hose fitting prevents the ingress of moisture and dust into the junction box to ensure an IP68 rating. This method of cable protection is widely used in the machine and equipment building and chemical -and petrochemical industries to mention a few.

Advantages of cable protection systems for harsh conditions

• Optimally tailored product range for all standard sensor types, consisting of adapter with thread for sensor fixation, flexible metal conduit and cable-hose fitting.
• Robust solution made of high-quality materials to protect the installation against mechanical and chemical influences.
• Reliable dust- and liquid tight seal (IP 68) to protect the junction box.
• Maximum usability even in environments with extreme temperatures and/or applications with moving parts.
• Easy assembly and installation

The complete sensor assembly is available at Pepperl+Fuchs. Individual solutions for self-assembly are available via Anamet Europe.

Even when preassembled the sensor can be adjusted to the right position.

If additional thermal protection is needed to protect the assembly it is possible to use a Hiprojacket sleeve installed over the conduit to shield against contact radiation with, for example, liquid metal splash (1640°C – short time), sparks and radiation heat (durability depends on thermal insulation in combination with cable properties; for more information and advice please consult a local sales manager of Anamet Europe). Additionally, a self-fusing tape (Hiprosiltape) can be used to seal the ends.

Anamet Europe is a specialist in cable protection and developing individual solutions for any application.  If you are searching for a cable protection solution for your particular application, please consult our website: https://www.anameteurope.com/products/

Altenatively, please contact one of our experienced sales engineers to discuss the options for your specific application: https://www.anameteurope.com/contact/