TIPS FROM TECHS

Sensors with
Integral Softline Cable Energy & Power Generation

Written By:
Meredith Christman,
Product Marketing Manager, IMI division of PCB Piezotronics

Visit us online at www.imi-sensors.com Toll-Free in USA 800-959-4464 716-684-0003

SENSORS WITH INTEGRAL SOFTLINE CABLE

Article by:
Meredith Christman, Product Marketing Manager, IMI division of PCB Piezotronics, Depew, New York

In dusty or wet vibration monitoring applications, sealing of the cable to the sensor is of prime importance in order to
avoid contamination of the sensor/cable connection. In these types of environments, sensors with an integral softline
cable are an ideal solution as they eliminate the possibility of liquid or particulate infiltration.

Most accelerometers, vibration transmitters and smart switches produced by IMI Sensors have several integral cable
options available. Sensors with an integral softline cable can be easily identified by their model designation as the fifth
character of the model number defines the connector/cable type. (ie. Model 608A11) See Table 1 below for additional
explanation.

Table 1: Definition of Cable/Connector Type Based on Model Designation’s Fifth Alphanumeric Character
Character Connector/Cable Type Character Connector/Cable Type
0 2-pin MIL connector 5 10-32 side exit
1 Unarmored, polyurethane-jacketed cable 6 Armored, polyurethane-jacketed cable
2 Unarmored, PTFE-jacketed cable 7 Terminal block connector
3 Bayonet MIL connector 8 Mini-MIL connector
4 10-32 top exit 9 4-pin M12 connector

APPLICATIONS REQUIRING SENSORS WITH INTEGRAL SOFTLINE CABLE

As seen in Table 1 in the previous section, there are three standard options for integral softline cable- unarmored cable
with a polyurethane jacket, unarmored cable with a PTFE jacket and armored cable with a polyurethane jacket. Each of
the cable types are designed to meet the requirements of a specific application.
 Unarmored cable with a polyurethane jacket- Ideal for general purpose applications with an ambient
temperature below 250 °F and no exposure to caustic elements. (This option is the most commonly-selected
integral cable option.)
 Unarmored cable with a PTFE jacket- Ideal for environments with an ambient temperature between 250-392 °F
or environments with exposure to caustic elements (ie. acids, acetone, chlorine, fuel oils, salt water).
 Armored cable with a polyurethane jacket- Ideal for environments where objects could pierce, damage or crush
the cable.

Specific examples of each of the above-referenced environments are listed in the Table 2.
Table 2: Examples of Applications Requiring Sensors with Integral Softline Cable
Unarmored, Unarmored, Armored,
Application
Application Polyurethane- PTFE- Polyurethane-
Type
Jacketed Jacketed Jacketed
Industrial Slurry Manufacturing X
Offshore Oil Rigs X
Wet
Paper Mills X
Water/Wastewater Treatment X
Cement Production X X
Coal Processing X X
Graphite Milling X
Grain Milling X
Dusty
Metal Machining Operations X X
Rice Hulling Facilities X
Rock Quarries X X
Technical Ceramics Production X X
TYPES OF INTEGRAL SOFTLINE CABLE

As described in the previous section, each of three standard options for integral softline cable is tailored to specific
application requirements. That tailoring is based upon the unique characteristics of each of the cables. An overview of
each cable type is provided in Table 3 below.

Table 3: Characteristics of Three Different Types of Integral Softline Cable

Unarmored,
Characteristic
Polyurethane-Jacketed
052 (two-conductor)
Most Common Cable Models
059 (four-conductor)
Unarmored, Armored,
PTFE-Jacketed Polyurethane-Jacketed
047 (armored 052)
055 (two-conductor)
043 (armored 059)

Temperature Range -58 to +250 °F -85 to +392 °F -58 to +250 °F

Bend Radius (Minimum) 2.5 in 1.9 in 4.1 in
0.67 oz/ft (052) 1.61 oz/ft (047)
Weight 0.52 oz/ft
0.75 oz/ft (059) 1.69 oz/ft (043)

Conductors Stranded AWG 19/32 tin-plated copper

Conductor Configuration Twisted Pair or Bundle
Insulation Fluorinated ethylene propylene (FEP)
Shield Braided with at least 85% coverage
Cable Jacket Material Polyurethane PTFE Polyurethane
Armor N/A N/A Stainless Steel

CREATING A LASTING SEAL

In order to ensure a water/dust-tight seal between the sensor

and the softline cable, a precise manufacturing process is
followed.

Raw cable is first securely and permanently fastened to the

stainless steel cable tube with overmold. After wiring the cable
conductors to the element assembly, the entire cable/cable
tube/overmold assembly is permanently attached to the sensor
housing by welding the exposed portion of the cable tube to the sensor housing.

For product with an integral armored cable, the

manufacturing process continues with the armor
being attached to the exposed portion of the
cable tube in order to provide complete
protection for the cable. See Figures 1 and 2.

The manufacturing process concludes with the

assembly and attachment of the terminating
connector. For most IMI Sensors’ products, the
customer can select the terminating connector.
 TIPS FROM TECHS
What are divisions of PCB Piezotronics?
PCB Piezotronics, a member of the PCB Group families of companies, has five major divisions, all of which offer targeted sensor technologies. These
divisions are supported by an active outside direct sales force of Field Application Engineers, as well as international direct sales offices throughout
the world. Individual PCB Piezotronics divisions, locations and their primary product specialties include:

Depew, NY, USA - www.pcb.com – Piezoelectric, ICP®, piezoresistive & capacitive

pressure, acoustic, force, torque, load, strain, shock & vibration sensors.

Depew, NY, USA - www.pcb.com/aerospace – Sensors & Instrumentation for

aerospace & defense applications, including air and spacecraft testing.

Novi, MI, USA - www.pcb.com/auto – Sensors & Instrumentation for automotive testing,
including modal analysis; NVH; component durability; powertrain testing; vehicle dynamics;
safety and regulatory testing.

Depew, NY, USA - www.imi-sensors.com – Industrial vibration sensors, bearing fault

detectors, mechanical vibration switches, panel meters, cables & accessories for
predictive maintenance and equipment protection.

Depew, NY & Provo, UT, USA www.larsondavis.com – Precision microphones,

sound level meters, noise dosimeters, audiometric calibration systems.

San Clemente, CA, USA - www.pcb.com – Research & development engineering

center for special technologies.
MEMS AdvAncEd dESign cEntEr Seattle, WA, USA - www.pcb.com – Process development and fabrication of
MEMS sensors.

Farmington Hills, MI, USA - www.pcb.com/LoadAndTorque – Designs and manufactures

high quality, precision load cells, wheel force transducers, torque transducers, telemetry
systems, and fastener torque-tension test systems.

PCB® Group Companies:

Cincinnati, OH, USA - www.modalshop.com – Global leader in dynamic calibration offering a

DYNAMIC METROLOGY complete line of automated calibration systems and recalibration services to support dynamic
vibration, pressure and force sensors in applications such as: national standards, commercial
labs, government/military research, consultancies, and industrial/plant floor operations.

Rochester, NY, USA - www.sti-tech.com – Mechanical engineering consulting firm

specializing infinite element analysis, advance analytical techniques, experimentation,
technology development, &design optimization for turbo machinery, industrial machine
systems & mechanical structures.

Corporate Headquarters 3425 Walden Avenue Depew, NY 14043-2495 USA

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