Allen-Bradley 1442 User manual

1442 Eddy Current Probe System
User Manual

Important User Information
Read this document and the documents listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to
familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,
and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required
to be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be
impaired.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the
use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
Labels may also be on or inside the equipment to provide specific precautions.
Allen-Bradley, Rockwell Software, and Rockwell Automation are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
IMPORTANT
Identifies information that is critical for successful application and understanding of the product.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Rockwell Automation Publication ICM-UM004C-EN-E - February 2014 3
Summary of Changes
This manual contains new and updated information. Changes throughout this
revision are marked by change bars, as shown to the right of this paragraph.
New and Updated
Information
Temperature ranges and wire sizes were corrected as appropriate in this manual.
Topic Page
Corrected temperature range 13, 17
Added Speed Measurements section and relocated speed measurement figure 16
Corrected wire size 37, 51

4Rockwell Automation Publication ICM-UM004C-EN-E - February 2014
Summary of Changes
Notes:

Rockwell Automation Publication ICM-UM004C-EN-E - February 2014 5
Table of Contents
Preface Measurement Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
System Configuration Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Chapter 1
Installation
Installation Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Driver Installation Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Sensor Installation Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Extension Cable Installation Environment . . . . . . . . . . . . . . . . . . . . . 17
Outer Dimensions and Part Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . 17
1442 Sensor Outer Dimensions and Part Nomenclature . . . . . . . . . 17
Extension Cable Outer Dimensions and Part Nomenclature . . . . . 22
Driver Outer Dimensions and Part Nomenclature . . . . . . . . . . . . . . 24
Install the Driver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Mount the Driver on the Housing or Panel . . . . . . . . . . . . . . . . . . . . . 25
Mount the Driver to a DIN Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Install the Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Use a Sensor Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Use a Stinger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Adjust the Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Connect the Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Connect the Extension Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Connect the Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Connect the Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Verify the Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Set Gap Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Recommended Specifications for the Monitor Cable . . . . . . . . . . . . . . . . 37
Chapter 2
Maintenance and Inspection
Periodic Inspection Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Unit Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Troubleshoot the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Chapter 3
Individual Characteristic Data
Characteristic Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Standard Static Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Sensor Temperature Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Driver Temperature Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Static Characteristic Effect Due to Power Source Voltage Variation .
44
Static Characteristic Effect by Target Material . . . . . . . . . . . . . . . . . . 45
Static Characteristic Effect Due to Target Diameter. . . . . . . . . . . . . 46
Static Effect by Target Curved Surface . . . . . . . . . . . . . . . . . . . . . . . . . 47
Static Characteristic Effect Due to Target End Face . . . . . . . . . . . . . 48

6Rockwell Automation Publication ICM-UM004C-EN-E - February 2014
Table of Contents
Static Characteristic Effect Due to Side Wall. . . . . . . . . . . . . . . . . . . . 49
Frequency Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Appendix A
Wire the Unit to a Monitor System
Cable Wiring/Laying Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Index

Rockwell Automation Publication ICM-UM004C-EN-E - February 2014 7
Preface
This manual describes how to install and use the 1442 Series Eddy Current Probe
System.
The 1442 Series eddy current probe system performs non-contact measurement
of the distance between the sensor and the measured object (target), and outputs
a proportional voltage signal. The static component of the measurement is the
"gap," the absolute (DC) distance from the target surface to the probe tip. The
dynamic component of the measurement is the "vibration," the cyclical (AC)
movement of the target toward and away from the probe.
By combining this system with an Allen-Bradley® 1440 or 1444 Series
measurement module, you can measure the vibration of a rotating shaft, its
eccentricity, thrust position and rotating speed. The system is used for
continuous measurement or monitoring of shafts rotating at high speeds, such as
turbines, generators, and compressors.
Measurement Principles The gap between the sensor and the target is found according to the following
principles:
•When an approximately 1 MHz high frequency current is supplied from
the oscillator to the sensor, a high frequency magnetic field is created at the
sensor tip.
•The inter-linkage of the high frequency magnetic flux on the target
induces an eddy current that flows on the target surface.
•When the eddy current flows on the target surface, a magnetic field is
created at the target side, and the sensor impedance changes.
•When this change in output of the oscillator is detected, the distance
versus output voltage is made linear by a linearizer circuit, and the result is
output.

8Rockwell Automation Publication ICM-UM004C-EN-E - February 2014
Preface
You can find the gap between the sensor and the target by measuring the sensor
impedance if the following relationships are identified:
•Relationship between the sensor and the target gap.
•Relationship of the sensor impedance.
System Configuration
Example
This system is designed to fulfill the specifications when used under the following
configuration.
Figure 1 - System Configuration Example
IMPORTANT
Always combine the components of this system (sensor, extension cable,
and driver) to configure it as follows. If this system is not configured as
shown below, or if the 1442 extension cable is not used in combining the
1442 sensor and driver, the output characteristics will differ dramatically.
Sensor Extension Cable System Cable Length Driver(1)
0.5 m (1.64 ft) + 4.5 m (14.76 ft) = 5.0 m (16.40 ft) →1442-DR-xx50
1.0 m (3.28 ft) + 4.0 m (13.12 ft) = 5.0 m (16.40 ft) →1442-DR-xx50
0.5 m (1.64 ft) + 8.5 m (27.89 ft) = 9.0 m (29.53 ft) →1442-DR-xx90
1.0 m (3.28 ft) + 8.0 m (26.25 ft) = 9.0 m (29.53 ft) →1442-DR-xx90
(1) Where xx = appropriate code for probe size.

Rockwell Automation Publication ICM-UM004C-EN-E - February 2014 9
Preface
Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
You can view or download Rockwell Automation publications at http://
www.rockwellautomation.com/literature. To order paper copies of technical
documentation, contact your local Allen-Bradley distributor or Rockwell
Automation sales representative.
Resource Description
1442 Eddy Current Probe Systems Specifications Technical Data, publication 1442-TD001. Provides specifications for the 1442 Eddy Current Probe System.
Turbine Supervisory Instrumentation System Selection Guide, publication GMSI10-
SG002.
Provides details to help you choose a Turbine Supervisory Instrumentation system.

10 Rockwell Automation Publication ICM-UM004C-EN-E - February 2014
Preface
Notes:

Rockwell Automation Publication ICM-UM004C-EN-E - February 2014 11
Chapter 1
Installation
This chapter describes how to install a 1442 Series Eddy Current Probe System.
ATTENTION: Always ground the system. Never apply power until all
wiring work and connection work has been completed. If this is not
followed, there is a possibility of electrocution.
Installation work, wiring, and connections must be performed by a person
with knowledge in instrumentation.
ATTENTION: Be sure to adhere to the following guidelines:
•Before touching this unit, be sure to touch a metal section near by to
discharge any static electricity. The device can be damaged if exposed to
static electricity from a person’s body.
•Before applying power, make sure that all wiring is properly connected.
There is a possibility of damage to the unit and fire if improperly
connected.
•Install this unit away from motors and relays.
•Install the input/output signal cables away from power system and
control system cables. Noise occurring from the motor or relay can
adversely affect the measurement value. We recommend using separate
wiring ducts.
•Do not pull or bend the sensor cables and extension cables with
excessive force. The conductor in the cable can get cut off.
•The allowable tension of the sensor cables and extension cables is
98.1 N•m (10 kgf•m). The allowable bend radius is as follows:
–Without armored cable: 30 mm (1.18 in.)
–With armored cable: 50 mm (1.97 in.)
•After completing the installation, make sure all connections are correct
and tight before powering the system.
TIP
Refer to Appendix A on page 51 for recommended cable wiring, and
installation methods.

12 Rockwell Automation Publication ICM-UM004C-EN-E - February 2014
Chapter 1 Installation
Installation Environment
Driver Installation Environment
Install the driver in a location that satisfies the following environmental and
installation conditions.
Environmental Conditions
Install Conditions
•If there are walls or other obstacles at the cable connection surface of the
driver, make sure to keep spacing as illustrated below. Take care not to bend
the cable excessively.
Feature Specification
Ambient temperature Must be in a range of -30…80 °C (-22…176 °F) when devices are operating.
Ambient humidity Must be in a range of 30…95% RH (noncondensing) when devices are operating.
Vibration condition Must be 10 m/s2(1 g) or less at 10…150 Hz.
Air cleanliness We recommend an air dust-particle amount of 0.2 mg/m3or less.
We recommend an especially low amount of corrosive gasses, such as hydrogen
sulfide, NOx gas, and chlorine, and conductive particles, such as iron dust and
carbon. The allowable amounts of hydrogen sulfide and NOx gas, based on JEIDA-
29 (1979) Class S1, are shown below.
JEIDA: Japanese Electronic Industry Development Association
JEIDA-29 (1979) CLASS S1
Hydrogen sulfide: 0.01 ppm or less, NOx gas: 0.05 ppm or less
(Ambient temperature: 25 °C ± 5 °C (77 °F ± 9 °F), humidity: 40…80%
RH)
60 mm (2.4 in.)

Rockwell Automation Publication ICM-UM004C-EN-E - February 2014 13
Installation Chapter 1
•Do not locate above heat emitting objects.
Sensor Installation Environment
Install the sensor at a location that satisfies the following environmental and
installation conditions.
Environmental Conditions
Installation Conditions
•Do not install at a location exposed to rain or other moisture. Moisture can
lead to reduced sensitivity of the sensor, and reduced insulation.
•A target surface area of not less than three times the tip diameter centered
on the sensor is required, as illustrated below.
Feature Specification
Ambient temperature ATEX applications must be in a range of -35…80 °C (-31…176 °F) when devices
are operating.
CSA applications must be in a range of -35…85 °C (-31…185 °F) when devices
are operating.
Other applications must be in a range of -35…177 °C (-31…350 °F) when devices
are operating
Ambient humidity Must be in a range of 30…95% RH (noncondensing) when devices are operating.
Vibrational conditions Must be 10 m/s2(1 g) or less at 10…150 Hz. (If the sensor vibrates, an accurate
measurement cannot be made.)
Air cleanliness We recommend an air dust-particle amount of 0.2 mg/m3or less.
We recommend an especially low amount of corrosive gasses, such as hydrogen
sulfide, NOx gas, and chlorine, and conductive particles, such as iron dust and
carbon. The allowable amount sof hydrogen sulfide and NOx gas, based on JEIDA-
29 (1979) Class S1, are shown below.
JEIDA: Japanese Electronic Industry Development Association
JEIDA-29 (1979) CLASS S1
Hydrogen sulfide: 0.01 ppm or less, NOx gas: 0.05 ppm or less
(Ambient temperature: 25 °C ± 5 °C (77 °F ± 9 °F), humidity: 40…80%
RH)

14 Rockwell Automation Publication ICM-UM004C-EN-E - February 2014
Chapter 1 Installation
•When placing other sensors next to each other, separate the sensor tops by
not less than 10 times the sensor tip diameter to prevent interference.
•The sensor must be installed on a surface with adequate rigidity that is not
affected by an outside vibration. If the sensor vibrates, an accurate
measurement cannot be taken.
•For shapes and dimensions around the sensor, refer to the installation
examples (1…3) below. If a piece of metal other than the target is near the
sensor, an accurate reading cannot be taken.
If it is unavoidable to install the sensor as illustrated in examples 4…7,
check the characteristics at the attachment completed conditions.
Table 1 - Installation Examples
Example Description
Example 1 (most recommended) Dimension X is to be not less than 1.2 times the tip
diameter.
Example 2 (recommended) Dimension X is to be not less than 1.2 times the tip
diameter
Dimension Y is to be not less than 3 times the tip
diameter.
Example 3 (recommended) After constructing as shown in example 2, the area shown
by the shaded line in the illustration is filled with resin or
other insulating material.
40 mm (1.57 in.) or more
40 mm (1.57 in.) or more

Rockwell Automation Publication ICM-UM004C-EN-E - February 2014 15
Installation Chapter 1
Example 4 If dimension X is less than 1.2 times the tip diameter, the
measurement will be affected by the attachment plate.
Example 5 If dimension Y is less than 3 times the tip diameter, the
measurement will be affected by the attachment plate.
Example 6 If the attachment plate around the sensor top is
chamfered, it will be affected by the attachment plate.
Example 7 If the target and the sensor top are not parallel
(dimension X1 and X2 are not the same), it will affect the
reading.
Example 8 If dimension X is less than the minimum linear range from
sensor tip specification for the sensor, the measurement
will not be accurate.
Table 1 - Installation Examples
Example Description

16 Rockwell Automation Publication ICM-UM004C-EN-E - February 2014
Chapter 1 Installation
The characteristics of output (V) and gap (mm) are as shown in the graph below.
Speed Measurements
Assumes measurements are made with a 5 mm or 8 mm probe.
Figure 2 - Dimension of target (recommended for rotational speed measurement):
mm mils
Recommended dimension of
target (mm)
A ≥6A≥ 236
B ≥7B≥275
C ≥2.5 C ≥98
D ≥15 D ≥590
Recommended set gap (mm) 1.0...1.5 39...59
DA
B
C
DD
A
C
B
C

Rockwell Automation Publication ICM-UM004C-EN-E - February 2014 17
Installation Chapter 1
Extension Cable Installation Environment
Install the extension cable in a location that satisfies the following environmental
and installation conditions.
Outer Dimensions and Part
Nomenclature
1442 Sensor Outer Dimensions and Part Nomenclature
5 mm Sensor
L1 = Unthreaded length
L2 = Case length
L3 = Cable length
Feature Specification
Ambient temperature Cable must be in a range of -35…177 °C (-31…350 °F) when devices are
operating.
Connector must be in a range of -35…125 °C
(-31…257 °F) when devices are operating.
ATEX applications must be in a range of -35…80 °C (-31…176 °F) when devices
are operating.
CSA applications must be in a range of -35…85 °C (-31…185 °F) when devices
are operating.
Ambient humidity Must be in a range of 30…95% RH (noncondensing) when devices are operating.

18 Rockwell Automation Publication ICM-UM004C-EN-E - February 2014
Chapter 1 Installation
8 mm Sensor
L1 = Unthreaded length
L2 = Case length
L3 = Cable length
Reverse 8 mm Sensor
L3 = Cable length

Rockwell Automation Publication ICM-UM004C-EN-E - February 2014 19
Installation Chapter 1
11 mm Probes - Non Armored
L1 = Unthreaded length
L2 = Body length
L3 = Cable length
11 mm Probes - Armored
L1 = Unthreaded length
L2 = Body length
L3 = Cable length

20 Rockwell Automation Publication ICM-UM004C-EN-E - February 2014
Chapter 1 Installation
18 mm Probes - Armored
L1 = Unthreaded length
L2 = Body length
L3 = Cable length
25 mm Probes - Armored
L1 = Unthreaded length
L2 = Body length
L3 = Cable length