What is Vibration

Vibration is simply the motion of a machine or machine part back and forth from its position of
rest. The simplest way to show vibration is to follow the motion of a weight suspended on the end
of spring as shown in the Fig.1

This is typical of all machines since they; too have weight and spring like properties. Until
a force is applied to the cause it to move, we have no vibration. By applying an upward force, the
weight would move upward, compressing the spring. If we released the weight, it would drop
below its neutral position to some bottom limit of travel, where the spring would stop the weight.
The weight would then travel upward through the neutral position to position. This motion will
continue in exactly the same manner as the force is reapplied. The vibration is the response of a
system to same internal or external excitation (stimulus) or force applied to the system.

What Causes Vibration

With few exception mechanical troubles in a machine cause vibration. Listed Below is the
most common problem that produces vibration. They are:

Unbalance of rotating parts Torque variations

Electromagnetic force Misalignment of coupling
Aerodynamic force Bent shaft.
Hydraulic force Worm, eccentric or damage gear
Looseness Bad driver belts and driver chains
Rubbing Bad bearing-anti- friction type
Resonance
The cause of vibration, regardless of type, must be a force, which is changing in either its
amount, and the resulting characteristics will be determined by the manner in which the forces are
generated. This is why each cause of vibration has its own individual characteristics.

The Characteristics of Vibration

A machine condition and mechanical problems are determined by measuring its vibration
characteristics. The more important of these characteristics include.

1. Frequency 5. Phase
2. Displacement 6. Spike energy
3. Velocity
4. Acceleration
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 Referring to the weight suspended one a spring, we can study the detailed characteristic of
vibration by plotting the movement of the weight against time. This plot is shown in Fig.2

The motion of the weight from its neutral position, to the top limit of travel back through the
neutral Position, represents one cycle of motion and has all the characteristics needed to measure
the vibration continued motion of the weight would simply
be respecting these characteristics.

Vibration Frequency

As shown in Fig. 3 the amount of time required completing one full cycle of vibration pattern
is called the period of vibration. If a machine completes one full cycle of vibration in 1/60th of a
second, the period of vibration is said to be 1/60th second.

The period of vibration is simple a meaningful characteristic that is often used in vibration
detection and analysis. A characteristic of equal simplicity and more meaning is frequency.
Vibration frequency is measure of the number of complete cycles that occur in a specified period
of time. Frequency is related to the period of vibration pattern by this simple formula.
Frequency = 1/ period.
The frequency of vibration is usually expressed as the number of cycles that occur each minute.
This is the origin of the term cycle per minute, or CPM
Specifying vibration frequency in terms of CMP marks it’s easy to relate this characteristic to
another important specification for rotating machinery-RPM, or the number of revolutions per
minute. So if you have a machine that rotates at 3600RPM, you can certain problems to create
vibration at a frequency of 3600CPM.
A third way to specify frequency is in terms of the number of cycle per second, or Hertz. Because
1Hz is equal to 60CPM the equations in *Note can be used for converting frequency specified in
Hz to units of CPM and vice-versa.
*Note: Given a frequency specified on Hz, you can convert it to CPM.
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 CPM = Hertz X 60

Given a frequency specified in CPM, you can convert it to Hz.

Hertz = CPM / 60

Vibration Displacement (Peak To Peak)

The total distance traveled by the vibrating part, from the one external limit of travel to the
other extreme limit of travel is referred to as the “Peak-to-Peak Displacement”. Peak-to-Peak
vibration displacement is usually expressed in Mils, where 1 mils is equal to one thousand of an
inch (0.001 inch). In metric unit, the Peak-to-Peak vibration displacement is expressed in
micrometer, where 1 micrometer equals one thousand of millimeter (0.001 millimeter).

Vibration Velocity (Peak)

Since the vibrating weight Fig.4 is moving, it must be moving at same speed. However, the
speed of the weight is constantly changing. At the top limit of the motion the speed is zero since
the weight must come to a stop before it can go in the

Opposite direction. The speed of velocity is greatest as the weight passes through the neutral
position The velocity of the motion is directly a characteristic of the vibration, but since it is
constantly changing throughout the cycle, the highest “Peak” velocity is selected for measurement.
Vibration velocity is expressed it terms of inch-per-second peak of English units. In Metric units,
vibration velocity is expressed in millimeter per second peak.
In discussing vibration velocity, we pointed out that the velocity of the part approaches zero at
the (maximum) extreme limits of travel of course, each time the part come to a stop at the limit of
travel, it must “Accelerate” to pick up speed as it travels towards the other extreme limit of travel
Vibration acceleration is another important characteristics of vibration. Technically acceleration is
the rate of change of velocity.

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 Referring to the motion plot Fig.5 the acceleration of the part is maximum at the extreme
limit of travel where the velocity is zero Point ‘A’. As the velocity of the part increases, the
acceleration decreases .at the Point ‘B’ the neutral position, the velocity is maximum and the
acceleration is zero. As the part passes through the neutral point it must now “Decelerate” as it
approaches the other extreme limit of travel. At Point ‘C’ acceleration is greatest.
Vibration acceleration is normally expressed in“g’s” peak where one ‘g’ is the acceleration
produced by the force of Gravity at the surface of the earth. By international
agreement, the value of 980.665 cm/sec/sec (386.087 inch/sec/sec or 32.1739 feet/sec/sec) has
been chosen as the standard acceleration due to Gravity.

Vibration Phase

Another important characteristics of vibration are “Phase”. Phase is defined as “The position of
vibrating part at a given instance with reference to a fixed point or another vibrating part”.

In a practical sense, phase measurement offer a convenient way to compare one vibration
motion with another; or to determine how one part is vibration relative to another part. For
example two weight in Fig.6 are vibrating at the same frequency and displacement however
weight “A1” is at the upper limit of travel at the same instant weight “B1” is at the lower limit We
cane use phase to express the comparison. By Plotting one complete cycle of motion of these two
weight, starting at the same given instant we see that the points of peak displacement are separated
by 1800 (One complete cycle = 3600) Therefore, we would say that these two weights are vibrating
1800 out of phase

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In Fig.7 weight “X” is at the upper limit of Travel at the same instant weight “Y” is at the neutral
Position, moving toward the lower limit. These two weights are vibrating 900 out of phase.

In Fig.8 weight “C1” and “D1” reach the upper limit of travel at the same instant. “These weight
are in phase”.

Vibration Spike Energy TM Measurement

Still another characteristic of vibration that is of special interest is “SPIKE ENERGYTM”

measurement. This is a fairly abstract quantity that cannot be readily related to a picture of
vibrating weights.
Spike Energy measurement include very short duration, high frequency, spike - like
Pulse of vibration energy that occur in machinery as a result of:

a. Surface flaws in rolling element of bearing or gears.

b. Rub, impact and metal-to-metal contact in rotating machines.
c. High-pressure steam or air leakage
d. Cavitations of flow turbulence in fluids.

Spike Energy measurements have their own unique unit of measurement. A through Spike Energy
measurement are basically a measure of vibration acceleration, the special electronic circuit that
process the signals make them particularly sensitive to the high- frequency vibrations produced by

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bearing and gear defects. For this reasons Spike Energy measurements are expressed in “g-SE’
units.

Other Characteristics

There are several additional characteristics whit, which you should become familiar to aid to
understanding machinery vibrations.

Force vibration: is a vibration causal by a vibratory force such as an unbalance that forces a
machine or structure to vibrate at the frequency of vibratory force.

Free vibration: is a vibration that occurs when a machine or structure is allowed to vibrate in the
absence of any external force (e.g. after removal of the forced vibration).

Driving frequency: is the frequency of a force vibration.

Natural frequency: is a frequency at which 2 machine or structure will vibrate when under going
free vibration. It is a frequency at which machine “prefers” to vibrate. For example, when a bell is
struck it will vibrate at the frequency for which it was designed. Most machines and structures
have many natural frequencies at which they will vibrate. Any momentary force (e.g. striking the
structure with a hammer) can cause the excitation at one or more natural frequencies.

Resonant frequency: is a frequency at which coincidence occurs between a Natural frequency and
a Driving frequency. Usually, the vibration become large as the Driving frequency approaches a
Natural frequency and reach a maximum when they coincide.

Critical speed: is a special case of resonant frequency that occurs when the rotational speed
(RPM) of a machine, which is the Driving frequency, coincides with a Natural frequency of the
machine. Most commonly, this is a Natural frequency of the shaft that causes it to bend with
resulting large vibration amplitudes.

Measurement Units

Peak-to-Peak, Peak, RMS, Average

A number of units are used to describe vibration measurements. Fig .9 shows the
relationship between the various units. The waveform is sinusoidal. The Peak-to-Peak value
describes the maximum excursion between the upper limit and the lower limit of travel.

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 Historically, vibration reading have been compared to reading obtained using a dial
indicator which measure movement in terms of thousandths of inch or mils (1 mil = .001 inch)
vibration displacement measurement are often measure in mils, Peak-to-Peak.

MULTIPLY PEAK-TO- PEAK RMS AVERAGE

NUMBER PEAK
OF

TO
OBTAIN

PEAK-TO- 1.000 2.000 2.828 3.142

PEAK
PEAK .0.500 1.000 1.414 1.571

RMS 0.354 0.707 1.000 1.110

AVERAGE 0.318 0.636 0.9000 1.000

Peak measurements are Peak-to-Peak divided by two or one half the Peak-to-Peak value.
Another term often used to characterize the severity of machine vibration is RMS or
Root-mean-square. This term is often used when vibration are random or consist of a number of
sinusoidal vibration of different frequencies. The RMS value is a measured of the effective energy
used to produce the vibration of the machine..
Electrical meter often read the average value of the waveform. The average value of a
sinusoidal waveform is 0.637X peak. For a sinusoidal motion RMS value is 0.707X peak

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 Conversion of measurement parameter

If vibrations are simple (i.e. sinusoidal), displacement velocity and acceleration are directly
related. One parameter can be converted to another by the following equations:

ENGLISH METRIC
D = Displacement (mils peak-to-peak) Dm = Displacement (micro m peak-to-peak)
V =Velocity (in/sec peak) Vm = Velocity (mm/ sec peak-to-peak)
A =Acceleration (g peak) A = Acceleration (g peak)

D = 19.10 X 10 3 (V) / (RPM) Dm = 19.10 X 10 3 (Vm) / (RPM)

D = 70.40 X 10 6 (A) / (RPM) 2
V = 52.36 X 10-6 (D) (RPM)
V = 3.87 X 10 3 (A) / (RPM)
A = 14.20 X 10-9 (D) (RPM) 2
A = 0.27 X10-3 (V) (RPM)
Dm = 1.79 X 10 9 (A) / (RPM) 2
Vm = 52.36 X 10-6 (Dm) (RPM)
Vm = 93.58 X 10 3 (A) / (RPM)
A = 0.56 X 10-9 (Dm) (RPM)
A = 10.69 X 10-6 (Vm) (RPM)

Seismic Velocity Pickup (Moving Coil Type)

Fig.10 is simplified diagram of a Seismic velocity vibration transducer. The system consists of
a coil of fine wire supported by a soft springs. A permanent magnet, firmly attached to the
case of transducer, provides a strong magnetic field around the coil.

Fig. 10

Whenever this transducer is fixed or held tightly against a vibrating object the permanent
magnet vibrates, while the spring-suspended coil of wire remains stationary in space when a coil of
wire cut magnet line of force, a voltage is generated in that wire. The voltage is proportional to the
Velocity of motion, the strength of the magnetic field and the number of turns of wire in the coil.
Velocity transducers are widely used for general measurement analysis and balancing
requirements. This is because velocity pickups are rugged, easy to apply and can be hand held. In
addition, they have relatively high electrical output levels and system calibration is virtually
unaffected by cable length. They are self-generating and required no power input. Velocity pickup
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has limitations on the maximum and minimum vibration amplitudes and frequencies, which can be
measured. The voltage generated in a seismic velocity transducer is normally expressed in term of
mill volt per inch per second. The sensitivity of a velocity transducer is constant over a wide range
of frequencies, but there is limitation. At low frequencies of vibration, the sensitivity decrease
because the coil no longer remains fixed in space, but trends to follow the motion of the magnet.
The practical significance of this fact is that amplitude reading typically below 600 CPM for the
standard seismic-velocity transducer are not true reading, vibration will shows less than actual
amplitude of the vibration being measured.

Specification Of Seismic Velocity Transducer

Frequency Range 10 Hz –1000Hz

Sensitivity 764= 10% mv RMS/in/sec. (peak)
Impedance R=2K ohm, L=0.7 Hy
Damping factor 0.7 (critical)
Transverse response Less than 5% (average) between 10Hz, &1000Hz
Magnetic field 0.15 inch/sec/gauss
Max. Amplitude 125 mils peak-peak to 700 Hz; 30g above 70Hz

Seismic (Piezo Electric)

The piezo electric velocity transducer has an output that is proportional to velocity, but has no
internal moving parts. A stress due to vibrational forces applied to the pickup causes a crystal or
special ceramic material to produce an electric charge.
The electric charge from the piezoelectric elements so small that the signal must be
amplified before it can be measured. It can measure down to 1Hz (60CPM). The built amplifier
provides a high output signal and low impendence to enable it to drive long cables without signal
loss. The low residual noise combined with small phase shift makes it an ideal transducer for low
speed balancing applications. Under most conditions the piezoelectric velocity pickup is not
affected by magnetic field. As Fig .11 shows.

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 Specifications Of Piezoelectric Pickup

Frequency Range Flat +/ - 10% from 1 Hz to 4.5 KHz

Max. Usable Amplitude 5 in/sec Peak
Residual Noise 0.0007 equivalent in/sec broad band
Power Input +/ - 15 Vdc at +/ -5mA max.
Cable Drive Capability Drive 500 feet (25000 pF) cable without clipping of
1KHz 5in/sec signal

Phase Shift 10 degree at 7Hz, 30 degree at 3Hz max.

Non-contact (Proximity) Transducer

Many high speeds machine, such as Turbines, compressors and centrifugal pumps; consist
of relatively lightweight rotors mounted in massive case and rigid bearings. Because of the weight
and stiffness of the massive machine case and bearing externally mounted vibration and
acceleration pickup often shows little outward evidence of rotor or shaft vibration. The rotor
however, might be vibrating excessively within the clearances of bearing. In such instances; it is
necessary to measure the actual shaft vibration in order to know when seal and bearing clearances
are in danger. This is the function of the non-contact transducer. A non-contact transducer mounted
through the bearing housing. It is basically a displacement of the bearing or housing, it measure the
shaft displacement relative to the bearing and housing
Non-contact transducers can be used with proper and permeantly mounted. A non-contact
transducer does not have an element that generates a voltage or electrical charge in response to
vibration. Non-contact sensor requires external electronic circuitry to generate a very high-
frequency A.C. signal and detect vibration in the A.C. signal caused by the vibration of the shaft.
The electronic circuit, called a signal sensor, generates a very high-frequency electrical
signal called the carrier signal. This signal is applied though a coaxial cable to a small coil of wire
in the tip of the non-contact pickup. The high frequency electrical signal applied to the coil
generates a magnetic field. Any metallic object in the vicinity of the coil mainly the steel shaft
absorbs some of this magnetic energy. This absorption effect places an electrical “LOAD” on the
electrical signal, there by reading its strength. The amount of loading---reduction in strength--- is
inversely proportional to the coil to the shaft, the greater the loading effect and the smaller the
amount of carrier signal As Fig .12 shows
As the shaft moves relative to the tip of the pickup, the strength of the electrical signal
changes proportional to the movement. The signal sensor provides an A.C. signal voltage
proportional to vibration and a D.C. signal voltage proportional to the gap. The vibration in the
strength of the carrier signal is this proportional to the amount of vibration.
This is “DISPLACEMENT” signal sent through cable to a vibration monitor.
Non-contact transducers are installed in the machine with the tip of the transducer is
closed proximity to the rotating shaft. This distance between the tip of the transducer and he shaft
is called the “GAP”.

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 Specification Of Non-Contact Pickup

Gap Range 80 miles (2000 micro meter)

Nominal Gap 20 miles (500 micro met.) to 100 miles (2500micro met.)
between pickup tip and target
Sensitivity 200 mV/mil (8 micro met.)+/- 2% over 80 miles gap range
Radial Vibration 40-80 miles nominal gap range +-5%
Axial Position (20-100mile nominal gap range)
+/-1 mile (9- feet system)
+/-2mile (20- feet and 30-feet system)
System Freq. Range DC to 600000 CPM (0-10 KHz)
Power Required -23.0 to -27.0 V dc at 20 mA

Vibration Protection System

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 Component of the system

The proximity transducer system consists of a Proximitor, Probe and Extension cable.

Proximitor

The Proximitor contains electronic circuitry to generate a radio frequency (RF)

signal, sense the loss in power, and generate an output voltage, which is proportional to GAP.
Proximitor are calibrated for either 5.0 m or 9.0 m cable electrical length. The cable electrical
length includes the combination length of the probe lead and the extension cable. As Fig .13 shows

Fig. 13

Probe

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 The probe is the sensor of the system. It is positioned near the shaft surface so that
it can sense the gap between the probe tip and the shaft surface. The probe is coil of wire with a
diameter of approximately 5 mm (0.2 inch). A protective covering of Polyphenylen sulfide (PPS)
increase the tip size to 8 mm (0.315 inch). The protective covering provide mechanical strength
and protective from harsh environments. Probes are available with or without armor and
connectors on the probe lead. As Fig. 14 shows

Fig.14
Extension Cable

The extension cable connects the probe and Proximitor and makes the electrical length of the
system either 5.0 meter or 9.0 mete. The extension cable and the probe lead both have a protective
armor braid, outer shield, which is coated with Teflon insulation. Extension cables are available
with or without armor and connectors. As Fig .15 shows

Fig.15
How The System Works

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 The proximity transducer system uses the eddy current principle to measure the
distance between the probe tip and the surface to be observed.
The Proximitor generates a low power radio frequency (RF) signal. This RF signal
is connected to the coil of wire inside the probe tip by the extension cable. When no conductive
material is with in the range of RF signal, which surrounds the probe tip, virtually all the power
released to the surrounding area is returned to the probe. When a conductive surface approaches
the probe tip, the RF signal set up small eddy currents on the surface. These eddy current create a
measurable power loss in the RF signal. The nearer the target material, the greater the power loss.
The system uses this power loss to generate an output voltage. The output voltage of the
Proximitor is linearly proportional to gap over a wide range. This range permit the use of wide gap
tolerance during installation of the probe and allows for axial thrust position measurements.
Proximity Transducer System has a liner measurement range of
2mm (80mils) that extends from approximately 0.25mm (10mils) from the probe face to
approximately 2.28 (90mils) from the probe face.
The system’s sensitivity to gap, or the slope of the output voltage verses gap curve, is
7.87 v/mm (200mv/mil) providing high resolution in gap distance measurement.

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 Typical Probe Applications

The three most typical types of probe applications are radial vibration measurement,
axial position measurement and providing Keyphasor.

Radial vibration: An ideal method for mounting XY radial vibration probes is to position then
vertically and horizontally 900 +/- 50 apart. Another common mounting position is with the probes
450 on each side of the vertical centerline maintaining 900 between the probes. The probes can be
mounted in any angular position around the shaft as long as 900 +/- 50
separation between probe is maintained. As Fig.16 shown. Throughout the machine train It is
desirable to mount the probes laterally in the same plane. Mount the probe close to the
bearing so the maximum shaft displacement as measured by the probes are virtually the
same as that occurring at the bearing. Mount probes with in the following specifications.

Y-axis 900 +/- 5 0 X-axis

Fig. 16

Fig. 16

Bearing Diameter Maximum Distant from Bearing

Inch mm Inch mm
0 to3 0 to 76 1 25
3 to20 76 to 508 3 76
> 20 > 508 6 152

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Axial position: Axial position THRUST probe is
mounted to directly observe a surface that is
connected to the shaft so the measurement will be
true shaft displacement. Mount the thrust probes
observing the shaft within 305mm (12 inch) of the
thrust collar. A typical system uses two probes to
monitor thrust position so the machine will be
protected if one probe is damage or fails. At least
one probe should observe a surface that is integral
to the rotor so that the measurement will not be
lost if a thrust collar becomes loose on the rotor.
As in Fig. 17 shows. Fig. 17

Keyphasor: The Keyphasor signal provides a once per turn shaft reference mark for measuring
speed and phase lag angle. Mount the Keyphasor probe in a radial rather than an axial position.
When probes are mounted in an axial plane, axial movement, or thrust may cause excessive
voltage change at the Proximitor output, which will cause improper Keyphasor amplitude.

The notch or projection must be large enough to create a pulse of at least % volt
peak-to-peak. The marker must be at least 7.6 mm (0.30 inch) wide, 1.5 mm (0.06 inch) deep (or
height) of
2.5 mm (0.100 inch) is recommended. The length of the marker must be long enough to
accommodate any expected axial movement of shaft.

Side Clearance

Because the radio Frequency (RF) field extends outward from the side pf the probe tip,
you must remove all conductive material near the side of the probe tip. Otherwise the system will
generate false information if this is not done. properly gapping the probe or removing conductive
material by counter boring will prevent problems with side clearance.
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 Typical Resistance At 250 C For The Probe

Probe Length Resistance From Center conductor to outer

conductor (ohm)

0.5 7.45 +/- 0.50

1.0 7.59 +/- 0.50
1.5 7.73 +/- 0.50
2.0 7.88 +/- 0.50
.

Typical Resistance At 250 C For The Extension Cable

Length Of Extension Cable Resistance From Center Resistance From Outer

Conductor To Center Conductor To Outer
Conductor (ohm) Conductor (ohm)

3.0 0.66 +/- 0.10 0.20 +/- 0.04

3.5 0.77 +/- 0.12 0.23 +/- 0.05
4.0 0.88 +/- 0.13 0.26 +/- 0.05
4.5 0.99 +/- 0.15 0.30 +/- 0.06
7.0 1.54 +/- 0.23 0.46 +/- 0.09
7.5 1.65 +/- 0.25 0.49 +/-0.10
8.0 1.76 +/- 0.26 0.53 +/- 0.11
8.5 1.87 +/- 0.28 0.56 +/- 0.11

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 Common Probe Installation Errors

Type Of Error Result Of Error

Measurement for installing the probe is not
accurate enough to allow for a proper fit.
External hole in the machine case are drilled at
an angle to the centerline.
The probe mounting must be redesigned.
The probe face is too far to one side of the shaft
centerline resulting abnormally low peak-to-
peak reading.

The probe is mounted over chrome plating, The reading from the probe is erratic.
coupling hubs, or shrink on collars.
An axial position probe is mounted at the The probe reads very high change in position
opposite end of the rotor from the thrust bearing. that is unrelated to the conditions at the thrust
bearing.

A probe is mounted on brackets that are not Resonance causes the probe to vibrate at high
rigid enough. amplitude with the frequency range of interest.
The vibration reading is meaningless.

The probe is gapped at 1.0 mm because there
are 2.0 mm of linear range.
The conduit for the extension cable is not sealed
adequately.
The probe remains connected to the extension
cable while gapping the probe electrically.
Too much torque (7.22 Nm) is applied to the
probe cause during installation.
The electrical length of the extension cable does
not match the probe lead and Proximitor.
Probe is mounted too close together.
The probe is not gapped at midrange because the
linear range starts at 0.25 mm and at zero.
The Proximitor housing becomes filled with lube
oil.
The extension cable or the probe leads are
twisted and break.
The probe case is broken.
The reading is either too higher or too low.
The electromagnetic field of probe tips cross-
couple, causing a small amplitude ac signal to be
superimposed on the Proximitor output

Probe and extension cable not insulated by any The reading may be change due humid or
type of protector. corrosive atmosphere

Calibration Check Of The Transducer System

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This procedure provides a method for checking the accuracy of the transducer system. Reasons for
checking accuracy include using target materials other than AISI 4140, verifying accuracy after
changing a probe or extension cable connection, and verifying accuracy after changing transducer
parts. The tolerance shown for calibration accuracy includes interchangeability error for the
Proximitor, Probe, and Extension cable.
Step 1 : Connect test equipment as shown in Fig.19.
Step 2 : Adjust the spindle micrometer on TK-3 test and calibration kit unit shows 0.51mm.
Step 3 : Insert the probe into the TK-3 probe holder. Adjust the probe in the holder unit the digital
Multimeter shows –3.00 +/- 0.10 Vdc.
Step 4: Adjust the micrometer to a 0.200 mm indication, and then back it out again to the 0.25 mm
indicators to compensate for any mechanical backlash in the micrometer. Record the
output voltage.
Step 5: Increase the gap in 0.25 mm increase by adjusts the micrometer. Record the voltage
indicator at each increment.
Step 6: For each gap increment, subtract the voltage at the high gap from the voltage at the low
gap. Divide the result by 0.25 mm. This should result in a system increment scale
factor (ISF) of 7.87 +/- 0.79 V/mm (200 +/- 20 mV).
Step 7: Subtract the 0.25 mm voltage from the 2.28 mm voltage and divide by 2.03mm. This
Should result in a system average scale factor (ASF) of 7.87 +/- 0.43 V/mm.
Step 8: If the increments scale factor (ISF) or the average scale factor (ASF) of the system is out
of tolerance, replace step by step – Probe, Proximitor and Extension Cable.
IRD- MECHANALYSIS

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 6600 Monitoring systems consist of Rack or Panel mounting frame in which the various
monitor fit, together with their respective Power supplies. The Power supplies in turn accept both
AC and DC power, providing automatic back up in the event of either supply failing.
There are significant differences between the Ver. 2 & Ver. 3 monitor hardware, although
they are pin compatible and interchangeable. Ver.3 can only used with Model 6692 power supply
and Relay unit. No damage will be caused if the wrong combination of monitor and power supply
unit are fitted to the Rack Mounting frame; they will not work however without the correct
combination.

Safety In Operation

Connection of Power

Ac Mains Power Unit: AC power input must be in the range of 80 to 240 Volt +/-10% AC 50/60
Hz.
DC Power Unit: Dc power input must be in the range of + 18 Volt to + 40 Volts.

Power Requirement On Switch On: The in-rush current on switch on can be significant, and must
be taken into account in designing the panel wiring system. This is particularly true of DC power
systems.
Each monitor required 25VA power under normal operating conditions, and 150VA for
approximately 250M Sec. after power is switch on.

Panel Wiring

For electrical safety, the Rock-Mounting Frame must be connected to a safety ground. This can be
achieved by connecting ground. Under no circumstances must the unit be powered without the
ground connection made.
The alarm relays are designed to switch a maximum AC voltage of 110V/ 50-60 Hz, and
must be used to switch higher voltage. Where DC voltage are to be switched by the relays, the
maximum power that can be switched is 3 watts, and the maximum DC voltage applied to the relay
is 110V.

Power Fusing

Power Supply & Relay Unit 6691 6692

Type
Fuse Rating In Amps (AC I/P) 1 Amps 1 Amps
(DC I/P) 5 Amps *

* The 6692 have AC I/p only. If the system is powered from +24 V, the connection is made direct
to the monitor from the back plane connection, and is not routed through the 6692 Power supply
and Relay unit.

Basic Facilities Of 6600

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 This family of machine monitors covers all the requirement of API670, providing
traditional 4 – 20 mA output and power free relay contacts, yet bring a new degree of technology
to the industry with monitors that are configurable from the front panel.

Monitor Type

In the table on the page, a schedule of available 6600 monitors is listed (which we are use)

6652: Dual (X/Y) Vibration monitor. (ECP I/P)

6675: Tachometer / Speed monitor.
6682: Dual Thrust (Axial Position) monitor.
6691: Power Supply & Relay unit.
6692: Power Supply & Relay unit with 4 – 20 mA output Interface.

Programming 6600 Monitor

Introduction: This section explains the method of programming 6600 monitors. It describes first
the two levels of Set-up, or programming that are available, and then discusses the operation of
menu system.

Available Levels: Two levels of set-up are available in this series of monitor, and are accessed
using the front panel keys. To prevent unauthorized or inadvertent changes, two buttons must be
pressed continuously for predetermined periods to gain access to the programming facilities.

Factory Set-Up Facilities: This is the lowest level of programming SET

in the monitor and covers all the basic settings. COMM’S
It is accessed by pressing the two lowest keys RANGE 1
(Down arrow and “SEL”) on the front panel. These keys must be RANGE 2
pressed simultaneously and continuously for a period of at least TX OK
“14 seconds”. If this condition is met the menu above will be RELAYS
available on the display. EXIT

User Set-Up Facilities: The higher level of setting up facilities SET

with in the 6622 monitor are defined as user functions, and are ALERT 1
accessed by pressing and holding down the two buttons DANGER 1
simultaneously and continuously for a period of about ALERT 2
“4 seconds”. Then the following menu will appear. To select DANGER 2
another Sub-Menu. Move the bar up or down by using the INHIBIT
arrow keys. When the bar is over the item required, press EXIT
“SEL”.

Changing Numeric Values: With the required parameter selected, press the up or down arrow key
as required until the display shows the desired number. Note that where large range must be
accommodated there is a special algorithm, which controls the operation of these key and allow the
number to change more quickly, the longer the key is pressed. This allows for large numerical
change to be made in short time.

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 Glossary Of Menu Term’s

The following is schedule of menu items, together with a detailed explanation of their
operation.

BAUD: This configures the baud (bits per second)of the RS 422/ 485 serial interface and
should be to the rate required by the host system. Available setting are
4800,9600,19200 and 38400 Baud.

ALERT: To guide the setting of alarm levels, the current alert alarm threshold is now shown
both numerically and graphically by a “flag” or box on the bar graph display. The
danger threshold is always set to a higher level than the alert threshold.

CHANS: The selection of time and date are self-explanatory. The Set command when selected
requires an answer “YES” or “NO”. If YES then the clock alterations will be written to
memory when exiting form the CLOCK menu, and the set time and date will be briefly
displayed.

DANGER: With “DANGER” highlighted, press the “SEL” key. This threshold can be set in a
similar manner to above, nothing that if the danger level is initially below the alert
level, than as its value is increased, the alert box on the bar graph display will also
move until it attains its correct position.

EVENT: If this is set to YES, the monitor will only enter transient analysis mode if, the sped of
the Machine is between the HS and LS limits, and the event line 6 on the rear panel is
hold Connected to DIG. COMM. If the setting is NO, then the monitor will enter
Transient Analysis mode, providing that the machine speed is between HS and LS
limits, and the Condition of event line 6 will be ignored.

EXIT: End the current selection and returns to the previous display.

DELAYS: By selecting DELAYS, the display will show a sub menu offering GLOBAL or
START-UP delay for the alarm relays. Typical selections are 3 seconds for the
GLOBAL delay and 30 seconds for the START-UP delay.

FAIL SAFE: The setting can be cycled through the following selections
A- Alert only is FAIL SAFE for both channels
AD Both Alert and Danger are FAIL SAFE for both channels
-D Danger only is FAIL SAFE for both channels
NO No relay are selected FAIL SAFE, except the system OK relay which is
always FAIL SAFE.

INHIBIT: The setting can be cycled through the following options

YES: Danger relay on the both channels will not operate in the event of DANGER
Alarm.
NO : Danger relay operate normally.

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LATCHED: The setting can be cycled through the following options.
YES: All relays will latched on alarm and will only released if the RES (reset)
button is pressed, or the remote reset line is grounded.
NO : None of the relays will latch and will return to normal operation if the
condition that caused the relay to operate is removed.

OFFSET: This item is located in the TX OK menu and is used to offset any DC voltage
Level, which may be present on the tacho signal, applied.
The available range is –24.8V to +25 V.

RANGE 1: This main menu item when selected leads to a Sub-menu and allows setting
RANGE 2 of the signal parameter of the monitor. See also ‘ LIMITS OF SETTING OF
INTEGRATING MONITOR’ is the programming section of the manual.

SCALE : This selects the full scale value of channel 1, in the units selected in TX1 UNT
And set the scaling of the bar graph on the front panel Dot Matrix graphics
display.

TACHO : This item is located in the TX OK menu. The available selection are YES or
NO. If YES is selected, the monitor will expect to receive a tacho signal. If the
TACHO Signal is not present, the monitor will show a TACHO flashing window
On the secondary display page.
If TACHO is set to NO then spectrum data will be free running with a frequency
range of 1-1 Kz.

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 Model 6652 Dual Channel Vibration Monitor

OVERVIEW: This two-channel monitor will accept signal from eddy current probe systems process
and analyze the signals and then display the results on the front panel graphic display. Full alarm facilities
are provided, and isolated 4-20 mA current signals are available to drive external SCADA (DCS) or other
logger.

APPLICATION: This monitor is designed for monitoring rotating machines in a variety of

configurations. It’s unique monitoring method allows easy selection of monitoring method allows easy
selection of monitoring band widths by the user and the extremely comprehensive alarm system provides
a degree of protection available on monitors of this type.

OPERATION: The 6652 accepts two channels of input signal from its associated eddy current probe
systems, conditions and range them, then displays the levels of vibration in engg. Units on the front panel
graphics display. It provides separated 4 – 20 mA signals for each channel at the termination block on the
rear panel.
Operation of the 6652 is partly analogue and partly digital and the particular way the
different circuit techniques are employed is the key to the monitor’s unique capability. A microprocessor
operating at high speed carries out the digital processing and operates in a real time mode dealing with the
various tasks. Response time to changes in level and spectrum are measured in milliseconds and the
unusually sophisticated alarm monitoring system is quite exceptionally easy to set up and use.
Once the 6652 have been set up, the operator’s requirements the set up information is
stored in nonvolatile memory and will remain safe in a power down condition for up to 5 Years.

GRAPHICS DISPLAY: The 6652 employs a dot matrix graphics display, which provides a series of
display screen to advise the operator of the machine’s vibration behavior. Under normal operating
conditions the display will feature two bar graphs showing the vibration level for each channel.

MONITORING SEQUENCE: The monitor operation can best be described by dealing with one
channel only, although the second channel monitoring is carried out in parallel with the first. The
incoming signal is scaled to suit its level and sampled at high speed by an internal analogue to digital
converter. The resultant sample are continuously stored and processed as required. The 6652 can accept an
independent tacho signal for each channel and if the “TACH PRESENT” selection is made during the
monitor’s initial setup, then the FET process is related to the speed of the machine and the rotational order
information (amplitude and phase) of the transducer signal is also calculated for three orders (1X, 2X and
3X rpm). If the “TACHO NOT PRESENT” condition exists, the FET is calculated over a default
bandwidth of 10KHz.

RANGE SETTING: The full range of each channel is entered using the programming key on the front
panel. Full details of this procedure are contained within the programming section of this manual.

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 Technical Specifications of 6652 vibration Monitors

Transducer input Eddy current probe system

Sensitivity Programmable in range 1 to 9999.9 mV/ EU

EU selectable as mills micro or mm peak-to-peak

Band width Maximum: dc to 20KHz

Settable 1 Hz to 20 KHz (HP fixed at 1 Hz)

Output Isolated 4 – 20 mA per channel into max. Load of

1000 ohms.
Buffered Input signal on the front panel BNC

Other Input Start up alarm inhibit run up/down event line remote
calibrate relay reset

Communications Four wire multi-drop high speed (38.4 K baud data

transfer) serial interface used either with Model
3603 Data interface Unit or direct to host computer

Power Consumption Total module consumption 9 VA

Peak load is 3.7 @ 24V for 250ms following start
up

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 Model 6675 Tachometer

OVERVIEW : This monitor is designed to measure and display machine speed in revaluation per
minute. It can operate from an eddy current probe Input signal, or in special circumstances from a passive,
magnetic sensor. The monitor can be used to capture the speed relative to an external event. This is
particularly useful when carrying out over speed checks.

APPLICATION : The 6675 is designed primarily for use within a rotating machine protection system
although it can be used as a stand alone speed monitor. It has a wide operating range and can be used
effectively on almost all machines.

OPERATION : The 6675 receives its input signal from a CML-1900 series eddy current probe and
driver. The probe signal is scaled and conditioned with in the unit to drive TTL compatible pulses.
The frequency of the resultant pulse train is measured, and converted into RPM by
tacking into account the number of teeth (or event) per revolution.
A microprocessor carries out the supervision and numerical calculation functions and
drives the digital display. A $ - 20 mA isolated Output is a available at the rear panel.

GRAPHIC DISPLAY : The 6675 uses a dot matrix graphics display to indicate the machine speed and
alarm state.

RANGE AND ALARM SETTING : The range of 6675 Tacho monitor extends up to 20,000 RPM. This
range is continuously available with out need for adjustment.

Technical Specifications of 6675 Monitors

Input Signal Eddy current probe system

Speed Range Up to 20,000 RPM
Output Isolated 4 – 20 mA into max. Load of 1000 ohms
20 mA correspond to selected speed range
Reconstituted tacho pulse available on the front
panel BNC connection

Communications 4 wire multi- drop high speed serial data link using
MODBUS protocol
Baud rate: 300,600,1200,2400,4800,9600,19200 or
38400 programmable

Power consumption Peak load is 3.73 @ 24V for 250ms

If al relay energized then 18VA

Environmental Tempr - 2000 to + 5000 C

Humidity Max 95% non-condensing.

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 Model 6682 Dual Channel Thrust Monitor

OVREVIEW : This two channel monitor will accept signals from eddy current probe system process
and analyze the signals and then display the result on the front panel graphics display.

APPLICATION : The 6682 is designed for monitoring rotating machines in a variety of configurations.

OPERATION : The 6682 accept two channels of Input signal from its associated eddy current probe
system, conditions and range them, then displays the gap (between probe tip and shaft) in engineering
units on the front panel graphic display. Operation of the 6682 is partly analogue and partly digital and the
particular way the different circuit techniques are employed is the key to the monitor’s unique capability.
A microprocessor operating at high speed carries out the digital processing and operates in a real time
mode dealing with the various tasks. Reponses time to change in level is measured in milliseconds and the
unusually sophisticated alarm monitoring system is quite exceptionally easy to set up and use.

GRAPHICS DISPLAY : The 6682 employs a Dot matrix graphics display which provides a series
of display screens to advise the operator of the machine’s thrust behavior.

MONITORING SEQUANCE : The monitor operation can best be described by dealing with one
channel only, although the second channel monitoring is carried out in parallel with the first The incoming
signal is scaled to suit its level and sampled at high speed by an internal A to D converter. The resultant
samples are continuously stored and processed as required.

RANG SETTING : The operator must determine the units to be to be used, which can either
micrometer or mils(0.0001//).
Technical Specifications of 6682 Monitors

Transducer Input Eddy current probe system

Band width Max. Band width – dc to 20KHz

Low pass setting 20 Hz to 20 KHz

Output Isolated 4-20 mA per channel into

Max. Load 100 ohm

Other Input Start up alarm inhibits run up/ Down event lines
remote calibrate and relay reset.

Communication 4 wire multi-drop high speed serial interface

Power consumption Total module consumption 9VA

Peak load is 3.7 A@ 24 V for 250 ms following start
up.

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 Model 6691 Power Supply & Relay Unit

OVERVIEW : The model 6691 Power supply and Relay unit is a Switch mode power supply (SMPS)
providing various Output voltage directly to the 6600 series of monitors.
It incorporates seven relays with 5A amp rated contacts and plays directly into the
mounting frame rear panel termination unit.
Each 6600 series monitor in a system needs its own 6691 power supply.

UNDERSTANDING SWITCHING SUPPLIES: The great disadvantage to ordinary LINEAR power

supplies is their tremendous waste. At least half of all power provided to a liner supply is thrown away as
heat. Most of this waste occurs in the regulator portion of the supply. Ideally, if there was just enough
energy supplied to the regulator to achieve and maintains astable output voltage, regulator waste could be
reduced almost entirely, and supply efficiency would be vastly improved. This concept behind a switching
power supply.

CONCEPT OF SWITCHING REGULATION: Instead of throwing away extra Input energy, a switching
power supply creates a feedback loop. A feedback circuit sense the Output voltage provided to a load, then
switches the AC primary (or secondary) voltage on or off as needed to maintain steady level at the Output.
In effect a switching power supply is constantly tuning on and off in order to keep the Output voltage(s)
steady. A block diagram of typical switching power supply is given below.

Fig. 20

Raw AC line voltage entering the supply is immediately converted to pulsating DC, and
then filtered to provide a primary DC voltage. Notice that unlike a liner supply, AC is not transformed
before rectification, so primary DC can easily reach level exceeding 170 Volts. Remember that AC is 120
volts RMS. Since capacitors charge to the peak voltage (peak = RMS X 1.414), DC level can be higher
than your AC voltage reading.
On start up, the switching transistor is turned “ON” and “OFF” at high frequency (usually
20 Hz to 40 KHz) and a long duty cycle. The switching transistor act as a CHOPPER, which break up this
primary DC to form chopped DC that can now be used as the primary signal for a step-down transformer.
The duty cycle of chopped DC will affect the AC voltage level generated on the transformer’s secondary
winding (output). A long duty cycle means a large output voltage (for heavy loads). DUTY CYCLE itself
refers to the amount of time that a signal is “ON” compared to its overall cycle. The Sensing/ Switching
circuit continually adjusts the duty cycle. AC voltage produced on the transformer’s secondary winding
(typically a step-down transformer) is not a pure sine wave, but it alternates regularly enough to be

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treated as a AC by the reminder of the supply. Secondary voltage is re-rectified and refiltered to form a
secondary DC voltage that is actually applied to the load. Output voltage is sensed by the
sensing/switching circuit, which constantly adjusts the chopped DC duty cycle. As load increases on the
secondary circuit (more current is drawn by the load) Output voltage trend to drop. This is perfectly
normal, at the same thing happens in every unregulated supply. However, a sensing circuit detects this
voltage drop and increases the switching duty cycle. In turn, the duty cycle for chopped Dc increases,
which increases the voltage produced by the secondary winding Output voltage climbs back again to its
desired value Output voltage is regulated.
The reverse will happen as load decrease on the secondary circuit (less current drawn by
the load). A smaller load will trend to make Output voltage climb. Again, the same actions happen in an
unregulated supply. The sensing/ switching circuit detects this increase in voltage and reduces the
switching duty cycle. As a result, the duty cycle for chopped Dc decreases, and transformer secondary
voltage decreases. Output voltage drops back to its desired value. Output voltage remains regulated.

Circuit Description of 6691 Power Supply

The circuit diagram of the 6691 power supplies and relay unit is shown on drawing
A1-23994. The circuit operation can be summarized as follows.
The system consists of two power supplies; an AC Input system and a DC Input system.
Dealing first with AC input system, power is fed in via link fuse and solid state fuse to bridge rectifier.
The Dc voltage developed across C8 is applied to the switching transistor Q8 circuit which is switched
ON/OFF in a controlled manner.
The switched current of the primary of L2 transformers energy to the various secondary
windings. The DC Input circuit is very similar, except that it does not have an Input bridge rectifier, and
transformer primary current is switched by Q7.
Diode assemblies, which also act as blocking diodes, effectively isolating the two
supplies from one another, rectify both Outputs from the transformers. Voltage control is carried out on the
8-volt supply with feedback optically coupled to the primary stage. Relay are driven by logic line from the
associated monitor via a open collector darling ton drive U8

Fig. 21

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