Part Number 167684-01
Revision A, October 2004
Air Gap Transducer System
Manual
R
4000 Series Air Gap Sensor System Manual
Copyright © 2004 General Electric Company.
All Rights Reserved.
The information contained in this document is subject to change without notice.
Proximitor® is a registered trademark of the General Electric Company in the
United States and/or other countries.
Clickloc™ is a mark of the General Electric Company.
Teflon® is a registered trademark of DuPont.
The following ways of contacting Bently Nevada are provided for those times when you cannot
contact your local Bently Nevada representative:
Mailing Address
Telephone
Fax
Internet
ii
1631 Bently Parkway South
Minden, NV 89423
USA
1 775 782 3611
1 800 227 5514
1 775 215 2876
www.bently.com
Related Documents
The following documents contain additional information that you may find
helpful when you install the transducer.
Transducer Installation Accessories
3300 XL Proximitor Housing Data Sheet (141195-01)
Reference
Performance Specifications for the 4000 Series Air Gap Sensor System
(167545).
Bently Nevada Glossary (133055-01).
3500/46M Hydro Monitor Module Operation and Maintenance Manual (14440301)
3300 XL Proximitor® Housing Data Sheet (141195-01)
Disposal Statement
Customers and third parties who are in control of the product at the end of its life
or at the end of its use are solely responsible for proper disposal of the product.
No person, firm, corporation, association or agency that is in control of product
shall dispose of it in a manner that is in violation of United States state laws,
United States federal laws, or any applicable international law. Bently Nevada,
LLC is not responsible for the disposal of the product at the end of its life or at
the end of its use.
iii
4000 Series Air Gap Sensor System Manual
Symbols
Procedures in this manual use the following symbols:
Connect
Disconnect
Observe
European CE mark for the
Bently Nevada 4000 Series Air
Gap Sensor System
In this Document
Is a list of the 4000 Series Air Gap Sensor Assemblies that have the CE mark,
applicable standards used for certification, and installation instructions required
for compliance.
TCF through TUV Rheinland of North America
A Technical Construction File has been prepared through TUV Rheinland of
North America (TUV Rheinland File Number: 30461397.001). The Certificate
of Compliance is for Directive 89/336/EEC (EMC Directive). The applicable
Generic Norms are: EN61000-6-2 and EN61000-6-4.
Installation Instructions
These instructions are an addition to the Installation Instructions in Section 2.
The 4000 Series Air Gap Sensor System due to its inherent sensitivity, is
susceptible to EMI at levels EN61000-6-2. Special EMC (Electromagnetic
Compatibility) protection measures may be necessary to achieve reliable
measurements. Each unique installation must be considered.
Capacitive Probes All probes must be mounted in an EMI shielded environment
(i.e. typically a machine casing ). All probe cables and extension cables,
running from the point exiting the machine to the EMI shielded enclosure, must
be inside metal conduit (or equivalent) with the conduit grounded at the
machine and the enclosure.
⑤
⑥
③
②
④
Field Wiring All field wiring , from the Proximitor Sensor enclosure to a
receiving unit (i.e. monitor), must be shielded from EMI energy. Acceptable EMI
shielding includes solid metal conduit or multi-conductor cable with both a foil
and braid shield.
EMI Shielded Enclosures and EMI Shield Grounding Enclosures made of
metal typically provide EMI shielding. Covers should be electrically connected
to the enclosure or have overlap with the sides of the enclosure, both are
preferable. Bently Nevada Proximitor Sensor Housings and Probe Housings,
which are made of metal, provide adequate EMI shielding.
iv
⑦
Grounding EMI shields at the point of entrance to the Proximitor Sensor
enclosure and any subsequent junction enclosure is required. The shield must
be maintained around the wiring as it is grounded to the enclosure.
④
Exposure of the systems when the EMI shielding is removed (i.e. enclosure
cover) will increase EMI susceptibility.
Figure 1
Compliant Systems and Component Part Numbers
#
Model
1
4000
Model Numbers
400100, 400102
Includes all options
v
4000 Series Air Gap Sensor System Manual
Testing and Test Levels
Title
EN
IEC
IEC
EN
IEC
IEC
55011
61000-4-2
61000-4-3
61000-4-4
61000-4-5
61000-4-6
Emission
ESD
Rad. RFI
EFT
Surge
Cond. RFI
Test
Levels
Emission
Class A
±4kV;
±8kV
10V/m
Criteria †
N/A
B
A
±2kV
±0.5kV
10V
B
B
B
These notes listed below apply only to the table “Testing and Test Levels”
Discharge method: Contact; Air
80-1000 MHz sweep with 80% 1 kHz sine wave amplitude modulation
Lines tested: I/O
150 kHz-80 MHz sweep with 80% 1 kHz sine wave amplitude modulation
Based on the high sensitivity of the signal ports, it has to be assumed that the
application of immunity test signal temporarily causes incorrect readings.
These do not indicate a failure of the system by itself but a possible reason
for misinterpretations. For Conducted RF immunity testing, criterion B is
therefore used.
† For the purposes of the 4000 Series Air Gap Sensor System CE
certification, the following criteria are defined as follows:
vi
-
Criteria A: Sensor system will output less than one third of a 2000
mil meter scale and will return to steady state after test completion.
-
Criteria B: Sensor system may react in any manner during test, but
must self recover after test completion.
-
Criteria C: N/A
Contents
Symbols ...................................................................................................................................iv
Section 1 – System Description ............................................................ 1
Sensor System...............................................................................................................................1
Proximitor® Sensor.......................................................................................................................1
Probe and Extension Cable............................................................................................................1
Receiving, Inspecting, and Handling the System............................................................................2
Customer Service ..........................................................................................................................2
Section 2 — Installation ......................................................................... 3
Sensor Installation .........................................................................................................................3
Introduction...............................................................................................................................3
Additional Equipment List.........................................................................................................3
Important Installation Tips.........................................................................................................3
Stator Surface Preparation .........................................................................................................4
Attaching The Sensor ................................................................................................................4
Determining Sensor Offset ........................................................................................................5
Teflon® Conduit Installation .........................................................................................................7
Introduction...............................................................................................................................7
Tube Preparation .......................................................................................................................7
Triaxial Extension Cable Installation .............................................................................................8
Introduction...............................................................................................................................8
Installation ................................................................................................................................9
Installation of Wiring Inside Generator Housing ..........................................................................10
Enclosure, Power Supply & Proximitor® Sensor Installation.......................................................10
Introduction.............................................................................................................................10
Mounting The Enclosure .........................................................................................................11
Power Supply And Proximitor® Sensor Layout .......................................................................11
Sensor Connection...................................................................................................................12
Electrical Connection ..............................................................................................................12
Verification .............................................................................................................................13
Section 3 — Maintenance and Troubleshooting ............................... 14
Troubleshooting ..........................................................................................................................15
Fault Type 1: VXDCR < 23.2 Vdc or VXDCR > 24.8 Vdc ................................................................16
Fault Type 2: VSIG = 0 Vdc .........................................................................................................17
Fault Type 3: 0 Vdc < VSIG < 0.01 Vdc .......................................................................................18
Fault Type 4: VSIG > 14 Vdc with verification fixture on the face of the probe.............................20
Section 4 — 3300 XL Proximity Housing Description ...................... 21
Mounting Options .......................................................................................................................21
Environmental Certifications .......................................................................................................21
Removable Gland Plates..............................................................................................................21
Din Mount Orientation ................................................................................................................23
Section 5 — 4000 Series Air Gap Sensor System Specifications and
Ordering Information ............................................................................ 24
Electrical.....................................................................................................................................24
System ........................................................................................................................................24
Mechanical..................................................................................................................................25
Environmental Limits..................................................................................................................25
Ordering Information ..................................................................................................................26
vii
4000 Series Air Gap Sensor System Manual
4000 Series Capacitive Proximity Probe.................................................................................. 26
4000 Series Air Gap Proximitor® Sensor ................................................................................ 26
4000 Series Extension Cable ................................................................................................... 26
Accessories ............................................................................................................................. 26
Graphs and Dimensional Drawings ............................................................................................. 27
viii
Section 1 — System Description
Section 1 – System Description
Sensor System
The 4000 Series Air Gap Sensor System consists of:
•
a 4000 Air Gap Probe
•
a 4000 extension cable
•
a 4000 Proximitor® Sensor
Bently Nevada’s Air Gap monitoring system provides monitoring and diagnostic
capability for all new and existing hydro generators and motor/generators. Air
gap monitoring is fully integrated with the 3500/System 1™ platform and
utilizes the 46M Hydro Monitor.
Air gap is a measure of the distance between rotor and stator in the hydro
generator. Monitoring of air gap is critically important because both the stator
and the rotor on large hydro machines can be quite flexible and their shape and
location are affected by operating centrifugal, thermal, and magnetic forces. Offcenter or out-of-round conditions will at least reduce operating efficiency and, in
more severe cases, can lead to damage from magnetically induced heating or a
rotor to stator rub.
Air gap monitoring utilizes multiple specially designed capacitive proximity
probes that are mounted on the inner bore of the generator stator in one or more
planes. Measurements are made from the stator bore to each rotor pole as the
rotor turns. Minimum air gap dimension and location along with rotor shape are
directly measured during unit operation. Stator shape is calculated utilizing the
multiple air gap probes. The air gap monitoring system provides operations and
maintenance personnel with early warning of impending problems with shape
and concentricity of the generator rotor and stator.
Proximitor® Sensor
The 4000 series Air Gap Proximitor® Sensor is based upon our best selling 3300
XL Proximitor® Sensor technology. The Proximitor® Sensor uses a DIN rail
connection to ease installation and to minimize the number of cumbersome
screws required when working around the hydro generator. The grounding stud
on the Proximitor® Sensor features a safety thread in order to ensure the locking
nut does not inadvertently fall off during the installation of the ground wire on
the extension cable.
Probe and Extension Cable
The 4000 series Air Gap probe is designed for maximum survivability in the
harshest hydro generator environment. It can continually operate and maintain
its accuracy in temperatures up to +125 ºC (257 ºF). The probe can also
continually operate and maintain its accuracy in the 1.5 Tesla magnetic field
often experienced between the rotor pole and the stator. ClickLoc™ connectors
come standard on both the probe and extension cable.
1
4000 Series Air Gap Sensor System Manual
Receiving, Inspecting, and Handling the System
The probe, extension cable, and Proximitor® Sensor are shipped as separate
units and must be interconnected at the installation site by the user. Carefully
remove all equipment from the shipping containers and inspect the equipment for
shipping damage. If shipping damage is apparent, file a claim with the carrier
and submit a copy to the nearest Bently Nevada office. Include the part numbers
and serial numbers on all correspondence. If no damage is apparent and the
equipment is not going to be used immediately, return the equipment to the
shipping containers and reseal until ready for use.
Store the equipment in an environment free from potentially damaging
conditions such as high temperature or a corrosive atmosphere. See
Environmental Limits section for environmental specifications.
Customer Service
Bently Nevada maintains numerous Sales and Service offices worldwide. To
locate the office nearest you, visit our website at www.bently.com. Here, you can
also find specifications on all standard product offerings.
Support for products and services should be directed to one of these departments:
For product quotations, product applications, product ordering, scheduling onsite
Services, and questions regarding existing orders, please contact your nearby
Bently Nevada Sales and Service Office.
For general product pricing, delivery, or other ordering information, contact your
local Bently Nevada office or contact Customer Service Department, Minden,
Nevada, USA Phone: 1-775-215-1011 Fax: 1-775-215-2873
For technical questions or problems regarding installed Bently Nevada products,
contact our Technical Support Staff at:
techsupport@bently.com
or at the following locations:
Technical Support (North America)
Phone: 1-775-782-1818 Fax: 1-775-215-2890
Technical Support (UK)
Phone: (44) 1925 818504 Fax: (44) 1925 817819
2
Section 2 — Installation
Section 2 — Installation
Sensor Installation
Introduction
Anywhere from 4 to 16 sensors will be attached to the stator laminations at
evenly spaced intervals on the same plane. The stator wall shall be well
prepared, as described below prior to attaching the sensor.
Handle the sensor with care. Do not pull on the cable or connector. Never paint
or attach anything to the sensor surface.
Additional Equipment List
•
Isopropyl alcohol
•
Disposable cloth rags
•
Fine grit sandpaper (non-metallic)
•
Depth Micrometer
•
Electric Drill (with #7 drill bit)
•
¼-20 tap
•
18 gauge wire stripper
•
Hand crimper (for ring lugs)
•
Safety Wire (optional and must be non-magnetic)
•
Cable tie downs (non-magnetic and ozone resistant)
•
Miscellaneous conduit fittings (Consult 3300 XL Proximitor® Housing data
sheet for a list of available fittings)
Important Installation Tips
• Be sure that all precautions have been taken to prevent objects from falling
through the air gap to the bottom of the generator
• Be sure to review the applicable Material Safety Data Sheets for the
chemicals used to assure proper personal protective equipment (PPE) is worn.
• When securing cable, conduit, or anything else inside the generator, use
ONLY clamps and hardware that are non-magnetic and not affected by ozone.
Ungrounded magnetic materials get very hot in the high magnetic field and can
cause shorting and damage to insulation or other components. Do not use nylon
cable ties to secure items except temporarily. Most plastics and natural rubbers
become brittle and eventually are destroyed by ozone present in the generator.
Panduit Corporation makes non-magnetic stainless steel hold-downs and cable
ties. If a softener is needed around the cables, use a silicon rubber or fiberglass
tape.
3
4000 Series Air Gap Sensor System Manual
• Be sure that the extension cable is tight at the sensor end. The wire must not
be allowed to become loose and get tangled in or damaged by the rotor.
Stator Surface Preparation
The stator surface must be properly prepared in order for the sensor to be fully
secured to the stator wall. Failure to do so could result in a lost sensor.
1. The sensor should be mounted such that it is centered over the stator slot
wedge and located beneath the second ventilation hole. Once a suitable
mounting location has been determined, moisten cloth rag with isopropyl
alcohol and thoroughly wipe down gluing area on stator to remove oil and
carbon deposits.
2. Using 200 grit, non-metallic sandpaper, scuff the stator wall along the stacks
and verify that there are no protrusions of paint that need to be removed or
sanded down. (The goal of sanding the stator is to roughen the surface for
adhesion, not remove the layer of painted insulation. Please be sure to wear
proper personal protective equipment, as required by the Material Safety
Data Sheet, when sanding the stator due to possible dust exposure.)
3. Once sanded, wipe down again, with a cloth rag moistened with isopropyl
alcohol.
4. Be sure that none of the stacks protrude out farther than the rest as the sensor
must be adhered to a flat surface. If this is the case, try moving the sensor
either to the left or right of the protrusion.
Attaching The Sensor
1. Prior to gluing the sensor to the stator verify that the sensor is functioning.
Power up the sensor and connect the grounding wires to a grounded object.
Pass your hand or an object over the face of the sensor and observe the
Proximitor® Sensor output. This should result in a decrease in voltage.
2. Apply the silicone adhesive (supplied) in two strips, approximately ¼” away
from the edges and approximately ¼” wide along the length of the sensor.
Even after sanding, the surface is not flat and there needs to be enough
adhesive to fill the gaps, but not so much that it will run out from the edges.
Be sure to save the remaining adhesive for securing the sensor cable.
3. Place the sensor in position such that it faces in between the poles and that
the top of the sensor is located just below the second ventilation hole, as
illustrated in the figure below. Pivot the sensor slightly to spread adhesive
and hold for approximately one minute onto stator wall. Avoid gluing the
sensor against the surface of the wedge.
4
Section 2 — Installation
4. If the wedges protrude out farther than the surface of the stator stack, the
supplied fiberglass spacers must be used in order to clear the wedges as
shown in the picture below. Use the supplied silicone to adhere the wedges
as shown below. After the adhesive has set (approximately 1 hour), run a ¼”
wide strip of silicone down the center of each spacer and attach to the stator
wall in the same fashion as mentioned above.
Fiberglass
Spacer
Fiberglass
Spacer
Determining Sensor Offset
The distance between the sensor surface and the stator surface must be measured.
As shown in the picture below, the measurement, D, accounts for the thickness of
the sensor, adhesive and spacers (if used). The measurement, D, is the average
of six offset measurements taken at points on the sensor as shown below. The
measurement, D, should be entered into the 3500 Configuration Software.
Consult the 3500/46M Hydro Monitor Module Operation and Maintenance
Manual for instructions on how to enter this data.
5
4000 Series Air Gap Sensor System Manual
Offset
Offset
Offset
Offset
Offset
Offset
Figure 2-1 Sensor offset for installations without spacers.
6
Section 2 — Installation
Figure 2-2 Sensor offset for installations with spacers.
Teflon® Conduit Installation
Introduction
The Teflon® conduit tubing protects the sensor cable, extension cable, and
connection from the stator windings. The tube is fed through the windings as
close as possible to the top of the sensor and anchored down with the supplied
loop strap and ¼-20 bolt.
The following materials will be required for this installation:
Installation kit (included with sensor)
Electric drill (with #7 drill bit)
¼-20 tap
Tube Preparation
1. An eighteen-inch tube is provided for the installation. This length should be
more than long enough, but some applications will require that this tube be
cut to length. Measure the distance through the windings from a point just
above the probe (and slightly recessed within the windings) to a point several
inches behind the stator windings. See the figure below for clarification.
7
4000 Series Air Gap Sensor System Manual
Teflon
Tube
Teflon
Tube
Clamp
2. Once the tube is in place, slide the clamp over the tube and place in the
approximate mounting positions. Mark its location and drill and tap the
stator (approximately ¾” deep) for a ¼-20 bolt.
3. For added security, safety wire the bolt to the tube and clamp by threading
the safety wire through each bolt.
¼-20
Bolt
Loop
Strap
Teflon
Conduit
Split-ring
Washer
Stator
Triaxial Extension Cable Installation
Introduction
The triaxial extension cable is used to connect the Air Gap Sensor to the
Proximitor® Sensor. This 10-meter cable has a female coaxial connector on one
end, and a BNC connector on the other end, each with a drain wire.
8
Section 2 — Installation
The following materials will be required for this installation:
Installation kit (included with sensor)
18 gauge wire stripper
Hand crimper (for ring lugs)
Installation
1. Carefully slide the green drain wire and female coaxial end of the extension
cable through the Teflon® conduit tube (near the clamp, behind stator
windings) until the connector protrudes out the other end (toward the rotor)
by about 2 inches.
2. Attach the male connector from the sensor to the female connector (finger
tight) from the extension cable. The Clickloc™ design will prevent these
from disconnecting.
3. Feed sensor cable drain wire through the Teflon® conduit tube as far as it
can go. Carefully pull the extension cable, until slightly taut, through the
Teflon® conduit tube. The connection will lie somewhere within the
Teflon® conduit tube. Be sure that drain wire from sensor protrudes out the
other side. See figure below for clarification.
Drain wire
Inserting extension
cable on stator side.
Rotor side
Extension cable
Sensor cable
4. Once the extension cable is attached to the sensor cable and the excess slack
is taken up, the exposed cable between the sensor and the Teflon® conduit
tube needs to be secured. Make sure the path of the cable is cleaned with
isopropyl alcohol before proceeding. Liberally cover the cable with the
silicone adhesive, securing it to the stator stacks. Do not paint, put silicone
on, or in any way cover the surface of the sensor.
9
4000 Series Air Gap Sensor System Manual
5. Allow the sensor to dry in place for a minimum of an hour and preferably
overnight before proceeding.
6. The drain wire from the sensor and extension cable may need to be trimmed
to reduce excess slack. Once trimmed (if necessary), strip wire and attach a
ring lug to both leads using the hand crimper. Attach both grounds to the ¼20 bolt securing the Teflon® conduit tube in place.
7. Using the supplied adhesive, seal the Teflon® conduit tube opening near the
clamp to prevent the cable from sliding.
Installation of Wiring Inside Generator Housing
•
IMPORTANT! When securing cable, Teflon® conduit tube, or anything
else inside the generator, use ONLY clamps and hardware that are nonmagnetic and not affected by ozone. Ungrounded magnetic materials get
very hot in the high magnetic field and can cause shorting and damage to
insulation or other components. Do not use nylon cable ties to secure items
except temporarily. Most plastics and natural rubbers become brittle and
eventually are destroyed by ozone present in the generator. Panduit
Corporation makes non-magnetic stainless steel hold-downs and cable ties.
If a softener is needed around the cables, use a silicon rubber or fiberglass
tape.
•
Teflon® conduit tube and cable inside of the generator housing should be
attached securely every 12-18 inches.
•
IMPORTANT! Be sure that the extension cable is tight at the sensor end.
The wire must not be allowed to become loose and get tangled in or damaged
by the rotor.
Enclosure, Power Supply & Proximitor® Sensor
Installation
Introduction
The 3300 XL Proximitor® Housing, P/N 330181-01-00-01-00, allows you to
protect Proximitor® Sensors and electrical terminal blocks in areas that would
otherwise be subjected to possible damage from moisture or other adverse
environmental conditions.
The housing is designed to accommodate a maximum of four Air Gap
Proximitor® Sensors and a +24 Vdc (BN P/N 02200627) power supply in a DIN
style configuration. For a hydro turbine with four sensors installed, we
recommend two Proximitor® Sensors and one power supply per housing, for a
total of two housings.
Prior to installing the enclosure, keep in mind the following requirements:
10
Position the enclosure such that the 10-meter extension cable will reach the
Proximitor® Sensor.
Access to sufficient ground.
Section 2 — Installation
Access to proper input power for external +24 Vdc power supply.
Mounting The Enclosure
This housing contains removable gland plates, making it easy to drill or punch
holes to install conduit fittings. There are also four mounting tabs on the unit
allowing simple attachment to any flat surface. The final mounting and conduit
configuration is to be determined by the end user.
Power Supply And Proximitor® Sensor Layout
The figure below depicts the ideal layout for two Proximitor® Sensors and a
power supply (housing not shown).
Power
Supply
DIN Mount Stops
Mounting
Plate
11
4000 Series Air Gap Sensor System Manual
Sensor Connection
See figure below for the following connections:
Attach male BNC connector from extension cable to the female BNC on
Proximitor® Sensor.
Loosen top locknut until it stops. Place spade lug from drain wire onto stud
and torque top locknut to between 8 and 15 lb-in.
Electrical Connection
The Proximitor® Sensor requires +24±3% Vdc. BN P/N 02200627 or a similar
+24 Vdc power supply is recommended to meet voltage requirement. Please see
schematic below for proper connection.
Note: Once the Proximitor® Sensors are powered and put into service they should remain
powered at all times except when being serviced. To protect the Proximitor® Sensors
from an unwanted Electrostatic Discharge (ESD), power should be removed from the
Proximitor® Sensors prior to having any work done inside the Proximitor® Housing. Do
not attach power to the Proximitor® Sensors if the temperature is below 0 ºC (+32 ºF).
Application Note: When connecting the Proximitor® Sensor to the 3500 Prox/Velom I/O
Module the A and B connections should be followed. The Air Gap Proximitor® Sensor is a
positive output device and the Signal (SIG) and Common (COM) outputs must be
reversed when connecting to the Prox/Velom I/O Module. The A output of the Proximitor®
Sensor should be connected to the A input of the I/O Module and the B output of the
Proximitor® Sensor should be connected to the B input of the I/O Module.
12
Section 2 — Installation
Verification
All sensors should be verified for proper operation prior to the commissioning of
the generator. Bently Nevada accessory P/N 168448-01 can be used to verify
that each sensor’s output correlates to a known gap voltage.
The verification plate is designed to provide an air gap of 388 ± 32 mils when
installed over the face of the sensor after it has been glued to the stator.
See figure below for installation orientation.
•
•
•
Place target on sensor, such that notched lip hooks on the top of the sensor
without disrupting cable.
Make sure the magnetic standoffs are on the sensor face and not resting on
any part of the stator.
Connect target to stator using supplied drain wire.
Verify output of the Proximitor® Sensor. This can be accomplished in two
ways:
• Measure the voltage between the SIG and COM outputs of the
Proximitor® Sensor. The voltage should be 1.94 ± 0.16 Vdc.
• Use the 3500 Configuration Software to verify the correct output of
the air gap sensor system and adjust if desired. The measurement
will be displayed in mils and should lie between the measurement for
the air gap listed above. Consult the 3500/46M Hydro Monitor
Module Operation and Maintenance Manual for instructions on how
to verify sensor readings and adjust readings if desired.
Remove the verification fixture from the sensor after verifying the output
voltage and gap prior to the starting of the generator.
Probe
Stator
Verification
Fixture
Verification
Fixture
Stand Off
Stator
13
4000 Series Air Gap Sensor System Manual
Section 3 — Maintenance and
Troubleshooting
This section shows how to verify that the system is operating properly and
identify parts of the system that are not working properly.
The 4000 Series Air Gap Sensor System (probe, cable and Proximitor® Sensor),
when correctly installed and verified, does not need calibration or verification at
regular intervals. If the monitor OK light (green) indicates a NOT OK condition
(light is not illuminated), either a fault has occurred in the field wiring,
transducer system, or power source.
Bently Nevada recommends the following practices to assure continued
satisfactory operation. Verify operation by using Bently Nevada accessory P/N
168448-01 and the verification method described in Section 2 if:
Any of the system components (probe, cable or Proximitor® Sensor) are
replaced.
Any of the components are removed and reinstalled or moved and
remounted.
Any of the components appear to be damaged.
Whenever the machine being monitored is over-hauled.
Please note that a step change in the output of the transducer system, or other
output that is not consistent with the associated machinery’s trended data is, in
most instances, not a transducer problem but a machinery problem. Verification
of the transducer system under these conditions can be done at the user’s
discretion.
Some users may prefer to verify all transducers at a regular interval. As noted
above, this is not required with the 4000 Series Air Gap Sensor System. Users
who wish to verify the system on a regular interval should use an interval
consistent with their own practices and procedures, which may or may not be
based upon ISO 10012-1 “Quality Assurance Requirements for Measuring
Equipment” (section 4.11).
14
Section 3—Maintenance and Troubleshooting
Troubleshooting
This section shows how to interpret a fault indication and isolate faults in an
installed transducer system. Before beginning this procedure, be sure the system
has been installed correctly and all connectors have been secured properly in the
correct locations.
When a malfunction occurs, locate the appropriate fault, check the probable
causes for the fault indication and follow the procedure to isolate and correct the
fault. Use a digital voltmeter to measure voltage. If you find faulty transducers,
contact your local Bently Nevada office for assistance.
The troubleshooting procedures use measured voltages as shown in the following
figure and tables:
15
4000 Series Air Gap Sensor System Manual
Table 3-1 Symbols for Measured Voltages
Symbol
Meaning
Voltage measured
between...
VSIG
Signal voltage from the transducer
SIG/A and COM/B
VPS
Power supply voltage
Power Supply and Ground
VXDCR
Supply voltage at transducer
+24V and GND
Note: VSIG, VPS, and VXDCR are all positive voltage values.
Table 3-2 Definitions
Symbol
Definition
Example
A>B
"A" value is more positive than "B"
23 > 21
A<B
"A" value is more negative than "B"
5 < 10
A=B
"A" same value (or very close) to "B"
3.40 = 3.41
Fault Type 1: VXDCR < 23.2 Vdc or VXDCR > 24.8 Vdc
Possible causes:
Faulty power source
Faulty field wiring
Faulty Proximitor® Sensor
Measure VPS: Is VPS < 23.2 Vdc or VPS > 24.8 Vdc?
Yes:
No:
16
Faulty power supply.
Go to next step.
Section 3—Maintenance and Troubleshooting
Measure VXDCR: Is VXDCR < 23.2 Vdc or VXDCR > 24.8 Vdc?
Yes: Faulty Field wiring.
No: Faulty Proximitor® Sensor.
Fault Type 2: VSIG = 0 Vdc
Possible causes:
Incorrect power source voltage
Short circuit in field wiring
Short circuit at Proximitor® Sensor terminal connection
Faulty Proximitor® Sensor
Does fault condition type 1 exist?
Yes:
No:
Use the procedure for fault type 1
Go to the next step
17
4000 Series Air Gap Sensor System Manual
Measure VSIG: Is VSIG = 0 Vdc?
No:
Yes:
Incorrect power source voltage or short in field wiring or short at
Proximitor® Sensor terminal connection.
Faulty Proximitor® Sensor.
Fault Type 3: 0 Vdc < VSIG < 0.01 Vdc
Possible causes:
Incorrect power source voltage
Faulty Proximitor Sensor
Short or open circuit in a connector (dirty or wet) or loose connectors
Short or open circuit in the probe
Short or open circuit in extension cable
Does fault condition type 1 exist?
Yes:
No:
Use the procedure for fault type 1
Go to the next step
Measure continuity at the following points on the extension cable:
Is 0.1
Ω<R
GND <
1.0
Ω?
Yes: Go to next step
No: Faulty extension cable
18
Section 3—Maintenance and Troubleshooting
Is 0.1
Ω<R
COAX
< 1.0
Ω?
Yes: Go to next step
No: Faulty extension cable
Is 7
Ω < RCENTER < 8 Ω ?
Yes: Go to next step
No: Faulty extension cable
Disconnect the BNC connector and the grounding wire from the
Proximitor® Sensor. Measure the resistance between the grounding
wire and the outer conductor of the BNC connector with the probe
connected to the extension cable and the probe grounding wire
connected to the probe side extension cable grounding wire;
Ω<R
Is 200.8 k
PROBE
Ω?
< 201.2 k
No: Faulty probe
19
4000 Series Air Gap Sensor System Manual
Fault Type 4: VSIG > 14 Vdc with verification fixture
on the face of the probe
Reconnect the BNC connector and the grounding wire to the
Proximitor® Sensor. Power up the system and install the Air Gap
verification fixture over the face of the probe. Make sure both the
surface the probe is resting on and the Air Gap verification fixture are
grounded. Measure VSIG.
Is VSIG > 14 Vdc?
Yes: Faulty probe, Proximitor® Sensor or cable
No: Go to next step
At this point, set up a known good system and verify that VSIG of the
Proximitor® Sensor is in the following range with the Air Gap
verification fixture properly placed on the probe face:
1.85 Vdc < VSIG < 2.10 Vdc
With the verification fixture in place, begin swapping the questionable
individual components in to the known good system to determine which
component is faulty. Whichever component causes VSIG to fall outside of the
above voltage range is defective.
20
Section 4—3300 XL Proximity Housing Description
Section 4 — 3300 XL Proximity Housing
Description
The 3300 XL Proximitor® Housing allows you to protect Proximitor® Sensors,
interface modules and electrical terminal blocks in areas that would otherwise be
subjected to possible damage from moisture or other adverse environmental
conditions.
Mounting Options
The 3300 XL Proximitor® Housing is designed to accommodate both DIN-rail
and panel mounted Proximitor® Sensors although the 4000 Series Air Gap
Proximitor® Sensors only come with DIN mount option. The housing holds up
to four 4000 Series Air Gap Proximitor® Sensors and one power supply.
Environmental Certifications
The 3300 XL Proximitor® Housing has been tested and certified to meet
stringent IP66 and Type 4X environmental ratings for protecting enclosed
electronic equipment in harsh conditions. The 304L stainless steel construction
resists moisture, corrosion, and impacts in virtually all installations. The housing
may be hosed down for cleaning when necessary. The 3300 XL Proximitor®
Housing can be used for North American Division 1 and 2 and European Zone 0,
1, and 2 hazardous area applications when used with approved fittings.
However, it is not an explosion-proof housing.
Removable Gland Plates
The 3300 XL Proximitor® Housing is our only housing with removable gland
plates. This feature makes it easy to remove the side plates or bottom gland plate
for drilling or punching conduit holes. In addition, the door can be easily
unlatched and removed due to its stainless steel slip hinge.
The gland plates have four thickness options to suit various conduit installation
requirements. If you want a threaded conduit hole, a gland plate thickness of
3.05 mm (0.120 in) or greater is required in order to properly drill and tap the
holes.
The conduit fittings come with a lock nut and O-ring to firmly tighten and seal
the conduit fitting into both tapped and untapped holes. Fittings are available in
stainless steel, brass, aluminum or chrome-plated zinc.
21
4000 Series Air Gap Sensor System Manual
Figure 4-1 3300 XL Housing Outline Drawing
(1)
(2)
(3)
(4)
(5)
(6)
(7)
22
Stainless steel slip hinge. Allows cover to be removed from housing
M10 x 1.5 – 6 g grounding stud, stainless steel
M6 slotted hex head captive fastener, stainless steel
Approval/ identification label
M6 x 16 mm hex head bolt, stainless steel
φ 8.33 [0.328] padlock hasp
Removable gland plate, 3 places
Section 4—3300 XL Proximity Housing Description
Din Mount Orientation
The following illustration shows the correct orientation for two DIN mounted
4000 Series Air Gap Proximitor® Sensors in the 3300 XL Proximitor® Housing:
The next illustration shows the correct orientation for four DIN mounted 4000
Series Air Gap Proximitor® Sensors in the 3300 XL Proximitor® Housing:
23
4000 Series Air Gap Sensor System Manual
Section 5 — 4000 Series Air Gap Sensor
System Specifications and Ordering
Information
Unless otherwise noted, the following specifications are for a 4000 Series Air
Gap Proximitor® Sensor, extension cable, and probe between 0ºC and +50ºC
(+32ºF to +122ºF), with a +24 Vdc power supply, and a 10 kΩ load.
Electrical
Proximitor® Sensor Input
Accepts one non-contacting 4000 Series Capacitive
Probe and Extension Cable
Power
Requires +23.25 Vdc to +24.75 Vdc at 75 mA maximum
consumption
Supply Sensitivity
Less than 20 mV change in output voltage per volt
change in input voltage
Output Resistance
50 Ω ± 5%
Extension Cable capacitance
75.5 pF/m (23.0 pF/ft) typical
Field Wiring
0.2 to 1.5 mm2 (16 to 24 AWG)
Recommend using two-conductor shielded cable.
Maximum length of 305 metres (1000 feet) between the
4000 Series Proximitor® Sensor and the monitor.
Linear Range
45.7 mm (1800 mils). Linear range begins at
approximately 5.1 mm (200 mils) from the face of the
probe and is from 5.1 to 50.8 mm (200 to 2000 mils)
(approximately +1 to +10 Vdc).
System
Average Scale Factor (ASF)
0.20 mV/µm (5.0 mV/mil), nominal
Deviation from a straight line
Less than ±2.54 mm (±100 mils) with system between 0
ºC and +50 ºC (+32 ºF and +122 ºF).
Frequency Response
0 to 5.0 kHz: +0, -3 dB typical with up to 305 metres
(1000 feet) of field wiring.
24
Section 5—4000 Series Air Gap Sensor System Specifications and Ordering Information
Electrical Classification
Complies with the European CE mark.
Mechanical
Probe Material
FR4 type material
Probe Cable Specifications
75 Ω triaxial, fluoroethylene propylene (FEP) cable
Extension Cable Material
75 Ω triaxial, flouroethylene propylene (FEP) cable
Proximitor® Sensor Material
Aluminum
Tensile Strength (maximum rated)
312 N (70 pounds) probe lead to probe. 89 N (20
pounds) at probe lead to extension cable connectors.
Connector Material
Gold-plated brass and gold-plated beryllium copper
Connector-to-connector torque
Recommended
Torque
Finger tight
Maximum Torque
0.565 N•m (5 in•lb)
Minimum Bend Radius
25.4 mm (1.0 in)
System Mass (typical)
Probe
Approximately 140 g (0.3 lbs)
Extension Cable
Approximately 320 g (0.7 lbs)
Proximitor® Sensor
Approximately 380 g (0.8 lbs)
Environmental Limits
Probe Temperature Range
Operating
Temperature
0 to +125 ºC (+32 to +257 ºF)
Storage Temperature
-35 to 125 ºC (-31 to 257 ºF)
Extension Cable Temperature Range
Operating
Temperature
0 to +125 ºC (+32 to +257 ºF)
25
4000 Series Air Gap Sensor System Manual
Storage Temperature
-35 to +125 ºC (-31 to +257 ºF)
Proximitor® Sensor Temperature Range
Operating
Temperature
0 to +70 ºC (+32 to +158 ºF)
Storage Temperature
-35 to +85 ºC (-31 to 185 ºF)
Relative Humidity
Less than a 5% change in average scale factor when
tested in 93% humidity in accordance with IEC standard
60068-2-78 for up to 56 days.
Patents Pending
Ordering Information
4000 Series Capacitive Proximity Probe
400102-01
45.7 mm (1800 mils) linear range probe
4000 Series Air Gap Proximitor® Sensor
400100-AXXX-BXX
A: System Length Option
1 0 0 10.0 metre (33 feet) system length
B: Probe Size Option
02
Use with 400102-01
4000 Series Extension Cable
400130-AXXX
A: Cable Length
1 0 0 10.0 metre (33 feet) cable length
Accessories
167545
Performance Specification
02200627
+24 Vdc Power Supply
330181
3300 XL Proximitor® Housing. Suggested configuration is 330181-01-0001-00-00; a housing with DIN mount hardware, no conduit fitting, standard
2.34 mm (0.92 in) gland plate thickness, no terminal blocks, and no
approvals.
26
Section 5—4000 Series Air Gap Sensor System Specifications and Ordering Information
02173006
2
Bulk Cable (specify length in feet) 1.0 mm (18 AWG), 2-conductor,
twisted, shielded cable used for the PROX OUT signal on the Air
Gap Proximitor® Sensor terminal strip
168448-01
Air Gap Verification Kit
Graphs and Dimensional Drawings
5.1
10.2
15.2
20.3
25.4
30.5
35.6
40.6
45.7
50.8
5.1
160
4.1
120
3.0
80
2.0
40
1.0
0
0.0
-40
-1.0
-80
-2.0
-120
-3.0
-160
-4.1
-200
-5.1
DSL Error (mils)
200
DSL Error (mm)
Gap (mm)
12
11
10
Output (Volts)
9
8
7
6
5
4
3
2
1
Gap (Mils)
0
200
400
600
0°C (32°F)
800
1000
1200
23°C (73°F)
1400
1600
1800
2000
50°C (122°F)
Figure 5-1 Typical Air Gap Proximitor® Sensor at Temperature
27
4000 Series Air Gap Sensor System Manual
5.1
10.2
15.2
20.3
25.4
30.5
35.6
40.6
45.7
50.8
200
5.1
160
4.1
120
3.0
80
2.0
40
1.0
0
0.0
-40
-1.0
-80
-2.0
-120
-3.0
-160
-4.1
-200
-5.1
12
11
10
Output (Volts)
9
8
7
6
5
4
3
2
1
Gap (Mils)
0
200
400
600
800
1000
1200
0°C (32°F)
23°C (73°F)
85°C (185°F)
125°C (257°F)
1400
1600
1800
50°C (122°F)
Figure 5-2 Typical Air Gap Probe at Temperature
28
2000
DSL Error (mm)
DSL Error (mils)
Gap (mm )
Gap (mm)
5.1
50.8
5.1
160
4.1
120
3.0
80
2.0
40
1.0
0
0.0
-40
-1.0
-80
-2.0
-120
-3.0
-160
-4.1
-200
-5.1
DSL Error (mils)
200
10.2
15.2
20.3
25.4
30.5
35.6
40.6
45.7
DSL Error (mm)
Section 5—4000 Series Air Gap Sensor System Specifications and Ordering Information
12
11
10
Output (Volts)
9
8
7
6
5
4
3
2
1
Gap (Mils)
0
200
400
600
800
1000
1200
0°C (32°F)
23°C (73°F)
85°C (185°F)
125°C (257°F)
1400
1600
1800
2000
50°C (122°F)
Figure 5-3 Typical Air Gap Cable at Temperature
29
Gap (mm)
50.8
5.1
160
4.1
120
3.0
80
2.0
40
1.0
0
0.0
-40
-1.0
-80
-2.0
-120
-3.0
-160
-4.1
-200
-5.1
DSL Error (mils)
200
5.1
10.2
15.2
20.3
25.4
30.5
35.6
40.6
45.7
12
11
10
Output (Volts)
9
8
7
6
5
4
3
2
1
Gap (Mils)
0
200
400
0°C (32°F)
600
800
23°C (73°F)
1000
1200
1400
50°C (122°F)
1600
1800
2000
70°C (158°F)
Figure 5-4 Typical Air Gap Sensor System at Ambient Temperature
30
DSL Error (mm)
4000 Series Air Gap Sensor System Manual
Section 5—4000 Series Air Gap Sensor System Specifications and Ordering Information
1
Magnitude (dB)
0
-1
-2
-3
-4
-5
-6
100
1000
10000
Frequency (Hz)
Field Wiring Length
0 m (0 ft)
300 m (1000 ft)
600 m (2000 ft)
20
Phase Lag (deg)
0
-20
-40
-60
-80
-100
100
1000
10000
Frequency (Hz)
Field Wiring Length
0 m (0 ft)
300 m (1000 ft)
600 m (2000 ft)
Figure 5-5 Frequency Response
31
4000 Series Air Gap Sensor System Manual
Figure 5-6 400102 Air Gap Sensor Probe
Figure 5-7 400130 Air Gap Sensor Extension Cable
32
Section 5—4000 Series Air Gap Sensor System Specifications and Ordering Information
Figure 5-8 400100 Air Gap Sensor Proximitor® Sensor
33
4000 Series Air Gap Sensor System Manual
Figure 5-9 168448-01 Air Gap Verification Fixture
34