Model 649A03

Bearing Condition Transmitter

Installation and Operating Manual

For assistance with the operation of this product,

contact PCB Piezotronics, Inc.

Toll-free: 800-828-8840
24-hour SensorLine: 716-684-0001
Fax: 716-684-0987
E-mail: info@pcb.com
Web: www.pcb.com
 Warranty, Service, Repair, and
Return Policies and Instructions

The information contained in this document supersedes all similar information that
may be found elsewhere in this manual.

Total Customer Satisfaction – PCB recommended as this helps build

Piezotronics guarantees Total Customer confidence in measurement accuracy and
Satisfaction. If, at any time, for any acquired data. Equipment calibration
reason, you are not completely satisfied cycles are typically established by the
with any PCB product, PCB will repair, users own quality regimen. When in
replace, or exchange it at no charge. You doubt about a calibration cycle, a good
may also choose to have your purchase “rule of thumb” is to recalibrate on an
price refunded in lieu of the repair, annual basis. It is also good practice to
replacement, or exchange of the product. recalibrate after exposure to any severe
temperature extreme, shock, load, or
Service – Due to the sophisticated nature other environmental influence, or prior
of the sensors and associated to any critical test.
instrumentation provided by PCB
Piezotronics, user servicing or repair is PCB Piezotronics maintains an ISO-
not recommended and, if attempted, may 9001 certified metrology laboratory and
void the factory warranty. Routine offers calibration services, which are
maintenance, such as the cleaning of accredited by A2LA to ISO/IEC 17025,
electrical connectors, housings, and with full traceablility to N.I.S.T. In
mounting surfaces with solutions and addition to the normally supplied
techniques that will not harm the calibration, special testing is also
physical material of construction, is available, such as: sensitivity at elevated
acceptable. Caution should be observed or cryogenic temperatures, phase
to insure that liquids are not permitted to response, extended high or low
migrate into devices that are not frequency response, extended range, leak
hermetically sealed. Such devices should testing, hydrostatic pressure testing, and
only be wiped with a dampened cloth others. For information on standard
and never submerged or have liquids recalibration services or special testing,
poured upon them. contact your local PCB Piezotronics
distributor, sales representative, or
Repair – In the event that equipment factory customer service representative.
becomes damaged or ceases to operate,
arrangements should be made to return Returning Equipment – Following
the equipment to PCB Piezotronics for these procedures will insure that your
repair. User servicing or repair is not returned materials are handled in the
recommended and, if attempted, may most expedient manner. Before returning
void the factory warranty. any equipment to PCB Piezotronics,
contact your local distributor, sales
Calibration – Routine calibration of representative, or factory customer
sensors and associated instrumentation is service representative to obtain a Return
Materials Authorization (RMA) PCB for a complete statement of our
Number. This RMA number should be warranty. Expendable items, such as
clearly marked on the outside of all batteries and mounting hardware, are not
package(s) and on the packing list(s) covered by warranty. Mechanical
accompanying the shipment. A detailed damage to equipment due to improper
account of the nature of the problem(s) use is not covered by warranty.
being experienced with the equipment Electronic circuitry failure caused by the
should also be included inside the introduction of unregulated or improper
package(s) containing any returned excitation power or electrostatic
materials. discharge is not covered by warranty.

A Purchase Order, included with the Contact Information – International

returned materials, will expedite the customers should direct all inquiries to
turn-around of serviced equipment. It is their local distributor or sales office. A
recommended to include authorization complete list of distributors and offices
on the Purchase Order for PCB to can be found at www.pcb.com.
proceed with any repairs, as long as they Customers within the United States may
do not exceed 50% of the replacement contact their local sales representative or
cost of the returned item(s). PCB will a factory customer service
provide a price quotation or replacement representative. A complete list of sales
recommendation for any item whose representatives can be found at
repair costs would exceed 50% of www.pcb.com. Toll-free telephone
replacement cost, or any item that is not numbers for a factory customer service
economically feasible to repair. For representative, in the division
routine calibration services, the Purchase responsible for this product, can be
Order should include authorization to found on the title page at the front of this
proceed and return at current pricing, manual. Our ship to address and general
which can be obtained from a factory contact numbers are:
customer service representative.
PCB Piezotronics, Inc.
Warranty – All equipment and repair 3425 Walden Ave.
services provided by PCB Piezotronics, Depew, NY 14043 USA
Inc. are covered by a limited warranty Toll-free: (800) 828-8840
against defective material and 24-hour SensorLineSM: (716) 684-0001
workmanship for a period of one year Website: www.pcb.com
from date of original purchase. Contact E-mail: info@pcb.com

DOCUMENT NUMBER: 21354

DOCUMENT REVISION: B
ECN: 17900
 SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
Model 649A03 Series Industrial 4-20mA Bearing Condition
Transmitter

Operating Guide with Enclosed Warranty Information

3425 Walden Avenue, Depew, New York 14043-2495

Phone (716) 684-0003

Fax (716) 684-3823

Toll Free Line 1-800-959-4IMI

MANUAL NUMBER: 45611

MANUAL REVISION: NR
ECN NUMBER: 38356
 SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
Table of Contents

Introduction...................................................................................................................... Page 3
General Features

649A03 Programming Software ...................................................................................... Page 5

Dimension Drawing ......................................................................................................... Page 9

Operation and Wiring .................................................................................................... Page 10

Standard Wiring
Block Diagram

Installation ..................................................................................................................... Page 12

Direct Adhesive Mount
Standard Stud Mount
Adhesive Stud Mount
Magnetic Mount

ESD Sensitivity.............................................................................................................. Page 16

Warranty/Servicing

Warranty, Service & Return Procedure ......................................................................... Page 17

Customer Service.......................................................................................................... Page 18

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 SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
Introduction
The 649A03 Bearing Condition Transmitter is a USB Programmable loop powered device
with 4-20mA output, all contained in typical vibration sensor housing. It is specifically
designed to provide early warning of typical ball/rolling element bearing faults such as cracked
races, spalling, brinelling and looseness. It has five modes of detection that are user selectable
by a simple software program through a PC’s USB port. The options include RMS
acceleration, True Peak acceleration, Compensated Peak acceleration using bearing
diameter and speed to normalize output, Crest Factor, and Crest factor Plus(based on
original combination of the peak, RMS, and crest factor) for improved detection on variable
speed machinery. A structure diagram of the transmitter and test results are discussed.

Machinery and mechanical systems face potential failure when the ability to function
normally is compromised due to worn components or when operation conditions diverge from
normal. Continuous monitoring of vibration levels helps avoid expensive unplanned
shutdowns by detecting machinery faults before they become catastrophic events. It is known
that machinery vibration changes when problems such as worn bearings occur. Bearings are
needed whenever one part of a machine slides against another, and can be classified as either
sliding or rolling contact bearings. For rolling contact bearing condition monitoring, The
Rolling/Ball bearing Condition Transmitter, a new field programmable and cost-effective
sensor has been designed. The sensors are constructed with a two pin independent polarity
connector and can work directly with PLC, DCS, or SCADA, and other plant information
systems. All parameters and configurations of the sensor are USB programmable through a
PC.

Two groups of methods are widely adopted for the determination of rolling bearing health and
the presence of faults. Although not always possible, the best results are obtained when both
methodologies are adopted.

The first group of methods, which are diagnostics orientated, is based on the separation and
analysis of discrete components of certain frequencies which make up excited oscillations in
the bearing. The diagnostic features are frequency components of the spectrum and
characteristics of the signal pulse shaped associated with the characteristic frequencies of the
bearings. These are the pulse peak value (usually harmonic amplitude), the ratio of the
harmonic energy to the noise level, and the amplitude of spectrum components at the pulse
repetition frequency. To analyze these parameters, use is made of vibration signal spectra,
spectra of AM-envelopers of narrow band high frequency components of the vibration signal
in a range of 0.1 to 40 kHz and vibration time waveforms.

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 SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
The second group of methods is based on the determination of the technical condition of the
bearing as a whole. In the case of loss of serviceability, it is paramount to determine the
necessity of bearing replacement (i.e. determine its health). The cause of the failure may be
determined later, if required, by visual inspection of the bearing. The condition of the bearing is
evaluated by the degree of development of degradation; a process that may be separated into four
known stages. The following is a list of possible diagnostic parameters (RMS and Peak of
acceleration, characteristics of amplitude distribution, moment characteristics (dispersion,
excess), correlation and regression variances ,amplitude discriminates, various parameters with
use of Peak(Crest) Factor and its combination with RMS and Peak of vibration and comparison
of vibration parameters in various frequency bands. One important property of the field
applicable methods is a strong ability to separate current process characteristics, such as speed
and loading, from bearing defects. The RMS, Shock Pulse, Crest Factor, Kurtosis, High
Frequency Resonance Technique (HERT), Spike Energy™ , gSE, HFD, etc., are the main
methods of bearing conditions related to the second group. Several popular methods for
determining bearing conditions are listed below.

• Real or true PK of Acceleration and HFD

• True RMS of Acceleration
• Crest (peak) factor CF = Apk/Arms (trend is required)
• Shock pulse method (rpm is required)
• W1X (Apk/Arms) + W 2 x Arms
• Enveloping with Spectrum Analyses, Cepstrum and others
• K – factor K= Apk x Arms and other high order moments (rpm is required)
• Strum factor K0/Kt = Apk0xArms0/Apkt x Armst
• Kurtosis (rpm is required)
• Modulation deepness of envelop signal (rpm is required)

The 649A03 product uses the first five methods listed above. When programming the sensor,
the user selects the method most closely matched to his application. Factory application
assistance is always available 24/7.

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 SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
The Bearing Condition Transmitter can be programmed by the user by using the 600A21
programming kit for the 2-pin Mil Style connector. The kit contains the 070A89 programmer
cable as well as the software on a CD. The 600A2X kit contains the same plus and extra cable
adapter (model 042M17) for use with integral cable models as well as the terminal block style
connector used in conjunction with a 90 ° conduit e lbow for hazardous areas. The latest copy of
this software is also available as a free download via the IMI Website (www.imi-sensors.com).
The software must be installed on the computer before connecting the programming cable to
sensor.

Program Installation
Copy the Files: Insert the software disk provided into the CD drive. Create a new directory on the
computer and copy the entire contents of the disk to the directory created. Be sure to remember where
this new file is located, because you will need to browse to it once the device is first connected.
Install the Drivers and Software: NOTE: If the computer does not find the new hardware automatically
as described below, the drivers can also be installed by either using the “Add Hardware” function in the
Control Panel or by gong to System, Hardware, Device Manager in the Control Panel. Please contact IMI
if you need further assistance.

NOTE: It is important to connect the USB Programmer in the sequence described for proper operation.
Connect the Model 070A89 USB Programmer first to the 2-pin MIL connector on the Series 649A and
then to the USB connection on the computer. If the switch has a terminal block connector or integral
cable, use the Model 042M17 adapter cable with the USB Programmer. After a few seconds, you will be
prompted with the following message. Note: In some cases, you may not get this message but get the
one that follows it below.

Select “Yes, this time only” and click

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 SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
The following screen should appear, select “Install from a list or specific location” and click

At the next screen prompt, select the option to “Include this location in the search”, and click
to select the “Calibrator1Driver” folder that is a subfolder of the “Software for 649AXX” folder that you
created when you copied the files. Click

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 SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
When the following screen appears; click “Continue Anyway”

The drivers will now be properly installed and you should get the following screen. Click “Finish”. The
software is now ready to use.

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 SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
A 649 Series Programming Screen similar to the one above will be displayed. The data in the
“STATUS” window indicates the current programming settings of the Series 649 Sensor. The
left side of the screen provides the choices for programming the sensor and consists of 2
sections. The top left section is used to program constant speed machinery and includes the
following selections: True Peak of acceleration (A pk), True RMS of acceleration (A rms),
which are both user programmable from 2-50 g. The third choice is True Peak of acceleration
with compensation (A pk with compensation) which is a modified shock pulse method for non-
resonance measurements. This selection will call for the user to enter the bearing diameter as
well as the rotation speed. The bottom section is used for “Variable Speed Machinery” and
includes Crest (peak) factor which is the ratio of Acceleration peak and Acceleration RMS and is
represented as sensor output in mA equal to the CF. The Crest Factor Plus (CFR+) is a
combination of the Peak, RMS and Crest Factor is modified known technology for improving
bearing defect detection on variable speed machinery. The output is useful for detecting high
level defects. The CF+ algorithm recognizes when defects get severe enough to increase RPM
output (acting to reduce the value of CF ratio) and compensates for it. Once the proper mode is
selected from the above and entered into the program through 070A89 programming cable by
selecting the set up button.

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SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING

PAGE 9
Inch (mm)
Dimension Drawing
 SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
Operation and Wiring

Standard Wiring
The Model 649A Series operates from a standard 2-wire, 4-20mA loop. If using a loop powered unit,
attach the positive (+) input from the power supply to Pin A or Red wire on the sensor and the negative (-
) input from the power supply to Pin B or Blue wire of the sensor.

Figure 1 – wiring: loop powered Figure 2 – wiring: loop powered/DC

source

If using a standard DC power supply, install either an ammeter and/or load resistor in line with the output,
Pin B or Blue wire.

The resistor will generate a DC voltage that is proportional to current by:

V = IR
If R = 500 ohms and I = 6 mA, then V = 3 VDC

Note:
- Resistor value must be less than: (Vsupply – 12) x 50.
- For integral cable sensors: RED wire is positive, BLUE wire is negative.

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 SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
Block Diagram

Simplified block diagram of the bearing Condition Transmitter is shown above.

The Bearing Condition Transmitter includes an embedded accelerometer (piezo-sensor) that
generates a voltage output that is proportional to the shock and vibration sensed on the machine
bearing. The output of the sensor is passed through a band pass filter (250 Hz to 10+ kHz) and
coupled through an amplifier to a high speed peak detector and thru another band filter (2.5 kHz
to 10+kHz) or directly to a true RMS detector.

The PK detector and RMS detector monitor the continuous vibration signal and hold the highest
values seen within the sample window. The PK and RMS values are passed through the analog-
to-digital convertor (A/D) to the CPU. The sensor output is a 4-20 mA current proportional to
measured parameter based on the USB programmed settings.

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 SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
Installation
When choosing a mounting method, consider closely the advantages and disadvantages of each
technique. Typical mounting types are stud, direct adhesive, adhesive mounting base and
magnetic mounting base. Since the frequency response is limited to 1 kHz on the 640/641, any
of the four methods can be used without seriously affecting the data values. The mounting
method might affect some of the 649 series because of the increased frequency response.

Direct Adhesive Mount Procedure

For restrictions of space or for convenience, most sensors (with the exception of integral stud models)
can be adhesive-mounted directly to the machine surface.

STEP 1 Prepare a smooth, flat mounting surface. A minimum surface finish of 63 µin [0,00016 mm]
generally works best.

STEP 2 Place a small portion of adhesive on the underside of the sensor. Firmly press down on the top
of the assembly to displace any adhesive. Be aware that excessive amounts of adhesive can make
sensor removal difficult.

Figure 5 – direct adhesive mounting

Firmly Press Down

Typical
Accelerometer

Adhesive

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 SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
Standard Stud Mount Procedure
This mounting technique requires smooth, flat contact surfaces for proper operation and is recommended
for permanent and/or secure installations. Stud mounting is also recommended when testing at high
frequencies.
Note: DO NOT attempt mounting on curved, rough or uneven surfaces, as the potential for misalignment
and limited contact surface may significantly reduce the sensor’s upper operating frequency range.

Figure 6 – mounting surface preparation

1/4-28 Stud 1/4-28 Captive Screw
1 . 1 T im e s
A (in) 0.250 0.250 S e n s o r D ia m e te r

B (in) 0.350 0.350

Torque (ft-lb) 2 to 5 2 to 5 A
B

STEP 1 First, prepare a smooth, flat mounting surface, and then drill and tap a mounting hole in the
center of this area as shown in Figure 6. A precision-machined mounting surface with a minimum finish of
63 µin [0,00016 mm] is recommended. (If it is not possible to properly prepare the machine surface,
consider using an adhesive mounting pad as a possible alternative.) Inspect the area, checking that
there are no burrs or other foreign particles interfering with the contact surface.

STEP 2 Wipe clean the mounting surface and spread on a light film of grease, oil or similar coupling fluid
prior to installation.
Figure 7 – mounting surface lubrication

Adding a coupling fluid improves vibration transmissibility by filling small voids in the mounting surface
and increasing the mounting stiffness. For semi-permanent mounting, substitute epoxy or another type
of adhesive.

STEP 3 HAND-tighten the sensor/mounting stud to the machine, and then secure the sensor with a
torque wrench to the mounting surface by applying the recommended mounting torque (see enclosed
specification data sheet for proper mounting torque). It is important to use a torque wrench during this
step. Under-torquing the sensor may not adequately couple the device; over-torquing may result
in stud failure and possibly permanent damage.

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 SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
Adhesive Stud Mount Procedure
Adhesive mounting is often used for temporary installation or when the machine surface cannot be
adequately prepared for stud mounting. Adhesives like hot glue or wax work well for temporary mounts;
two-part epoxies and quick-bonding gels provide a more permanent mount.

Note: Adhesively mounted sensors often exhibit a reduction in high-frequency range. Generally, smooth
surfaces and stiff adhesives provide the best frequency response. Contact the factory for recommended
epoxies.

This method involves attaching a base to the machine surface, then securing the sensor to the base.
This allows for easy removal of the accelerometer.

STEP 1 Prepare a smooth, flat mounting surface. A minimum surface finish of 63 µin [0,00016 mm]
generally works best.

STEP 2 Stud-mount the sensor to the appropriate adhesive mounting base according to the guidelines
set forth in Steps 2 and 3 of the Standard Stud Mount Procedure.

STEP 3 Place a small portion of adhesive on the underside of the mounting base. Firmly press down on
the assembly to displace any extra adhesive remaining under the base.

Figure 8 – mounting base: adhesive installation

Sensor Stud Mounts

to Top Surface of
Mounting Base
Firmly Press Down

Mounting Base Adhesive

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 SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
Magnetic Mount Procedure
Magnetic mounting provides a convenient means for making portable measurements and is commonly
used for machinery monitoring and other portable or trending applications.
Note: The correct magnet choice and an adequately prepared mounting surface is critical for obtaining
reliable measurements, especially at high frequencies. Poor installations can cause as much as a 50%
drop in the sensor frequency range.

Not every magnet is suitable for all applications. For example, rare earth magnets are commonly
used because of their high strength. Flat magnets work well on smooth, flat surfaces, while dual-
rail magnets are required for curved surfaces. In the case of non-magnetic or rough surfaces, it
is recommended that the user first weld, epoxy or otherwise adhere a steel mounting pad to the
test surface. This provides a smooth and repeatable location for mounting.

Figure 9 – magnet types

Sensor Stud M ounts to

Top Surface of M agnet

Flat M agnet Dual-Rail M agnet M ounting Pad

w ith M agnet

ALL SURFA CES S HO ULD BE FLAT AN D SM O OTH

STEP 1 After choosing the correct magnet type, inspect the unit, verifying that the mounting surfaces are
flat and smooth.
STEP 2 Stud-mount the accelerometer to the appropriate magnet according to the guidelines set forth in
Steps 2 and 3 of the Standard Stud Mount Procedure.
STEP 3 Prepare a smooth, flat mounting surface. A minimum surface finish of 63 µin [0.00016 mm]
generally works best. After cleaning the surface and checking for burrs, wipe on a light film of silicone
grease, machine oil or similar-type coupling fluid.
STEP 4 Mount the magnet/sensor assembly to the prepared test surface by gently “rocking” or “sliding” it
into place.
Note: Magnetically mounting accelerometers carelessly has the potential to generate very high (and very
damaging) g levels. To prevent damage, install the assembly gently. If unsure, please contact the
factory for assistance.

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 SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
Warning 1 – ESD sensitivity

The power supply/signal conditioner should not be opened by anyone other than qualified service
personnel. This product is intended for use by qualified personnel who recognize shock hazards and
are familiar with the safety precautions required to avoid injury.

Warning 2 – ESD sensitivity

This equipment is designed with user safety in mind; however, the protection provided by the equipment
may be impaired if the equipment is used in a manner not specified by PCB Piezotronics, Inc.

Caution 1 – ESD sensitivity

Cables can kill your equipment. High voltage electrostatic discharge (ESD) can damage electrical
devices. Similar to a capacitor, a cable can hold a charge caused by triboelectric transfer, such as that
which occurs in the following:

Laying on and moving across a rug,

Any movement through air,
The action of rolling out a cable, and/or
Contact with a non-grounded person.

The PCB solution for product safety:

Connect the cables only with the AC power off.

Temporarily “short” the end of the cable before attaching it to any signal input or output.

Caution 2 – ESD sensitivity

ESD considerations should be made prior to performing any internal adjustments on the
equipment. Any piece of electronic equipment is vulnerable to ESD when opened for adjustments.
Internal adjustments should therefore be done ONLY at an ESD-safe work area. Many products have
ESD protection, but the level of protection may be exceeded by extremely high voltage.

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 SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
Warranty

IMI instrumentation is warranted against defective material and workmanship for 1 year unless otherwise
expressly specified. Damage to instruments caused by incorrect power or misapplication, is not covered
by warranty. If there are any questions regarding power, intended application, or general usage, please
consult with your local sales contact or distributor. Batteries and other expendable hardware items are
not covered by warranty.

Service

Because of the sophisticated nature of IMI instrumentation, field repair is typically NOT recommended
and may void any warranty. If factory service is required, return the instrumentation according to the
“Return Procedure” stated below. A repair and/or replacement quotation will be provided prior to
servicing at no charge. Before returning the unit, please consult a factory IMI applications engineer
concerning the situation as certain problems can often be corrected with simple on-site procedures.

Return procedure

To expedite returned instrumentation, contact a factory IMI applications engineer for a RETURN
MATERIAL AUTHORIZATION (RMA) NUMBER. Please have information available such as model and
serial number. Also, to insure efficient service, provide a written description of the symptoms and
problems with the equipment to a local sales representative or distributor, or contact IMI if none are
located in your area.

Customers outside the U.S. should consult their local IMI distributor for information on returning
equipment. For exceptions, please contact the International Sales department at IMI to request shipping
instructions and an RMA. For assistance, please call (716) 684-0003, or fax us at (716) 684-3823. You
may also receive assistance via e-mail at imi@pcb.com or visit our web site at www.pcb.com.

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 SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
Customer Service

IMI, a division of PCB Piezotronics, guarantees Total Customer Satisfaction. If, at any time, for any
reason, you are not completely satisfied with any IMI product, IMI will repair, replace, or exchange it at no
charge. You may also choose to have your purchase price refunded.

IMI offers to all customers, at no charge, 24-hour phone support. This service makes product or
application support available to our customers, day or night, seven days a week. When unforeseen
problems or emergency situations arise, call the IMI Hot Line at (716) 684-0003, and an application
specialist will assist you.

3425 Walden Avenue, Depew, NY 14043-2495

Phone: (716) 684-0003 • USA Fax: (716) 684-3823 • INTL Fax: (716) 684-4703

ICP® is a registered trademark of PCB Group, Incorporated,

which uniquely identifies PCB sensors that incorporate built-in microelectronics.
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