Emerson Machinery Health AMS EZ 1000 User manual

Installation Guide
MHM-97883 , Rev 1.07
June 2023
Machinery Health™ Sensor
AMS EZ 1000 Sensor

Copyright
© 2023 by Emerson. All rights reserved.
No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any
language in any form by any means without the written permission of Emerson.
Disclaimer
This manual is provided for informational purposes. EMERSON MAKES NO WARRANTY OF ANY KIND WITH REGARD TO THIS
MATERIAL, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE. Emerson shall not be liable for errors, omissions, or inconsistencies that may be contained herein or for incidental or
consequential damages in connection with the furnishing, performance, or use of this material. Information in this document is
subject to change without notice and does not represent a commitment on the part of Emerson. The information in this manual is
not all-inclusive and cannot cover all unique situations.
Patents
The product(s) described in this manual are covered under existing and pending patents.
2

Contents
Chapter 1 General.......................................................................................................................... 5
1.1 Using this manual............................................................................................................................. 5
1.2 Symbols............................................................................................................................................5
1.3 Liability and guarantee..................................................................................................................... 5
1.4 Incoming goods inspection.............................................................................................................. 6
1.5 Technical support.............................................................................................................................6
1.6 Storage and transport.......................................................................................................................7
1.7 Disposal of the device.......................................................................................................................7
1.8 China RoHS Compliance................................................................................................................... 7
1.9 CCC Certification – AMS EZ 1000......................................................................................................7
1.10 Installation awareness.................................................................................................................... 8
Chapter 2 Safety instructions......................................................................................................... 9
2.1 Using the device............................................................................................................................... 9
2.2 Owner's responsibility.......................................................................................................................9
Chapter 3 Application and Design................................................................................................ 11
3.1 The sensors.................................................................................................................................... 11
3.2 The measuring chain...................................................................................................................... 12
Chapter 4 Installation and Mounting............................................................................................13
4.1 Choosing the measuring place........................................................................................................13
4.2 Mount the sensor........................................................................................................................... 14
4.2.1 Requirements and hints for the sensor mounting........................................................................ 15
4.3 Wiring hints....................................................................................................................................21
4.4 Sensor with extension cable........................................................................................................... 22
Chapter 5 Technical data..............................................................................................................25
5.1 Measuring targets.......................................................................................................................... 25
5.2 Measuring ranges and sensitivity.................................................................................................... 25
5.3 Environmental conditions...............................................................................................................26
Chapter 6 Drawings..................................................................................................................... 29
Chapter 7 Order information........................................................................................................37
Chapter 8 Certificates.................................................................................................................. 41
Appendix A Special AMS EZ 1000 Sensors........................................................................................43
Installation Guide Contents
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Contents Installation Guide
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1 General
1.1 Using this manual
This manual contains information concerning the proper and correct use of the device.
Read the installation guide completely prior to starting installation and operating the
device. Comply with all safety instructions.
Include the installation guide when transferring the device to third parties.
Note
When requesting technical support, please indicate type and serial number from the type
plate and the used converter type.
Table 1-1 shows a list of documents that are referred to in this installation guide.
Table 1-1: Referenced documents
MHM-97884 Operating manual AMS EZ 1000 Converter for
Eddy Current Sensors
MHM-97879 Operating manual Machine Studio - General
Functions
MHM-97873 Operating manual A6500-UM Universal
Measurement Card
MHM-97442 Operating manual AMS 6300 SIS, Overspeed
Protection System
1.2 Symbols
Note
This symbol marks passages that contain important information.
CAUTION
This symbol marks operations that can lead to malfunctions or faulty measurements, but
will not damage the device.
DANGER
A danger indicates actions that can lead to property damage or personal injury.
1.3 Liability and guarantee
Emerson is not liable for damages that occur due to improper use. Proper use also includes
the knowledge of, and compliance with, this document.
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Customer changes to the device that have not been expressly approved by Emerson will
result in the loss of guarantee.
Due to continuous research and further development, Emerson reserves the right to
change technical specifications without notice.
1.4 Incoming goods inspection
Check the content of the shipment to ensure that it is complete; visibly inspect the goods
to determine if the device has been damaged during transport. The following parts are
included in the scope of delivery and must be contained in the shipment.
•Eddy current sensor EZ105x-xx-xx-xxx, EZ108x-xx-xx-xxx, EZ116x-xx-xx-xxx (with
protection cap)
•Extension cable EZ190x-xxx (must be ordered separately)
•Mounting nuts (EZ105x-xx-xx-xxx, EZ108x-xx-xx-xxx, EZ116x-xx-xx-xxx)
•Two shrink sleeves (a black one and a blue one) to isolate the connection between
sensor cable and extension cable
•Documentation CD with Installation Guide.
If the contents are incomplete, or if you observe any defects, file a complaint with the
carrier immediately. Inform the responsible Emerson sales organization so your device can
be replaced. In this case, attache a tag with customer name and the observed defect.
1.5 Technical support
You may need to ship this product for return, replacement, or repair to an Emerson
Product Service Center. Before shipping this product, contact Emerson Product Support to
obtain a Return Materials Authorization (RMA) number and receive additional instructions.
Product Support
Emerson provides a variety of ways to reach your Product Support team to get the answers
you need when you need them:
Phone Toll free 800.833.8314 (U.S. and Canada)
+1.512.832.3774 (Latin America)
+63.2702.1111 (Asia Pacific, Europe, and Middle East)
Email [email protected]
Web http://www.emerson.com/en-us/contact-us
To search for documentation, visit http://www.emerson.com.
To view toll free numbers for specific countries, visit http://www.emersonprocess.com/
technicalsupport.
Note
If the equipment has been exposed to a hazardous substance, a Material Safety Data Sheet
(MSDS) must be included with the returned materials. An MSDS is required by law to be
available to people exposed to specific hazardous substances.
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1.6 Storage and transport
Store and transport the device only in its original packaging. Technical data specifies the
environmental conditions for storage and transport.
Related information
Technical data
1.7 Disposal of the device
Provided that no repurchase or disposal agreement exists, recycle the following
components at appropriate facilities:
•Recyclable metal
•Plastic elements
Sort the remaining components for disposal, based on their condition. National laws or
provisions on waste disposal and protection of the environment apply.
Note
Environmental hazards! Electrical waste and electronic components are subject to
treatment as special waste and may only be disposed by approved specialized companies.
1.8 China RoHS Compliance
Our products manufactured later than June 30, 2016 and those which are sold in the
People's Republic of China are marked with one of the following two logos to indicate the
Environmental Friendly Use Period in which it can be used safely under normal operating
conditions.
Products without below mentioned marking are either manufactured before June 30 or
are non-electrical equipment products (EEP).
Circling arrow symbol with "e": The product contains no hazardous substances over
the Maximum Concentration Value and it has an indefinite Environmental Friendly
Use Period.
Circling arrow symbol with a number: This product contains certain hazardous
substances over the Maximum Concentration Value and it can be used safely under
normal operating conditions for the number of years indicated in the symbol. The
names and contents of hazardous substances can be found in the folder "China
RoHS Compliance Certificates" on the documentation CD or DVD enclosed with the
product.
1.9 CCC Certification – AMS EZ 1000
With the announcement of the Chinese market regulation authority SAMR (State
Administration for Market Regulation), a Compulsory Product Certification (CCC
certification) is mandatory for many explosion protection products. This explosion proof
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(“Ex”) product complies to the CCC obligation and is certified (certification number:
2023322315005261).
This China Compulsory Certificate mark (CCC), is a compulsory safety mark for
many products imported, sold, or used in the Chinese market and indicates that the
product is certified in accordance to GB/T 3836.1-2021, GB/T 3836.3-2021, and
GB/T 3836.4-2021. If the product label is to small to contain the CCC certification
mark it is sufficient to have the mark printed on the minimum package and in the
attached document.
1.10 Installation awareness
Note
When planning a measurement, observe the following items:
•Consider environmental conditions which might have an influence on the
measurement such as temperature, humidity, substances aggressive to the sensor,
and pollution.
•Always use a stiff and vibration-free sensor holder.
•Define a suitable measuring range, not larger than necessary, in consultation with the
operator of the plant.
•Define the trip limit in consultation with the operator of the plant.
•Take measurement deviations into account when defining the trip limit.
•Use a sensor that meets the requirements of the defined measuring range.
•Ensure an EMC-compatible installation including the use of proper cables.
•Ensure proper function of the measurement before activating the measurement for
regular operation.
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2 Safety instructions
To ensure safe operation, carefully observe all instructions in this manual.
The correct and safe use of this device requires that operating and service personnel both
understand and comply with general safety guidelines and observe the special safety
comments listed in this manual. Where necessary, safety-sensitive points on the device
are marked.
DANGER
Because the device is electrical equipment, commissioning and service must be performed
only by trained and authorized personnel. Maintenance must be carried out only by
trained, specialized, and experienced personnel.
2.1 Using the device
Install and use the device as specified in this manual.
If the device is used in a manner not specified by the manufacturer, the protection
provided by the device may be impaired.
2.2 Owner's responsibility
If there is a reason to suspect that hazard-free operation, and thus, adequate machine
protection is no longer possible, take the device out of operation and safeguard it from
unintentional operation. This is the case:
•if the device shows visible damage.
•if the device no longer works.
•after any kind of overload that has exceeded the permissible limits (such as those
detailed in chapter "Technical data," section "Environmental conditions").
Related information
Environmental conditions
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Safety instructions Installation Guide
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3 Application and Design
3.1 The sensors
The AMS EZ 1000 Sensors EZ105x-xx-xx-xxx, EZ108x-xx-xx-xxx, EZ116x-xx-xx-xxx are
available in different variants. With or without the optional EZ190x-xxx extension cable.
See Order information for details. Figure 3-1 explains the parts of an AMS EZ 1000 Sensor.
Figure 3-1: Design of an AMS EZ 1000 Sensor
A. Plug with cap nut of the extension cable
B. EZ190x-xxx extension cable (optional)
C. Connection (plug of the sensor cable with cap nut and socket of the extension cable)
D. Sensor cable
E. AMS EZ 1000 Sensor
F. Unthreaded part of the sensor case
G. Sensor tip
H. Threaded part of the sensor case
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Which sensor type is applicable for a measuring application depends on several
requirements such as desired measuring range, available measuring track, and maximum
environmental temperature. Each AMS EZ 1000 Sensor requires an AMS EZ 1000
Converter to complete the measuring chain. Use the EZ190x-xxx extension cable to adjust
the sensor cable length to the installation requirements.
Note
Ensure that the overall cable length, sensor cable plus extension cable, does not exceed 10
meters.
3.2 The measuring chain
An AMS EZ 1000 Sensor, together with the AMS EZ 1000 Converter, form the eddy current
measuring chain. Use this measuring chain for contactless distance, vibration, or speed
measurements. Different types of sensors and the software-configurable AMS EZ 1000
Converter allow an optimal adaption to the requirements of the machine to be monitored.
Figure 3-2: Eddy current measuring chain
A. AMS EZ 1000 Converter
B. EZ190x-xxx extension cable (optional)
C. AMS EZ 1000 Sensor
To achieve a high accuracy, the parts of the measuring chain, the sensor, the sensor cable
(sensor cable plus optional extension cable), and the converter, are calibrated together.
See the AMS EZ 1000 Converter operating manual for the calibration details.
The characteristics of the measuring chain also depend on the material of the measuring
object (target), for example, the machine shaft material. The material mainly used for
turbo machinery is 42 Cr Mo 4, according to SAE 4140. During the calibration process, the
measuring chain is adapted to the material.
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4 Installation and Mounting
4.1 Choosing the measuring place
Figure 4-1 is an example scheme for where to place the sensors on a turbine shaft to
measure the axial displacement, shaft vibration, or speed. Consider the minimum shaft
diameter for the sensor type, the minimum material width in front of the sensor tip, and
the minimum gap (see Requirements and hints for the sensor mounting).
To measure shaft vibration, Emerson recommends using a sensor holder between bearing
and turbine housing, as close as possible to the rotor.
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Figure 4-1: Example scheme where to place the sensors
A. Measuring collar
B. Trigger wheel
C. Measuring chain for measuring shaft displacement with AMS EZ 1000 Converter and
AMS EZ 1000 Sensor.
D. Measuring chain for measuring shaft vibration with AMS EZ 1000 Converter and AMS EZ
1000 Sensor, preferably EZ105x-xx-xx-xxx or EZ108x-xx-xx-xxx.
E. Measuring chain for measuring speed/key with AMS EZ 1000 Converter and AMS EZ
1000 Sensor, preferably EZ105x-xx-xx-xxx or EZ108x-xx-xx-xxx. .
4.2 Mount the sensor
The following steps describe the mounting of the AMS EZ 1000 Sensors. See also the
respective AMS EZ 1000 Converter manual as listed in Table 1-1 for further details
regarding sensor adjustment.
Prerequisites
Calibrated eddy current measuring chain.
Procedure
1. Screw in the sensor into the holder.
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Ensure that the threads are clean and smooth-running.
Do not bend or twist the sensor cable. If the sensor cable has an adapter plug, open
it.
To avoid touching the shaft during installation, the maximum distance between
measuring target and sensor tip must be adjusted first. Screw in the sensor until the
converter output voltage starts changing (approximately at -20V DC). Close the
adapter plug for measuring the converter output voltage.
2. Adjust the distance between measuring target and sensor tip according to the
measuring task.
Use a voltmeter connected to the converter output to measure the output voltage.
Open the adapter plug at every two turns of the sensor to untwist the cable.
Ensure that in the direction of the sensor tip, at least the always unthreaded part of
the sensor case (length EZ105x-xx-xx-xxx: 5.0 mm, length EZ108x-xx-xx-xxx: 5.0
mm, length EZ116x-xx-xx-xxx: 6.0 mm ) remains free.
3. Secure the sensor by fixing the nuts.
The maximum tightening torque for fixing the nuts is:
•EZ105x-xx-xx-xxx: 1 Nm
•EZ108x-xx-xx-xxx: 15 Nm
•EZ116x-xx-xx-xxx: 98 Nm
4.2.1 Requirements and hints for the sensor mounting
This section contains information and installation requirements for the sensor. The final
adjustment of the sensor depends on the measuring task and requires a complete
measuring chain. The AMS EZ 1000 Converter manual and the manuals for the evaluation
electronics, such as the AMS 6500 ATG system, contain detailed information regarding the
final adjustment.
General holder requirement
To mount the sensor, use a stiff and vibration-free holder with a mounting thread for the
selected sensor.
General distance adjustment
For distance adjustment, the complete measuring chain consisting of sensor and
converter is required as the distance will be generally adjusted by means of the converter
output voltage.
Sensor fastening
•Use the enclosed nuts when installing sensors.
•Lock nuts to avoid loosening of the sensor. Loose parts can fall into the machine and
cause damage. A medium-grade, removable, screw-securing adhesive (for example:
Loctite® 242, blue) is recommended to secure the sensor.
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Measuring track on the measuring target
The measuring track on the measuring target must be free from irregularities as scratches,
corrosion, stress concentrations, metallurgical segregation, and should have a high
concentricity. These irregularities may cause changes in the converter output voltage
which are not related to a real position or vibration signal. The signal caused by these
irregularities is called runout. For the measuring track, Emerson recommends a surface
finish of 0.41 µm to 0.76 µm.
Free space
A free space around the sensor tip is required to avoid influences on the measurement by
surrounding ferromagnetic material. At least, a ±45° free space with a minimum diameter
of 24 mm is required for a mounting without any significant influence on the
measurement. To keep the influences low a free thread space is required, which depends
on sensor type and measuring range. See Table 4-1.
Figure 4-2: Free space around sensor tip
A. Threaded part of the sensor case
B. Unthreaded part of the sensor case, length of this part depends on the selected sensor
type
C. Tip length:
•EZ105x-xx-xx-xxx: 5.3 mm
•EZ108x-xx-xx-xxx: 5.8 mm
•EZ116x-xx-xx-xxx: approximately 16.0 mm
D. Free thread space
E. Always unthreaded part of the sensor case, length 5.0 mm
F. 24.0 mm
G. 7.0 mm
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Table 4-1: Required free thread space and additional linearity errors
Sensor type Measuring range
factor1
Free thread space
(Figure 4-2 ,D)2
Additional linearity
error
EZ105x-xx-xx-xxx 1.0 >0 mm <0.5%
1.5 >0 mm <1.0%
2.0 >1 mm <1.0%
EZ108x-xx-xx-xxx 1.0 >0 mm <2.0%
1.0 >4 mm <1.0%
1.5 >7 mm <2.0%
2.0 >10 mm <2.0%
1Factor to extend the measuring range. Set this factor in the AMS EZ 1000 Converter
configuration.
21 mm = 1 thread visible
If the sensor is surrounded by ferromagnetic material as shown in Figure 4-3, the
diameters listed in Table 4-2 are required to avoid influences on the sensor signal.
Figure 4-3: Influence of material in 90° to the sensor
A. Diameter of the counter bore
Table 4-2: Diameter of the counter bore
Sensor type Minimum diameter Recommended diameter
EZ105x-xx-xx-xxx 15 mm 20 mm
EZ108x-xx-xx-xxx 20 mm 24 mm
CAUTION
The measuring range at the upper end decreases and the linearity error increases when
the free space specifications are not met.
Influence of the material behind the sensor
Ferromagnetic material behind the sensor as shown in Figure 4-4 also has an influence on
the measuring accuracy. Table 4-3 lists different mounting positions including the
additional error. There is no significant influence at lengths of more than 12 mm.
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Figure 4-4: Influence of the material behind the sensor
A. Length of the sensor part outside of the material
Table 4-3: Influence of the material behind the sensor
Sensor type Length A Figure 4-4 Additional linearity error
EZ108x-xx-xx-xxx 12 mm1---
11 mm -0.14%
10 mm -0.34%
9 mm -0.86%
8 mm -2.00%
EZ105x-xx-xx-xxx 12 mm1---
10.2 mm 0.15%
8.4 mm 0.39%
6.6 mm 0.55%
5.7 mm -0.59%
4.8 mm -5.97%
EZ116x-xx-xx-xxx 27 mm1---
1Recommended mounting position
Maximum axial tilting angle
Ensure that the maximum axial tilting angle a is < 4°. In this case, the additional DSL error is
<0.2%. This requirement is valid for all AMS EZ 1000 Sensors.
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Figure 4-5: Maximum axial tilting
S: distance between measuring target and sensor tip
a: maximal axial tilting angle < 4°
Maximum tangential offset
Ensure that the maximum tangential offset X is less than 10% of the diameter of the shaft
D. In this case, the additional DSL error is <0.2%. This requirement is valid for all AMS EZ
1000 Sensors
Figure 4-6: Maximum tangential offset
X: maximal tangential offset
D: shaft diameter
X < D * 10%
Minimum measuring area
Ensure that the minimum measuring area matches the values in Table 4-4. Figure 4-7
shows the definition of the minimum measuring area.
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Table 4-4: Minimum measuring area
Sensor type Target diameter Additional linearity
error
EZ105x-xx-xx-xxx Recommended >20 mm <1%
Minimum 10 mm
EZ108x-xx-xx-xxx Recommended >20 mm <1%
Minimum 14 mm
EZ116x-xx-xx-xxx Minimum ≥80 mm <1%
Figure 4-7: Minimum measuring area
If using AMS EZ 1000 Sensors for speed measurement or key generation see referenced
protection card manuals for trigger wheel specifications.
Minimum lateral distance
Ensure that there is a sufficient lateral distance to ferromagnetic material. The minimum
lateral distance depends on the measuring range extension. See Table 4-5.
Figure 4-8: Minimum lateral distance
A. Lateral distance between sensor sleeve and ferromagnetic material
Table 4-5: Minimum lateral distance
Sensor type Extended range
factor1
Minimum distance Additional linearity
error
EZ108x-xx-xx-xxx 1.0 >5 mm <1%
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