PCB Piezotronics IMI SENSORS 649A04 User manual

Model 649A04
Programmable Loop Powered, Current Output, Industrial Vibration Sensor
Installation and Operating Manual
For assistance with the operation of this product,
contact PCB Piezotronics, Inc.
Toll-free: 800-959-4464
24-hour SensorLine: 716-684-0001
Fax: [phone]
E-mail: [email protected]
Web: www.imi-sensors.com

The information contained in this document supersedes all similar information that
may be found elsewhere in this manual.
Service –Due to the sophisticated
nature of the sensors and associated
instrumentation provided by PCB
Piezotronics, user servicing or repair is
not recommended and, if attempted,
may void the factory warranty. Routine
maintenance, such as the cleaning of
electrical connectors, housings, and
mounting surfaces with solutions and
techniques that will not harm the
physical material of construction, is
acceptable. Caution should be observed
to ensure that liquids are not permitted
to migrate into devices that are not
hermetically sealed. Such devices
should only be wiped with a dampened
cloth and never submerged or have
liquids poured upon them.
Repair –In the event that equipment
becomes damaged or ceases to
operate, arrangements should be made
to return the equipment to PCB
Piezotronics for repair. User servicing or
repair is not recommended and, if
attempted, may void the factory
warranty.
Calibration –Routine calibration of
sensors and associated instrumentation
is recommended as this helps build
confidence in measurement accuracy
and acquired data. Equipment
calibration cycles are typically
established by the users own quality
regimen. When in doubt about a
calibration cycle, a good “rule of thumb”
is to recalibrate on an annual basis. It is
also good practice to recalibrate after
exposure to any severe temperature
extreme, shock, load, or other
environmental influence, or prior to any
critical test.
PCB Piezotronics maintains an ISO-
9001 certified metrology laboratory and
offers calibration services, which are
accredited by A2LA to ISO/IEC 17025,
with full traceability to SI through
N.I.S.T. In addition to the normally
supplied calibration, special testing is
also available, such as: sensitivity at
elevated or cryogenic temperatures,
phase response, extended high or low
frequency response, extended range,
leak testing, hydrostatic pressure
testing, and others. For information on
standard recalibration services or
special testing, contact your local PCB
Piezotronics distributor, sales
representative, or factory customer
service representative.
Returning Equipment –Following
these procedures will ensure that your
returned materials are handled in the
most expedient manner. Before
returning any equipment to PCB
Piezotronics, contact your local
distributor, sales representative, or
factory customer service representative
to obtain a Return Warranty, Service,
Repair, and Return Policies and
Instructions Materials Authorization
(RMA) Number. This RMA number
should be clearly marked on the outside
of all package(s) and on the packing
Service, Repair, and Return
Policies and Instructions

list(s) accompanying the shipment. A
detailed account of the nature of the
problem(s) being experienced with the
equipment should also be included
inside the package(s) containing any
returned materials.
A Purchase Order, included with the
returned materials, will expedite the
turn-around of serviced equipment. It is
recommended to include authorization
on the Purchase Order for PCB to
proceed with any repairs, as long as
they do not exceed 50% of the
replacement cost of the returned
item(s). PCB will provide a price
quotation or replacement
recommendation for any item whose
repair costs would exceed 50% of
replacement cost, or any item that is not
economically feasible to repair. For
routine calibration services, the
Purchase Order should include
authorization to proceed and return at
current pricing, which can be obtained
from a factory customer service
representative.
Contact Information –International
customers should direct all inquiries to
their local distributor or sales office. A
complete list of distributors and offices
can be found at www.pcb.com.
Customers within the United States may
contact their local sales representative
or a factory customer service
representative. A complete list of sales
representatives can be found at
www.pcb.com. Toll-free telephone
numbers for a factory customer service
representative, in the division
responsible for this product, can be
found on the title page at the front of this
manual. Our ship to address and
general contact numbers are:
PCB Piezotronics, Inc.
3425 Walden Ave.
Depew, NY14043 USA
Toll-free: [phone]
24-hour SensorLineSM: [phone]
Website: www.pcb.com
E-mail: [email protected]

PCB工业监视和测量设备 - 中国RoHS2公布表
PCB Industrial Monitoring and Measuring Equipment - China RoHS 2 Disclosure Table
部件名称
有害物质
铅(Pb)
汞
(Hg)
镉
(Cd)
六价铬(Cr(VI))
多溴联苯 (PBB)
多溴二苯醚(PBDE)
住房
O
O
O
O
O
O
PCB板
X
O
O
O
O
O
电气连接器
O
O
O
O
O
O
压电晶体
X
O
O
O
O
O
环氧
O
O
O
O
O
O
铁氟龙
O
O
O
O
O
O
电子
O
O
O
O
O
O
厚膜基板
O
O
X
O
O
O
电线
O
O
O
O
O
O
电缆
X
O
O
O
O
O
塑料
O
O
O
O
O
O
焊接
X
O
O
O
O
O
铜合金/黄铜
X
O
O
O
O
O
本表格依据 SJ/T 11364 的规定编制。
O：表示该有害物质在该部件所有均质材料中的含量均在 GB/T 26572 规定的限量要求以下。
X：表示该有害物质至少在该部件的某一均质材料中的含量超出 GB/T 26572 规定的限量要求。
铅是欧洲RoHS指令2011/65/ EU附件三和附件四目前由于允许的豁免。
CHINA RoHS COMPLIANCE

DOCUMENT NUMBER: 21354
DOCUMENT REVISION: D
ECN: 46162
Component Name
Hazardous Substances
Lead
(Pb)
Mercury
(Hg)
Cadmium
(Cd)
Chromium VI
Compounds
(Cr(VI))
Polybrominated
Biphenyls
(PBB)
Polybrominated
Diphenyl
Ethers (PBDE)
Housing
O
O
O
O
O
O
PCB Board
X
O
O
O
O
O
Electrical
Connectors
O
O
O
O
O
O
Piezoelectric
Crystals
X
O
O
O
O
O
Epoxy
O
O
O
O
O
O
Teflon
O
O
O
O
O
O
Electronics
O
O
O
O
O
O
Thick Film
Substrate
O
O
X
O
O
O
Wires
O
O
O
O
O
O
Cables
X
O
O
O
O
O
Plastic
O
O
O
O
O
O
Solder
X
O
O
O
O
O
Copper Alloy/Brass
X
O
O
O
O
O
This table is prepared in accordance with the provisions of SJ/T 11364.
O: Indicates that said hazardous substance contained in all of the homogeneous materials for this part is below the limit
requirement of GB/T 26572.
X: Indicates that said hazardous substance contained in at least one of the homogeneous materials for this part is above
the limit requirement of GB/T 26572.
Lead is present due to allowed exemption in Annex III or Annex IV of the European RoHS Directive 2011/65/EU.

SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
649AX4-Series Programmable Industrial 4-20mA Sensor
Operating Guide with Enclosed Warranty Information
3425 Walden Avenue, Depew, New York 14043-2495
Phone [phone]
Fax [phone]
Toll Free Line 1-800-959-4IMI
MANUAL NUMBER: 45989
MANUAL REVISION: D
ECN NUMBER: 49766

PAGE 2
SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
Table of Contents
Introduction...................................................................................................................................................... Page 3
General Features
Installation........................................................................................................................................................ Page 4
Direct Adhesive Mount
Standard Stud Mount
Adhesive Stud Mount
Magnetic Mount
Wiring............................................................................................................................................................... Page 8
Programming Software.................................................................................................................................... Page 9
Program Installation
Running the Software
Programming Sections
Reading and Writing Parameters
Parameter Options
Portable 4-20 mA Loop Calibrator................................................................................................................. Page 16
Cable Ordering Information ........................................................................................................................... Page 17
ESD Sensitivity .............................................................................................................................................. Page 18
Warranty, Service & Return Procedure ..........................................................................................................Page 19
Customer Service .......................................................................................................................................... Page 19

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SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
Introduction
The Programmable Industrial 4-20mA sensor (Model 649A04) combines the capabilities of a piezoelectric
vibration sensor and a 4-20mA vibration transmitter. The sensor outputs a 4-20mA signal that is proportional to
the overall acceleration, velocity or displacement of the machinery. Ideal for monitoring the vibration of process
equipment such as fans, motors and pumps, the output of the sensor is used for process control or predictive
maintenance. The sensor can be configured many different ways in the field using the USB Programming
interface.
Every sensor is factory-programmed. See Page 15 for more information.
General Features
Embedded piezoelectric accelerometer for improved accuracy and frequency response.
Field-programmable vibration range for acceleration, velocity or displacement.
Allows for continuous vibration monitoring of critical applications.
Reduces the need for sophisticated vibration analysis requirements.
RV (Raw Vibration) option: 100mV/g signal for conducting frequency analysis and machinery diagnostics.
Easily interfaces with existing process control and predictive maintenance equipment.
Rugged stainless steel, hermetically-sealed construction for applications in harsh environments.
Flexible design allows for various custom requirements.

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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.
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 [0.0016 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 1 –Direct Adhesive Mounting

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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.
¼-28 Stud
¼-28 Captive Screw
A (in)
0.250
0.250
B (in)
0.350
0.350
Torque (ft-lb)
2 to 5
2 to 5
Step 1: First, prepare a smooth, flat mounting surface and then drill and tap a mounting hole in the center
of this area. A precision-machined mounting surface with a minimum finish of 63 µin (0.0016 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. 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-torqueing the sensor may not adequately couple the device; over-torqueing may result in
stud failure and possibly permanent damage.
Figure 2 –Mounting Surface Preparation Figure 3 –Mounting Surface Lubrication

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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 (0.0016 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 4 –Adhesive Installation of Mounting Base

PAGE 7
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 are 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 5 –Magnet Types
Step 1: After choosing the correct magnet, inspect the unit to verify 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 [0.0016 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.

PAGE 8
SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
Wiring
The sensor 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 on the sensor and the negative (-) input from the power supply to Pin B of
the sensor.
Figure 6 –Loop-Powered Wiring Figure 7 –Loop-Powered Wiring with DC Source
If using a standard DC power supply, install either an ammeter and/or load resistor in line with the output.
The resistor will generate a DC voltage that is proportional to current by:
VIR
If R ohmsand ImA thenV VDC  500 6 3,
Note:
- Resistor value must be less than: (Vsupply –12) x 50.
- For integral cable sensors: RED wire is positive, BLUE wire is negative.

PAGE 9
SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
Programming Software
The sensor can be user-programmed with either of two optional programming kits, Model 600A21 (non-ROHS
compliant) or Model 600A35 (ROHS compliant). Both kits include a USB programmer cable/dongle (Model
600A21 kit includes Model 070A89 cable; Model 600A35 kit includes Model 070A103 cable), software (Model
EE225) and terminal block/integral cable adapter (Model 042M17). The software can also be downloaded from
IMI’s website, www.pcb.com. This software must be installed prior to connecting the sensor to the computer using
the USB programmer cable. The software includes both the drivers and user interface needed for programming
the sensor. During initial installation, you may need administrative rights for the computer in order to install the
drivers. Once installed, administrative rights are not required for use.
Figure 8 –Model 600A21/600A35 USB Programmer Kit
Program Installation
Installing the Software and USB Driver: Insert the software CD provided into the CD drive. The software will start
the installation automatically if your PC is set to auto-install applications. If not, browse the CD and click on
Setup.exe to start the installation process. The default installation directory is C:\PCB\EE225. It is recommended
to use the default setting.
The installer will first install the software and then the WinUSB device driver. This device driver is required for the
programmer software to communicate with the 070A89 or 070A103 USB programmer cable.
The following screens will be displayed when the installer starts. Click the Next button to proceed from step to
step.
Figure 9 –Install Location Screen

PAGE 10
SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
Figure 10 –National Instruments Software License Agreement
Figure 11 –Installation Verification Screen
Figure 12 –Installation Complete Screen

PAGE 11
SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
After the software completes, the USB driver installer will start automatically. The initial USB installer will look
similar to the one below.
Figure 13 –WinUSB Driver Installation Screen
The drivers will now be properly installed and you should get the following screen. Click “Finish”. The software is
now ready to use.
Figure 14 –WinUSB Driver Installation Complete Screen

PAGE 12
SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
Running the Software
Connect the USB programmer cable to a USB port on the PC and then run the software from the Start | All
Programs | PCB EE225 Software menu item
Initially the screen will appear as in Error! Reference source not found. with a yellow bar and status indicating
‘Initializing…’ followed by the message: “Connecting to USB Dongle…”.
Figure 15 –Software While Connecting to USB Programmer Cable
Once the connection is made the bar at the top of the screen will turn green and the status will indicate “USB
Connection Success - Select a device”. If the software and programmer cable fail to connect, remove and
reinsert the USB programmer cable.
Figure 16 –Software After Connecting to USB Programmer Cable

PAGE 13
SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
To select a device, click on the Device Select pull down menu and select the device you’d like to program, in this
case, 649A04.
Figure 17 –Device Selection
Once a product is selected, the software will prompt you to confirm connection of the sensor to the PC using the
USB programmer cable. Click OK to proceed.
Figure 18 –Sensor Connection Screen
While the software is establishing communication with the sensor, the status will display ‘Checking Status…’ and
the colored indicator box next to the status will alternate between red and yellow. This will take approximately15
seconds. Once communication is established, the indicator box will turn green and the software will read the
sensor’s current settings and data. The fields presented in the main body of the screen will be specific to the
selected sensor.

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SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
Programming Sections
The screen has three sections:
649A04 Unit Selection & Vibration Data –This section displays the current vibration data and current
level. It also has a control to select English or metric display units.
Actual 649A04 Settings –This section shows the settings currently programed in the sensor.
649A04 Settings to Write –This section shows the options for programming the sensor.
Figure 19 –Typical Screen After Successful Parameter Read
Reading and Writing Parameters
Reading Parameters - To read the current sensor settings, click the Read Parameters button. This
operation takes approximately 45 seconds to complete.
Transferring Actual Settings to Settings to Write Field - Use the ‘>>>’ button to transfer all Actual Settings
to the Settings to Write fields.
Writing Parameters- Select the appropriate mode and enter any pertinent parameter information. Click the
Set Parameters button. This causes the settings to be sent to the sensor and then read back and
displayed in the Actual 649A04 Settings.

PAGE 15
SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
Figure 20 –Transferring Actual Settings to Settings to Write Field
Parameter Options
There are four parameters that can be programmed to optimize performance of the Programmable Vibration
Sensor. At any point during the programming process, the values can be changed between imperial and metric
measurements by clicking the Units dropdown in the top navigation menu and then selecting the appropriate
measurement type.
Parameter
Description
Options
Output Signal
Measurement type over which
output signal is scaled.
Acceleration
Velocity
Displacement
Full Scale Range
Minimum and maximum value in
the measurement type’s
acceptable range.
Acceleration (Imperial): 1.0-10.0 g pk
Acceleration (Metric): 9.8-98.06 m/s2pk
Velocity (Imperial): 0.5-3.0 ips pk
Velocity (Metric): 12.7-76.3 mm/s pk
Displacement (Imperial): 4.0-20.0 mils, pk-pk
Displacement (Metric): 100-500 µm, pk-pk
Low Pass Filter
Maximum frequency range value
above which data will not be
measured.
1kHz
5 kHz
10 kHz
High Pass Filter
Minimum frequency range value
below which data will not be
measured.
3 Hz
10 Hz
Unless otherwise specified, the sensor comes from the factory with a default setting of velocity output with a full
scale of 1 ips peak. The high pass filter is set at 3 Hz and the low pass filter is set at 1 kHz.