PCB Piezotronics Vibration Division 682A09 User manual

Model 682A09
MANUAL (682A09)
Installation and Operating Manual
For assistance with the operation of this product,
contact the Vibration Division of PCB Piezotronics, Inc.
Division toll-free: 888-684-0013
24-hour SensorLine: 716-684-0001
Fax: [phone]
E-mail: [email protected]

The information contained in this document supersedes all similar information that
may be found elsewhere in this manual.
Total Customer Satisfaction – PCB
Piezotronics guarantees Total Customer
Satisfaction. If, at any time, for any
reason, you are not completely satisfied
with any PCB product, PCB will repair,
replace, or exchange it at no charge. You
may also choose to have your purchase
price refunded in lieu of the repair,
replacement, or exchange of the product.
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 insure 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 traceablility to 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 insure 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 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.
Warranty – All equipment and repair
services provided by PCB Piezotronics,
Inc. are covered by a limited warranty
against defective material and
workmanship for a period of one year
from date of original purchase. Contact
PCB for a complete statement of our
warranty. Expendable items, such as
batteries and mounting hardware, are not
covered by warranty. Mechanical
damage to equipment due to improper
use is not covered by warranty.
Electronic circuitry failure caused by the
introduction of unregulated or improper
excitation power or electrostatic
discharge is not covered by warranty.
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, NY 14043 USA
Toll-free: [phone]
24-hour SensorLineSM: [phone]
Website: www.pcb.com
E-mail: [email protected]
DOCUMENT NUMBER: 21354
DOCUMENT REVISION: B
ECN: 17900

Model 682A09
Industrial in line ICP to 4 to 20 mA converter
Installation and Operating Manual
For assistance with the operation of this product, contact
the IMI-Sensors Division of PCB Piezotronics, Inc.
Division toll-free:
24-hour SensorLine:
Fax: [phone]
E-mail: [e-mail]
Document Number 43343
Revision: NR
ECO: 34177

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

Materials Authorization (RMA)
Number. This RMA number should be
clearly marked on the outside of all
package(s) and on the packing 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.
Warranty - All equipment and repair
services provided by PCB Piezotronics,
Inc. are covered by a limited warranty
against defective material and
workmanship for a period of one year
from date of original purchase. Contact
PCB for a complete statement of our
warranty. Expendable items, such as
batteries and mounting hardware, are not
covered by warranty. Mechanical
damage to equipment due to improper
use is not covered by warranty.
Electronic circuitry failure caused by the
introduction of unregulated or improper
excitation power or electrostatic
discharge is not covered by warranty.
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, NY 14043 USA
Toll-free: [phone]
24-hour SensorLine
SM
: [phone]
Website: www.pcb.com
E-mail: [email protected]

Operating Guide with Enclosed Warranty Information
3425 Walden Avenue, Depew, New York 14043-2495
Phone [phone]
Fax [phone]
Toll Free Line 1-800-959-41 Ml

A PCB PIEZOTRONICS DIV.
Table ofContents
Introduction......................................................................................................................Page 3
General Features
Dimension Drawing .........................................................................................................Page 4
Operation and Wiring.......................................................................................................Page 5
Standard Wiring
Taking Measurements
RV Option
RVVO Option
TO Option
Installation........................................................................................................................Page 7
Direct Adhesive Mount
Standard Stud Mount
Adhesive Stud Mount
Magnetic Mount
ESD Sensitivity...............................................................................................................Page 11

A PCB PIEZOTRONICS DIV.
Introduction
The Model 682A09 Series Industrial in line ICP to 4-20mA converter transfers the signal from any 100 mV/g ICP
industrial accelerometer to 4-20mA overall vibration velocity. The converter outputs a 4-20mA signal that is
proportional to the overall velocity and raw acceleration of the machinery. Ideal for monitoring the vibration of process
equipment such as fans, motors and pumps, the output of the converter is routed to a PLC, DCS or SCADA system
and used for process control or predictive maintenance.
General Features
• Loop powered, works with an open analog channel on PLC, DCS or SCADA system.
• Vibration range in velocity scaled for 0-1 inches per second peak
• Allows for continuous vibration monitoring of critical applications.
• Reduces the need for sophisticated vibration analysis requirements.
• RV (Raw Vibration) output for conducting frequency analysis and machinery diagnostics.
• Readily interfaces to existing process control and predictive maintenance equipment.
• Rugged stainless steel construction for applications in harsh environments.
PAGE 3

A PCB PIEZOTRONICS DIV.
Dimension Drawing
Page 4

A PCB PIEZOTRONICS DIV.
Operation and Wiring
Standard Wiring
The Model 682A09 Series operates from a standard 2-wire, 4-20mA loop. If using a loop power, attach at 3-
Pin connector side the positive (+) input from the power supply to Pin A and the negative (-) input from the
power supply to Pin B. Pin C is a buffered raw acceleration output (Fig. 1). At ICP side (2-Pin connector)
attach Pin A (+) to positive terminal of ICP sensor and Pin B (-) to negative (common) terminal of ICP sensor
(Fig. 2).
Suggested Cabling
For connecting 100 mV/g ICP accelerometer to 682A09 converter:
IMI suggests using model 052BRXXXBR cable where XXX is the cable length in feet. For example, model
052BR010BR is a 10 ft. polyurethane cable, 2-socket MIL (BR) on each end. The 2-socket MIL connector (BR)
mates to most any 2-pin MIL industrial accelerometer and also the model 682A09. Pictures of this cable and
connector can be found at IMI’s website www.imisensors.com.
For connecting 682A09 converter to PLC, DCS, SCADA system:
IMI suggests using model 059BVXXXBZ cable where XXX is the cable length in feet. For example, model
059BV010BZ is a 10 ft. polyurethane cable, 3-socket MIL (BV) to blunt termination. The 3-socket MIL (BV)
connector mates to the output of the 682A09. Wiring to acquisition is color coded as follows:
Red - connect to pos (+) loop-powered input on PLC, DCS, SCADA system
Black or Green – connect to neg (-) loop-power input on PLC, DCS, SCADA system
White – 100 mV/g analog sensor signal for frequency analysis, route to BNC for walk-up measurement with
portable data collector
Page 5
Figure 1 - wiring: loop powered

A PCB PIEZOTRONICS DIV.
RV Output
The RV (raw vibration) output is a pass-through for the 100 mV/g industrial accelerometer connected to the
model 682A09. The frequency range and accuracy of the signal will be dependant upon the accelerometer used.
Data collectors or analyzers can use this vibration signal for further analysis. Contact IMI if you require more
information on the accelerometer being connected to model 682A09.
Note:
-The RV Signal Negative has to be isolated from any grounding. If this terminal is grounded, the 4-
20mA loop will short, causing no output.
-The RV output signal is ideally suited for use with portable battery powered data collectors or
analyzers.
Page 6

A PCB PIEZOTRONICS DIV.
Accelerometer Installation
When choosing a sensor 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 at velocity is limited to 1 kHz on the 682A09, any of the four methods can be
used without seriously affecting this data values. If raw vibration output plan to be used the mounting method
might affect the 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.
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 3 - direct adhesive mounting
Page 7
Typical
Accelerometer

A PCB PIEZOTRONICS DIV.
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.
1.1 times sensor diameter
STEP 1 First, prepare a smooth, flat mounting surface, and then drill and tap a mounting hole in the center
of this area. 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 4 - 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
for another type of adhesive.
STEP 3 HAND-tighten the sensor/mounting stud to the machine, 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.
PAGE 8
1/4-28 Stud
1/4-28 Captive Screw
A (in)
B(in)
Torque (ft-lb)
0.250
0.350
2 to 5
0.250
0.350
2 to 5

A PCB PIEZOTRONICS DIV.
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.
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 5 - mounting base: adhesive installation
Page 9
Sensor Stud Mounts
to Top Surface of
Mounting Base

A PCB PIEZOTRONICS DIV.
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.
ALL SURFA CES SHOUL D BE FLAT AND SMOOTH
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. 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
Page 10

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.
Page 11