PCB Piezotronics IMI SENSORS EX686B77B User manual

Model EX686B77B
Vibration Switch
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

Manual 21354 Rev E
ECN 50523
Repair and Maintenance
PCB guarantees Total Customer Satisfaction through its
“Lifetime Warranty Plus” on all Platinum Stock Products
sold by PCB and through its limited warranties on all other
PCB Stock, Standard and Special products. Due to the
sophisticated nature of our sensors and associated
instrumentation, field servicing and repair is not
recommended and, if attempted, will void the factory
warranty.
Beyond routine calibration and battery replacements
where applicable, our products require no user
maintenance. Clean electrical connectors, housings, and
mounting surfaces with solutions and techniques that will
not harm the material of construction. Observe caution
when using liquids near devices that are not hermetically
sealed. Such devices should only be wiped with a
dampened cloth—never saturated or submerged.
In the event that equipment becomes damaged or ceases
to operate, our Application Engineers are here to support
your troubleshooting efforts 24 hours a day, 7 days a
week. Call or email with model and serial number as well
as a brief description of the problem.
Calibration
Routine calibration of sensors and associated
instrumentation is necessary to maintain measurement
accuracy. We recommend calibrating on an annual basis,
after exposure to any extreme environmental influence,
or prior to any critical test.
PCB Piezotronics is an ISO-9001 certified company whose
calibration services are accredited by A2LA to ISO/IEC
17025, with full traceability to SI through N.I.S.T. In
addition to our standard calibration services, we also offer
specialized tests, including: sensitivity at elevated or
cryogenic temperatures, phase response, extended high
or low frequency response, extended range, leak testing,
hydrostatic pressure testing, and others. For more
information, contact your local PCB Piezotronics
distributor, sales representative, or factory customer
service representative.
Returning Equipment
If factory repair is required, our representatives will
provide you with a Return Material Authorization (RMA)
number, which we use to reference any information you
have already provided and expedite the repair process.
This number should be clearly marked on the outside of
all returned package(s) and on any packing list(s)
accompanying the shipment.
Contact Information
PCB Piezotronics, Inc.
3425 Walden Ave.
Depew, NY14043 USA
Toll-free: [phone]
24-hour SensorLine: [phone]
General inquiries: in[email protected]
Repair inquiries: [e-mail]
For a complete list of distributors, global offices and sales
representatives, visit our website, www.pcb.com.
Safety Considerations
This product is intended for use by qualified personnel
who recognize shock hazards and are familiar with the
precautions required to avoid injury. While our equipment
is designed with user safety in mind, the protection
provided by the equipment may be impaired if equipment
is used in a manner not specified by this manual.
Discontinue use and contact our 24-Hour Sensorline if:
Assistance is needed to safely operate equipment
Damage is visible or suspected
Equipment fails or malfunctions
For complete equipment ratings, refer to the enclosed
specification sheet for your product.
Definition of Terms and Symbols
The following symbols may be used in this manual:
DANGER
Indicates an immediate hazardous
situation, which, if not avoided, may
result in death or serious injury.

Manual 21354 Rev E
ECN 50523
CAUTION
Refers to hazards that could damage
the instrument.
NOTE
Indicates tips, recommendations and
important information. The notes
simplify processes and contain
additional information on particular
operating steps.
The following symbols may be found on the equipment
described in this manual:
This symbol on the unit indicates that
high voltage may be present. Use
standard safety precautions to avoid
personal contact with this voltage.
This symbol on the unit indicates that
the user should refer to the operating
instructions located in the manual.
This symbol indicates safety, earth
ground.

Manual 21354 Rev E
ECN 50523
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

Manual 21354 Rev E
ECN 50523
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.

PAGE 1
SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
686-Series Smart Vibration Switch
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: 40112
MANUAL REVISION: G
ECO: 49766
ECN NUMBER: 47032

PAGE 2
SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
Table of Contents
Introduction...................................................................................................................................................... Page 3
General Features
Operating Principles ........................................................................................................................................ Page 4
Benefits of Solid State Relays
Installation........................................................................................................................................................ Page 5
Direct Adhesive Mount
Standard Stud Mount
Adhesive Stud Mount
Magnetic Mount
Wiring............................................................................................................................................................... Page 9
Legend
Indicating a High Level of Vibration in a Motor
Indicating High Levels of Vibration Simultaneously in Series (Such as Fan & Motor)
Constant Siren Alarming in the Event of High Vibration Levels
Two Switches in Parallel to Monitor Two Aces Simultaneously on Same Motor
Three Switches in Parallel to Monitor Three Motors Simultaneously
Automatic Machinery Shutdown Using an External Electromechanical Relay
Automatic Machinery Shutdown Using External Electromechanical Relay While Monitoring 2 Axes
Switch and External Latching for Automatic Machinery Shutdown
Both Alarm Siren and Automatic Machinery Shutdown Using Two Switches
Automatic Machinery Shutdown Based on Normally Open Solid State Relay
Automatic Machinery Shutdown of a Three Phase Electrical Motor Based on a N.O. Solid-State Relay
Programming Software.................................................................................................................................. Page 21
Program Installation
Running the Software
Programming Sections
Reading and Writing Parameters
Parameter Options
Execution of Delays
Magnetically Adjustable Vibration Threshold (MAVT™) .............................................................................. Page 29
MAVT™Procedure
Factory-Programmed Ordering Guide........................................................................................................... Page 30
Battery-Powered Signal Conditioner ............................................................................................................. Page 31
Calibration Cable ........................................................................................................................................... Page 31
Magnet Clip.................................................................................................................................................... Page 31
Cable Ordering Information ........................................................................................................................... Page 32
ESD Sensitivity .............................................................................................................................................. Page 33
Warranty, Service & Return Procedure ......................................................................................................... Page 34
Customer Service .......................................................................................................................................... Page 34

PAGE 3
SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
Introduction
The 686-Series Smart Vibration Switch is a low-cost electronic vibration switch designed to monitor vibration
levels on rotating machinery (ie. fans and cooling towers) and trip an alarm or shut down machinery when a
specified vibration limit is exceeded. An onboard accelerometer with precision, microprocessor-controlled
electronics ensures reliable operation and accuracy. The switch contains a two-pin MIL connector for easy drop-
in replacement of mechanical vibration switches and a reliable solid state relay. Multiple units can be installed in a
loop configuration for economical installation and expanded protection of critical machinery. This versatile switch
can be used to replace more expensive electronic vibration switches where separate vibration output is not
required and to replace troublesome mechanical vibration switches.
Every Smart Switch is factory-programmed. See Page 28 for more information.
General Features
Fully USB-programmable from any PC (with optional USB Programmer Kit).
Hermetically-sealed, stainless steel housing for use in corrosive environments.
Imbedded piezoelectric accelerometer for improved accuracy and frequency response.
Small footprint and single ¼-28 stud mounting.
Solid state (AC/DC) relay.
Universal AC or DC power.
Magnetically Adjustable Vibration Threshold (MAVT™).
Connects with industry standard MIL-C-5015 connector or integral cable.
Programmable features
oAlarm threshold level
oNormally Open (NO) or Normally Closed (NC) relay
oLatching or non-latching relay
oDelays
Power on
Startup
Operational
oResidual vibration level
Intrinsically-safe versions available (EX prefix)
oCSA

PAGE 4
SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
Operating Principles
The Smart Switch operates over just two wires. It installs in series with any load (ie. annunciator, PLC or relay
coil). To energize itself, the vibration switch scavenges power from the load’s power source. When the alarm
threshold is exceeded, the switch is activated and the load’s power circuit is completed to facilitate the desired
alarm or shutdown.
Figure 1 –Block Diagram
Benefits of Solid State Relays
A solid state relay is an electronic component that functions in the same way as an electromechanical relay, but
without any moving parts. A solid state relay offers the most reliable switch action, especially for vibration
applications where moving relay components run a greater risk of malfunction. They are purely electronic devices
composed of a low current control side and a high current load side for switching action.

PAGE 5
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.
Note: For a complete list of product specifications, see the “Specification Sheet” and “Outline Drawing” at the end
of this Manual.
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 2 –Direct Adhesive Mounting

PAGE 6
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 3 –Mounting Surface Preparation Figure 4 –Mounting Surface Lubrication

PAGE 7
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 5 –Adhesive Installation of Mounting Base

PAGE 8
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 6 –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 9
SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
Wiring
On the following pages are eleven different wiring scenarios for the Smart Switch. The wiring legend below is
applicable to all wiring diagrams.
Figure 7 –Wiring Diagrams Legend
For those wiring scenarios that suggest the use of an external electromechanical relay, IMI suggests Omron
general purpose relays as listed below. Visit www.omron.com for more information.
Attribute
Omron Model Number
MJN2C-
AC120
MJN2C-
AC240
MJN2C-
DC12
MJN2C-
DC24
MJN2C-
DC110
Contact Form
2 Form C (DPDT)
Relay Rated Resistive Load
10 A @ 240 VAC/28 VDC
Service Life- Electrical
(Min @Rated Loads)
100,000 operations “average”
Relay Max Resistive
Switching Capacity
2400 VA, 280
W
240 VAC
12 VDC
24 VDC
110 VDC
Coil Nominal Voltage
120 VAC
1.2 W
Coil Power Consumption
1.7 VA
Coil Type
Non-Latching
Seal Type
Unsealed
Termination Style
Socket Mount
Operating Temperature Range
-45 to +60 C
with no icing or condensation
-45 to +70 C
with no icing or condensation
Dielectric Strength
(AC for 1 min)
2500 VAC
Approved Standards
UL, CSA

PAGE 10
SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
Indicating a High Level of Vibration in a Motor
Figures 8 and 9 –Indicating a High Level of Vibration in a Motor
Pushing the Start pushbutton closes the M contacts and starts the motor. If the start-up delay option for the
switch is enabled, the Smart Switch will not trip regardless of the vibration level during the specified delay time.
After this delay, the vibration switch will be activated. If the vibration level exceeds the alarm threshold for a time
period greater than the specified operational delay time, the relay will trip. This action will close the contact to the
pilot lamp.
Since the NL (non-latching) option is specified, the pilot lamp will illuminate only while alarm threshold is
exceeded. Should the vibration level drop below the alarm threshold value (based also on the specified
hysteresis), the pilot lamp will turn off.

PAGE 11
SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
Indicating High Levels of Vibration Simultaneously in Series (Such as Fan & Motor)
Figures 10 and 11 –Indicating High Levels of Vibration Simultaneously in Series (Such as Fan & Motor)
The Smart Switches are hooked up in series and installed on the two most loaded bearings across the coupling in
the horizontal direction. Pushing the Start pushbutton closes the M contacts and starts the motor and fan. If the
start-up delay option for the switches is enabled, the Smart Switches will not trip during the specified startup delay
time, regardless of the vibration level. After this delay, the switch relays will be activated if the vibration level on
both machines exceeds the alarm threshold for a period greater than the specified operation delay time. This
action will close the contact to the pilot lamp.
Since the NL (non-latching) option is specified, the pilot lamp will illuminate only while set threshold on both
machines is exceeded. Should the vibration level for one or both of the machines drop below the threshold value
(based also on the specified hysteresis), the pilot lamp will turn off.

PAGE 12
SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
Constant Siren Alarming in the Event of High Vibration Levels
Figure 12 –Constant Siren Alarming in the Event of High Vibration Levels
The Smart Switch is hooked up for automatic constant siren alarming when the alarm threshold level is exceeded.
Pushing the Start pushbutton closes the M contact and starts the motor. If the start-up delay option for the
switches is enabled, the Smart Switches will not trip during the specified startup delay time, regardless of the
vibration level. After this delay, the switch relay will be activated if the vibration level exceeds the alarm threshold
for a period greater than the specified operational delay time. This action will close the contact to the alarm siren
and activate it.
Since the LA (latching) option is specified, the alarm siren will be constantly energized after this high vibration
event, even if the vibration level should drop below the alarm threshold. The Reset pushbutton should be
engaged to de-energize the alarm siren and return the system to its original monitoring condition.

PAGE 13
SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
Using Two Switches in Parallel to Monitor Two Axes Simultaneously on Same Motor
Figures 13 and 14 –Using Two Switches in Parallel to Monitor Two Axes Simultaneously on Same Motor
The Smart Switches are hooked up in parallel and installed on the motor in horizontal and vertical directions.
Pushing the Start pushbutton closes the M contact and starts the motor. If the start-up delay option for the
switches is enabled, then during the specified startup delay time, the switches will not trip regardless of the
vibration level. After this delay, the alarm siren will be activated if either of the switches experiences a vibration
level over the alarm threshold lasting greater than the specified operation delay time.

PAGE 14
SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
Since the NL (non-latching) option is specified, the alarm siren will sound while alarm threshold on one or both
switches is exceeded. Should the vibration level for both switches drop below the alarm threshold value (based
also on the specified hysteresis), the alarm siren will turn off.

PAGE 15
SENSORS AND INSTRUMENTATION FOR MACHINE CONDITION MONITORING
Using Three Switches in Parallel to Monitor Three Motors Simultaneously
Figures 15 and 16 –Using Three Switches in Parallel to Monitor Three Motors Simultaneously
The three Smart Switches
are hooked up in parallel
and installed on each motor
in the horizontal direction.
This provides an
economical solution for
monitoring a group of
machinery while only
having to run one cable.
Pushing any Start
pushbutton will close the
corresponding M contact
and start the motor. If the
start-up delay option for the
switches is enabled, then
during the specified startup
delay time, the switches will
not trip; regardless of the
vibration level. After this
delay, the pilot lamp will be
illuminated if any of the
switches experience a
vibration level over the
alarm threshold value
lasting greater than the
specified operational delay
time.
Since the NL (non-latching)
option is specified, the pilot
lamp will illuminate while
alarm threshold on any of
the switches is exceeded.
When the vibration level for
all switches drops below
their alarm threshold value
(based also on the
specified hysteresis), the
pilot lamp will turn off.