T2 - Proximity Transducer System Operation

3500 Installation and Maintenance - Section 2: Page 1
Rev J 139317

Proximity Transducer
System Operation

Topic Objectives:

You will be able to explain the general construction and operation of the proximity
probe system
You will be able to find probe calibration values both mathematically, and through
the use of calibration equipment
You will be able to identify the conditions that lead to problems with proximity
probes, including probe cable length(s), supply voltages, types of target material,
etc

Page 2: 3500 Installation and Maintenance - Section 2
Rev J 139317

Proximitor
SIGNAL COMMON
TRANSDUCER POWER
SIGNAL OUTPUT
ELECTRICAL LENGTH

The Eddy Current Proximitor

Transducers convert one form of energy into another. In the case of proximity
transducers, mechanical energy is transformed into electrical energy using the
proximity transducer system. The interface device used for this system is called a
Proximitor. This electronic device is mounted in a rugged metal case, and has two
basic functions:

1. Generates a radio frequency (RF) signal using an oscillator circuit.
2. Conditions the RF signal to extract usable data using a
demodulator circuit.

The Proximitor requires a -17.5 to -26.0 Vdc supply voltage connected between its
VT and COM terminals. Bently Nevada systems provide -24 Vdc, which is the
recommended supply voltage.
Rev J 139317

Proximitor Operation
<100mil
RF SIGNAL
EXTENSION
CABLE
AND PROBE
PROXIMITOR
DEMODULATOR
OSCILLATOR

Proximitor and Probe Operation

Once the Proximitors oscillator has power it will generate an RF signal at a specific
frequency. This frequency is dependent on the INDUCTANCE (L) value of the probes
coil and the CAPACITANCE (C) value of the extension and probe cables.

The RF signal frequency will be within a range from 500 Kilohertz (KHz) to 2.0
Megahertz (MHz). The signal can be properly conducted by matching the Proximitor
electrical length requirement to the extension cables and the probe cable lengths. The
electrical length, which is at least the physical length, is a product of the capacitive and
inductive response of the electronic circuit above.

The RF signal is transmitted from the probe coil which creates an RF field around the
probe tip. The RF field extends to a distance greater than 0.1 inches (100mils), although
only 0.08 inch (80mils) has to be linear.
Rev J 139317

Eddy Current Flow
CONDUCTIVE
MATERIAL
EDDY CURRENTS
RF SIGNAL

Eddy Current Flow

When conductive material is present in the RF field, EDDY CURRENTS flow in
the surface of that material. The penetration depth of the eddy currents depends on
the materials conductivity and permeability. 4140 steel penetration is around 0.003
inches (3 mils).
Rev J 139317

Small Gap
RF SIGNAL 0

Probe Close To The Material

Once the probe is close enough to cause eddy currents to flow in a conductive material
the RF signal is affected in two ways:

1. Amplitude is at a MINIMUM when distance (GAP) between probe and material
(TARGET) is at a MINIMUM. Maximum eddy current flow occurs.
Rev J 139317

Large Gap
RF SIGNAL
0

Probe Farther Away From The Material

Amplitude is at a MAXIMUM when distance (GAP) between probe and material
(TARGET) is at a MAXIMUM. Minimum eddy current flow occurs.
Rev J 139317

Changing Gap
RF SIGNAL
0

Vibration Signal

If the target is moving SLOWLY within the RF field, the signal amplitude INCREASES
or DECREASES SLOWLY. If the target is moving RAPIDLY within the RF field, the
signal amplitude INCREASES or DECREASES RAPIDLY. Oscillatory movement of
the target causes the RF signal to modulate.
Rev J 139317

Demodulator Operation
DEMODULATOR
INPUT
PROXIMITOR
OUTPUT
0
0

Resulting Vibration Signal

The demodulator circuit deals with a slowly or rapidly changing signal amplitude in the
same way. If the target is not oscillating, as might be the case with a thrust probe, the
Proximitor output is a constant DC voltage, called the gap. If the target is oscillating (gap
changing slowly or rapidly) the Proximitors output is a varying DC voltage (AC) shown
above by a sine wave. If the probe is observing a vibration, the Proximitor will provide
both a DC (gap) and an AC (vibration) component in the output signal. A typical system
frequency response is from 0Hz (DC) to 10kHz. Newer transducer systems, such as the
3300XL proximity system have responses up to 12 kHz.
Rev J 139317

Proximity Probe Usage
RADIAL MOVEMENT
AXIAL MOVEMENT

Applications - Vibration And Distance

Proximity transducer systems have many uses in monitoring the behavior of a machine's
shaft (target). The two most common being RADIAL VIBRATION (radial movement)
and THRUST (axial movement).
Rev J 139317

Proximity Probe Used
as a Keyphasor
NOTCH

Applications - Keyphasor

Another common use for the proximity transducer system is as a ONCE PER
REVOLUTION marker or KEYPHASOR (K) on a machine shaft. This proximity
transducer system is mounted so that it observes a "notch" or a "projection" on the shaft
and produces a voltage pulse once each revolution.

Passage over the notch or projection causes a much more significant voltage change than
expected from normal vibration or distance measurements. This significant difference in
voltage allows the 3500 monitoring system to discriminate between a legitimate ONCE
PER REVOLUTION signal, and background noise or vibration.

The Keyphasor is a very useful tool when diagnosing machinery problems. At a
minimum, the generated pulse can be used to measure machine speed.
Rev J 139317

Verification of
Proximity Probes
Probe response is verified by measuring and
creating a calibration curve
Problems that can cause proximity probes to
be out of tolerance:
probe cable length
power supply voltage
crosstalk and sideview conditions
target size and material

Performance Verification - Proximitor Calibration

The Proximitor is designed to give known output voltage changes equal to known gap
changes. This is called a SCALE FACTOR. For the proximity transducer system the
standard scale factor is set at 200 millivolts per mil (200mV/mil). Scale factor
information can be found on the nameplate attached to the Proximitor.
Rev J 139317

Proximitor Calibration Graph
C
H
A
N
G
E

I
N

V
O
L
T
A
G
E
CHANGE IN GAP
24
O
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P
U
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I
N

V
O
L
T
S

-
D
C
PROBE GAP
mils 0
0
10 20 30 40 50 60 70 80 90 100 110 120 130 140
2
4
6
8
10
12
14
16
18
20
22

Performance Verification - Scale Factors

The scale factor is the response of the transducer to target distance in mils or micrometers
compared to the voltage resulting from the measurement.

The overall average scale factor is an important tool for evaluating the performance of a
proximity probe system. In addition, the incremental variances are important as well.
When a probe response is evaluated, it should show little deviation from the linear
response curve shown. The API 670 conventions have specifications for both the overall
scale factors, and the incremental variances.
Rev J 139317

Performance Verification - Calibration Process

The graph above verifies the performance of a
proximity transducer system. It is created by
clamping the probe and a spindle micrometer,
with a target attached, in a bracket.

With the spindle micrometer set at ZERO,
clamp the probe tip flush to the target surface.
Gap is increased by rotating the spindle
micrometer away from the probe in 5 mil
increments and noting the Proximitor output
D.C. voltage at each step.

Proximitor Calibration Graph
C
H
A
N
G
E

I
N

V
O
L
T
A
G
E
CHANGE IN GAP
24
O
U
T
P
U
T

I
N

V
O
L
T
S

-
D
C
PROBE GAP
mils 0
0
10 20 30 40 50 60 70 80 90 100 110 120 130 140
2
4
6
8
10
12
14
16
18
20
22
PROXIMITOR CALIBRATION EQUIPMENT SETUP
Rev J 139317

Calibration of Scale Factor
Average Scale Factor
(ASF) equals:
change in gap voltage
change in gap

Performance Verification - Scale Factor Calculations

change in gap voltage

-18 Vdc - (-2 Vdc)
Average Sale Factor (ASF) = ---------------------------- = ------------------------

change in gap

0.090 in - 0.010 in

A tolerance of 11 mV is allowed for Average SF (189mV/mil - 211mV/mil).

Note: Change in gap is within the 80mils LINEAR RANGE which is between 10mils and
90mils.

Proximity System Verification Tip: For detailed information regarding Average Scale
Factor and verifying transducer system performance, refer to the 3300 5mm and 8mm
Proximity System Manual, or the 3300XL Proximity Transducer Manual. A system
performance verification record can also be found in the System Maintenance Topic.
Rev J 139317

Calibration of Scale Factor
(-18.0Vdc) - (-2.0Vdc)
0.08in or 2.0 mm
= 200 mV/mil
or
= 7.87 mV/um

Performance Verification - Potential Problems

If the performance graph does not fall within specified limits, i.e., LINEAR RANGE less
than 80mils, or the ASF is outside 11mV tolerance specification, the reason may be one
of a variety of problems. The first to consider is potential mismatch of the Proximitor
with the extension cable, and/or the proximity probe.
Rev J 139317

OUTER
SCREEN
CENTER
CONDUCTOR
INNER
SCREEN
INSULATION
Triaxial Cable

Performance Verification - Proximity Transducer System

The transducer system has three individual components. None of these alone are a
transducer. The three components are the PROBE, the EXTENSION CABLE and the
PROXIMITOR.

The PROBE has a tip assembly, made of a generic version of polyphenylene sulfide
(PPS), that threads into a stainless steel case. The tip assembly is 8mm in diameter and
contains a coil that terminates to a 75 ohm miniature triaxial cable that exits the stainless
steel casing. The triaxial cable has one center conductor and two screens. The inner
screen is a coil connection and the outer screen is not connected. This prevents unwanted
grounding of one side of the coil if the cable is damaged. The cable is very flexible, and
is tested to a one inch radius curve without impacting the proximity systems
performance.
Rev J 139317

Probe Numbering
CABLE
FIXED
LOCK NUT
TIP
ASSEMBLY
P/N 330106-05-30-10-02-00
S/N APRS 416567


The Probes cable terminates to a 75 ohm miniature coaxial male connector. The probe
part number and serial number are attached to the cable. Probe options are denoted by
the part number.

Example: 330106-05-30-10-02-00
where: 05 = 5 mm unthreaded length,
30 = 30 mm case length,
10 = 1.0 meter total length,
02 = with connector,
00 = hazardous area approval not required.
Transducer System Numbering
For a detailed system part number
breakdown refer to the Transducer System
catalog. For serial number breakdown refer
to the System Maintenance topic
Rev J 139317

Extension Cable Numbering
P/N 330130-085-00-00
P/N 330101-00-08-05-02-00


The extension cable is the part that connects to the probe and allows you to reach a
convenient junction box. One end of the cable terminates to a 75 ohm miniature coaxial
female connector for connection to the probe. The other end terminates to a 75 ohm
miniature coaxial male connector for connection to the Proximitor.

Heat shrink, special tape, or rubber boots are usually placed on the cable to be slid over
the probe to extension cable connection. This prevents unwanted grounding of one side
of the coil. As a note, standard electrical tape must never be used. The extension cable
part number is attached to the cable. Cable options are denoted by the part number.

Example: 330130-080-00-00
where: 080 = 8.0 meters total length
00 = without armor
Rev J 139317

Proximitor
SIGNAL COMMON
TRANSDUCER POWER
SIGNAL OUTPUT
ELECTRICAL LENGTH


As mentioned earlier, the Proximitor is the part that contains the electronics and is
usually mounted in a junction box. It has a die cast aluminum case with a blue coat that
resists oils, solvents and chemicals. A 75 ohm miniature coaxial female connector is
chassis mounted through the casing for connection to the extension cable. A terminal
strip is also case mounted for supplying voltage to and taking signals from the
Proximitor. The base has an isolation plate mounted on it that will prevent unwanted
grounding of one side of the probe coil. The circuit board mounted electronics are fully
encapsulated within the casing.
Rev J 139317

Proximitor
SIGNAL COMMON
TRANSDUCER POWER
SIGNAL OUTPUT
ELECTRICAL LENGTH


The part number and serial number are attached to the Proximitor. Proximitor options are
denoted by the part number.

Example: 330100-90-00

where: 90 = 9.0 meters total length (probe with integral cable and extension cable),

Note: It is an option to have a proximity transducer system with the probe's integral cable
and extension cable length as one piece.
Rev J 139317

Proximitor
SIGNAL COMMON
TRANSDUCER POWER
SIGNAL OUTPUT
ELECTRICAL LENGTH


All proximity Transducer Systems must have a Proximitor. The Proximitor dictates
which probe and extension cable length MATCHES the system.

Example: Proximitor Part No. 330100-90-00

Remember: 90 = 9.0 meters total system length of probe and cable (integral or
extension).
Rev J 139317

Proximitor
SIGNAL COMMON
TRANSDUCER POWER
SIGNAL OUTPUT
ELECTRICAL LENGTH


Probe and extension cables are manufactured in standard lengths. Proximitors are
manufactured that require ONLY TWO standard system lengths. The following
examples show some possible combinations of a system.

Standard 5.0 meter System. A 5.0 meter Proximitor (330100-50-XX)

needs a:

4.0 meter (330130-040-XX-XX) or 4.5 meter (330130-045-XX-XX) extension
cable

with a:

1.0 meter (330106-XX-XX-10-XX-XX) or 0.5 meter (330106-XX-XX-05-XX-
XX) probe.
Rev J 139317

Proximitor
SIGNAL COMMON
TRANSDUCER POWER
SIGNAL OUTPUT
ELECTRICAL LENGTH


Standard 9.0 meter system. A 9.0 meter Proximitor (330100-90-XX)

needs a:

8.0 meter (330130-080-XX-XX) or 8.5 meter (330130-085-XX-XX) extension
cable

with a:

1.0 meter (330106-XX-XX-10-XX-XX) or 0.5 meter (330106-XX-XX-05-XX-
XX) probe.

Note: "XX" in the previous examples denote any other options.

9.0 or 5.0 meter system lengths are quoted as ELECTRICAL lengths and not
physical lengths (although they will be close). As mentioned earlier, this is because
probes and extension cables are trimmed in length to ELECTRICALLY match
Proximitors. To allow maximum usable length extension cables are never physically
shorter than their stated lengths but may be up to 30% longer.
Rev J 139317

Component Mismatch Effects
PROBE GAP
O
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P
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I
N

V
O
L
T
S

-
D
C
SHORT
CORRECT
LONG
24
22
20
18
16
14
12
10
8
6
4
2
0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 mils

Performance Verification - Transducer Calibration Problems

If the performance graph does not fall within specified limits, i.e., LINEAR RANGE less
than 80mils, a scale factor outside 11mV, the first possible reason may be that one of
the system components is mismatched. The PROBE, EXTENSION CABLE or
PROXIMITOR is mismatched in electrical length making overall length too long or too
short.

The graph above shows effects of having a mismatched system. Where the graph shows
a curve that is too LONG a 5 meter (50) Proximitor is used with a 9 meter cable
(extension plus probe). Where the graph shows a curve that is too SHORT a 9 meter
Proximitor is used with a 5 meter cable (extension plus probe).
Rev J 139317

Power Supply Voltage Effects
-24V SUPPLY
PROBE GAP
-16V SUPPLY
O
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I
N

V
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L
T
S

-
D
C
24
22
20
18
16
14
12
10
8
6
4
2
0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 mils

Performance Verification - Transducer Calibration Problems

Transducer performance may also be out of tolerance if the provided -24 Vdc power
source is out of tolerance. Voltages between -17.5 to -26.0 Vdc may be used by the
transducer system; however, a loss of higher range response may occur as shown above.

The graph above shows effects of supplying the Proximitor with a lower voltage of -
16Vdc. Although the scale factor is within limits, the LINEAR RANGE has been
severely reduced. Note that there is approximately a four volt DC offset from the power
supplied to the maximum potential output of the transducer system. This means that the
maximum output signal will be about four volts less than the power supply voltage.
Rev J 139317

Probe Crosstalk

Performance Verification - Transducer Response Problems

While some installed conditions may cause the transducer system to be out of tolerance,
others may cause an incorrect or unacceptable response. For example, CROSSTALK
occurs when two probes are mounted too close together so that their RF fields interact
with each other. Probe RF frequencies are unlikely to be the same therefore when mixed
together a DIFFERENCE frequency is generated. This difference is usually within the
normal band of frequencies expected for vibration. Therefore, a target may appear to be
vibrating when it is not. The minimum distance between probe tips should be 0.70 inches
(17.8 mm) for the 8 mm probe, or approximately three probe tip widths.
Rev J 139317

Sideview Effect


Another installation problem called SIDEVIEW occurs when the probe is mounted in an
area that has insufficient side clearance around its tip. Eddy currents will be generated in
any conductive material within that area. This results in losses in the system that are not
due to the real target.

This problem may occur when a probe is being installed in a bearing, and it is not known
whether the probe has cleared the mounting hole and approached the shaft correctly. If
the installation decision is made solely on voltage readings, the installer may not realize
that the probe is measuring the wrong surface.
Rev J 139317

Effects of Target Size
YES
NO


The next installation issue to consider is TARGET SIZE. The surface area being
observed by the transducer system must be large enough to make contact with all of the
radiated RF field in FRONT of the probe. The minimum observed shaft diameter is
20mm (.80 in) for the 8mm probe. The effect on LINEAR RANGE and scale factor, with
an under-sized target, will vary depending on the amount of eddy currents created.
Rev J 139317

Target Material Effects
O
U
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P
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I
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V
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S

-
D
C
PROBE GAP
4140 STEEL
TUNGSTEN
ALUMINUM
COPPER
24
22
20
18
16
14
12
10
8
6
4
2
0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 mils


The final transducer calibration issue is related to the surface material being observed by
the transducer system. If the Proximitor nameplate does not give target material
information, the target material must be AISI 4140 Steel. The following graph gives
examples of the effect of different materials when observed by a Proximitor calibrated to
a AISI 4140 Steel target.

The Proximitor can be re-calibrated for some different target materials. This process must
be implemented at the Bently Nevada manufacturing facility, or an authorized repair
center.
Rev J 139317

Proximitor Calibration
Equipment

Performance Verification - Transducer Verification Tools

The two components shown above can be used to thoroughly test the respons15
e of a transducer system. The Digital Voltmeter, or DVM, is used to measure the DC
component of the transducer output, called the gap.

The Bently Nevada TK-3 (Test Kit 3) can be used to mechanically input a signal to a
transducer between 0 mil and 10 mils (thousandths of an inch) vibration. By rotating a
cambered plate under the probe, a vibration signal can be generated; since the motor
speed can be varied, different frequency inputs can be generated as well. In addition, the
same rotating plate has a notch on one side, so it can be used to generate a Keyphasor
signal in a transducer mounted there.

Finally, for purposes of finding the calibration curve mentioned earlier, a spindle
micrometer is mounted at the top of the unit. This is used to measure the distance to a
probe while the attached DVM captures the DC voltage data.
Rev J 139317

Proximitor Calibration
Equipment Setup

Performance Verification - Transducer Verification Tools

The DVM and TK-3 are shown above in the process of measuring the response of a
transducer system.
Rev J 139317

Q1. The three parts of a proximity transducer system are:

a. __________________________

b. __________________________

c. __________________________

Q2. The ruggedised Proximitor cable used is comprised of what three components?

____________, ____________, and ________________.

Q3. What is the electrical length of the following probe? 330106-05-30-05-02-00

___________.

Q4. What is the electrical length of the following extension cable?

330130-045-00-00 ___________.

Q5. What is the total electrical length required by the following Proximitor?

330100-50-00 ___________.

Q6. The Proximitor must be supplied with a dc voltage between ______________,

and ______________.

Q7. An _______ field is created around the probe. It extends away from the face of

the probe for linear range of at least ____________.

Q8. When a conductive material is within range of the probe, what kind of

electrical flow is induced in the surface of that material? _________________.

Q9. A Proximitor must be calibrated to suit the _____________ it has as a target.

Rev J 139317

Q10. The dc output from the Proximitor will become less ______________ as the
target moves closer to the probe.

Q11. A proximity system frequency response is from _____________

to ____________ and its output may contain an _________

and a _________ component.

Q12. Name three applications for a proximity transducer system.

a. ___________________

b. ___________________

c. ___________________

Q13. Calculate the scale factor from the following: 90mils = -18.5Vdc,

10mils = -2.25Vdc. _____ Is it within tolerance? ___________

Q14. Name six reasons why a proximity system could be out of tolerance.

a. ___ _______________ d. ____________________

b. __________________ e. ____________________

c. __________________ f. ____________________

Rev J 139317

Proximity Transducer
System Operation

Topic Objectives Revisited:

You will be able to explain the general construction and operation of the proximity
probe system
You will be able to find probe calibration values both mathematically, and through
the use of calibration equipment
You will be able to identify the conditions that lead to problems with proximity
probes, including probe cable length(s), supply voltages, types of target material,
etc

T2 - Proximity Transducer System Operation

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