Introduction

Welcome to Level 2, Lesson 4 – Selecting the Proper

Accelerometer for Your Application, part of CTC’s free online
vibration analysis training series.
We hope you enjoyed and benefitted from the previous course
and will continue to build your vibration analysis knowledge as
you progress through Level 2.

Selecting the Proper Accelerometer for Your Application is created and presented
by CTC for complimentary educational use only. This training presentation may not
be edited or used for any other purpose without express written consent from
CTC.
Training
Objectives

Upon completion of this lesson, you will:

1 Understand the general construction of an accelerometer

Understand how the differences in construction make a specific sensor more

2 suited to measuring specific types of applications

Understand how using the right tools will help analysts gather better, clearer
3 data from which to make very important decisions about machinery health
Preventive
Failures
A lack of lubrication was the root cause of the
catastrophic bearing failure pictured here.

If there had been a vibration monitoring program using

an accelerometer to measure the vibration, the lack of
lubrication would have been detected very early, and
many steps could have been taken to prevent this
failure.

Condition monitoring programs utilizing vibration

analysis techniques will always have a high value when
compared to sudden unexpected failures.
Measuring
Machinery Vibration
The measurement of machinery vibration using an accelerometer will prevent
unexpected machine failures.

Portable or permanent vibration measurements can be trended over time. If

vibration levels increase, a detailed analysis of the vibration can be performed,
and repairs can be scheduled prior to mechanical, electrical, or process failure.

Choosing the right accelerometer for the job will always provide the best
measurements and most detailed information.

One accelerometer does not fit all applications. Understanding how they work
and how to apply them for your specific application will be very beneficial to
the overall success of your vibration monitoring program.
Measuring
Machinery Vibration
Accelerometers are widely used to measure vibration on rotating machinery
due to:

✓ The broad frequency range and dynamic range that they can be used to
monitor

✓ The durability and portability that is inherent in their design

For this training we’ll focus on industrial accelerometers with the most common
construction on the market – shear mode design sensors with PZT ceramic.

This design provides a low-noise solution with a great deal of durability and
stability in a wide range of environments.
Parts Of An IEPE Sensor –
(Integrated Electronics Piezo Electric)

The external housing of the sensor

should be made from a material like
316L stainless steel.

This corrosive-resistant stainless

steel is well suited for industrial 316L Stainless Steel Housing
environments.

¼-28 Threaded Mounting

 Parts Of An IEPE Sensor –
(Integrated Electronics Piezo Electric)
The application of a rigid insulating
material between the sensing element and
sensor housing will provide case isolation
while still providing good transmission of
the vibration to the sensing element.

Case isolation is important in the industrial

environment due to a variety of grounding
Insulating Material and interference issues which could be
present. Lack of isolation will lead to data
with transient spikes which are unrelated
to vibration.
Parts Of An IEPE Sensor –
(Integrated Electronics Piezo Electric)

The pedestal (or post) is attached

to the base and holds the PZT
ceramic in place.

Vibration is transmitted through

the base of the sensor to the post.

Pedestal (or Post)

Parts Of An IEPE Sensor –
(Integrated Electronics Piezo Electric)
The PZT (piezoelectrical lead zirconate
titanate) ceramic acts as the internal stiffness
factor in the sensor.

When a force acts on the PZT material, an

electrical charge is produced proportional to
the forces.

The PZT ceramic is a very high-quality

material with excellent mechanical strength
and temperature stability.
PZT Ceramic
PZT has extremely low noise characteristics
and provides a high signal to noise ratio.
Parts Of An IEPE Sensor –
(Integrated Electronics Piezo Electric)

A mass is placed on the outside of

the PZT ceramic and acts as the
internal mass for the sensor.

A high quality (non ferrous)

stainless steel mass should be
used to prevent magnetic Stainless Steel Mass
interference and false vibrations.
Parts Of An IEPE Sensor –
(Integrated Electronics Piezo Electric)

The electronics on the PC board

are used to convert the charge
output of the PZT ceramic to a
voltage, apply filtering, and amplify
PC Board
the output of the sensor.
Parts Of An IEPE Sensor –
(Integrated Electronics Piezo Electric)

The faraday shield protects the

sensor electronics from RFI (radio
frequency interference) and EMI
(electro magnetic interference).

Faraday Shield
 Parts Of An IEPE Sensor –
(Integrated Electronics Piezo Electric)

2 Pin, MIL C 5015 Connector

The MIL C 5015 connector is the

standard connector used in
industrial vibration analysis.
Parts Of An IEPE Sensor –
(Integrated Electronics Piezo Electric)

A welded seam between the

Hermetic Welded Seam
connector and the sensor provides
a hermetic seal.

The hermetic seal prevents any

contamination from entering the
sensor.
Shear Mode
Functionality
When the sensor is mounted to the machine, the vibration of the machine
enters through the base of the sensor and makes the sensor vibrate.

Part of Newton’s first law of motion states: ”An object at rest tends to
stay at rest.”

The internal mass of the sensor, located on the outside of the PZT
ceramic is tending to stay at rest.

The pedestal or post, located on the inside of the PZT ceramic, is

vibrating at the same rate as the machine.

This places the PZT ceramic in “shear” between the internal vibration of
the post and the external stationary mass.

The stress put on the PZT creates a charge output proportional to the
vibratory forces. That charge is then filtered and amplified and sent to the
analysts’ systems.
Shear Mode
Benefits
Because the PZT ceramic is not used in a compression mode,
the sensor can be strained at the base with no effects on the
output signal of the senor.

The primary benefit of having a Base strain is often caused by temperature transients or a
lateral force on the sensor, such as a data collector cable.
shear mode sensor is the
resistance of the sensor to base Preventing base strain improves measurements.
strain.
Shear mode sensors also have minimal output changes as a
result of gravity.

The sensor mounting is unidirectional with little or no effect

from the earth’s gravitational force.
Bias Voltage
For IEPE Accelerometers
The IEPE accelerometer is a two-wire sensor
that will function with a constant current power
source that provides 2-10 mA with a DC
voltage level between 18 and 30 VDC.

The bias voltage is the DC operating voltage of

the electronics inside the accelerometer - it is
typically 7-14 VDC.

The vibration is an AC signal that rides on top

of the DC bias voltage. A decoupling capacitor
is used to separate the AC signal (vibration)
from the DC bias voltage in most power
supplies and data collectors.

The IEPE constant current power source is

usually built into the data collector, and no
additional electronics are required.
Sensitivity, Range,
And Application

10 mV/g 50 mV/g 100 mV/g 500 mV/g

Sensitivity Sensitivity Sensitivity Sensitivity

Dynamic Range ±500 g ±100 g ±50 g ±10 g

/
Dynamic Output ±5 VAC ±5 VAC ±5 VAC ±5 VAC

10 mV/g accelerometers are typically used for machinery that is generating

high amplitude vibrations. With large dynamic range, they are much less likely
to become saturated as a result of the high amplitude vibrations.
Sensitivity, Range,
And Application

10 mV/g 50 mV/g 100 mV/g 500 mV/g

Sensitivity Sensitivity Sensitivity Sensitivity

Dynamic Range ±500 g ±100 g ±50 g ±10 g

/
Dynamic Output ±5 VAC ±5 VAC ±5 VAC ±5 VAC

50 mV/g accelerometers are typically used for general purpose machinery

measurements and are sometimes offered as standard sensors for data
collectors.
Sensitivity, Range,
And Application
10 mV/g 50 mV/g 100 mV/g 500 mV/g
Sensitivity Sensitivity Sensitivity Sensitivity

Dynamic Range ±500 g ±100 g ±50 g ±10 g

/
Dynamic Output ±5 VAC ±5 VAC ±5 VAC ±5 VAC

100 mV/g accelerometers are the industry-leading standard for general

purpose machinery measurements and are typically offered as standard
sensors for data collectors.

Approximately 90% of all vibration analysis and data collection is

accomplished with a 100 mV/g accelerometer.

Note: some sensors are also available with a ±80 g dynamic range for
measuring larger signal amplitudes.
Sensitivity, Range,
And Application
10 mV/g 50 mV/g 100 mV/g 500 mV/g
Sensitivity Sensitivity Sensitivity Sensitivity

Dynamic Range ±500 g ±100 g ±50 g ±10 g

/
Dynamic Output ±5 VAC ±5 VAC ±5 VAC ±5 VAC

500 mV/g accelerometers are high-output sensors typically used for low-
speed equipment, low frequency measurements, and low amplitude analysis.

The high output provides a much better signal-to-noise ratio for low amplitude
signals.
Specialty Accelerometers –
High Temperature Accelerometers

High Temperature IEPE Sensors

Internally charged sensors for applications
up to 325 °F (162 ° C).

They are not suitable for temperatures over

325 °F (162 °C) due to limitations in
components in the amplifier board.
Specialty Accelerometers –
Intrinsically Safe Sensors

Intrinsically safe sensors are required for

vibration measurements in hazardous areas
including, gas, oil, mining, etc.
Specialty Accelerometers –
Piezo Velocity Sensors

Piezo velocity sensors use an analog

integration for applications where a
velocimeter has traditionally been used for
casing measurements.

It is helpful in identifying fundamental fault

frequencies.
Specialty Accelerometers –
Triaxial Sensors

Triaxial sensors are used to measure

vibration in three axes (X, Y, and Z)
simultaneously with one accelerometer.
Use of triaxial accelerometers can speed up
data collection in some cases and can reduce
installation time or provide more complete
data in some areas where there are limited
mounting options.
Specialty Accelerometers –
Dual Output Sensors

Dual output (vibration and temperature)

sensors provide the measurement of dynamic
vibration and temperature at the same time.
The additional data can give analysts
information that might be valuable in
assessing a machine’s condition.
Specialty Accelerometers –
4-20 mA Loop Power Sensors

4-20 mA loop power sensors provide current

output proportional to overall acceleration or
velocity value.
This signal can then be used to trigger a
variety of alarms and provide constant
monitoring of applications.
Specialty Accelerometers –
Dual Output Loop Power Sensors

Dual output loop power sensors provide

4-20 mA output proportional to vibration in
acceleration with °C temperature output.
Industrial
Requirements
Top three requirements for industrial sensors:

Functionality Durability Affordability

Industrial
Uses
Primary industrial uses for sensors include:

Trending Vibration Alarming High Diagnosing

Levels Vibration Amplitudes Machinery Faults

Remember, one sensor does not fit all applications, and several output sensitivities are available along with a
wide range of specialty sensors. Always choose the sensor you need for your specific application.
Prevent
Failures
Current passing through the bearing caused fluting in the
races resulting in rapid deterioration of the bearing.

Overheating eventually destroyed the bearing and the motor.

Vibration measurements with an accelerometer would have

provided early detection of the problem, and analysis would
have triggered further investigation and correction of the
root cause prior to catastrophic failure.

Don’t let this happen to your machines!

Why Choose
CTC?
Superior durability Accuracy and performance

Industry’s best lead times Knowledgeable staff

Industry leading warranties

Connect With CTC
We look forward to hearing from you
FAILURE
18-20 mA

www.ctconline.com [email protected]

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