Condition Monitoring Custom Products

2022/2023

Field Wiring in Vibration Monitoring

“Interference Prevention is Key”

STI Vibration Monitoring Inc. Phone: +(281) 334-0766

1010 East Main Street Website: https://stiweb.com
League City, Texas 77573
 Condition Monitoring Custom Products

Contents

Glossary ................................................................................................................................................... 3
Introduction .......................................................................................................................................... 3
The Challenges .................................................................................................................................... 4
Low Level Signals........................................................................................................................... 4
Noise Sources ................................................................................................................................... 4
The Solutions ........................................................................................................................................ 5
Sensor Cabling / Field Wiring................................................................................................. 5
Junction Boxes................................................................................................................................. 6
Conduit ................................................................................................................................................. 7
Rigid Metal Conduit........................................................................................................................ 8
Flexible Metal Conduit .................................................................................................................. 8
Grounding/Shielding ................................................................................................................... 8
Clean AC Power ............................................................................................................................. 10
Relay Connections ........................................................................................................................ 10
Startup Connections .................................................................................................................... 10
Checklist ................................................................................................................................................ 11

STI Vibration Monitoring Inc. Phone: +(281) 334-0766

1010 East Main Street Website: https://stiweb.com
League City, Texas 77573
 Condition Monitoring Custom Products

Glossary

Field Wiring / Cabling - Connection between the vibration sensors and the
associated Monitoring Instrument, along with any
External Monitor Connections

External Monitor Connections - Relay and Start Up Contacts, Recorder Outputs

Non-Contact Sensors - Proximity Probes (Eddy Current Probes)

Transducers / Sensors - Interchangeable terms for Accelerometers,

Velocity Sensors and Proximity Probes
(Eddy Current Probes)

Vibration Monitoring Systems - Any On-line System, Protection or Condition

Monitoring, hard-wired or wireless

Introduction
When installing a permanently mounted vibration monitoring system, one critical
consideration is the selection and installation of the wiring. The connection between
the vibration sensors and the associated Monitoring Instrument, along with any
external Monitor Connections, are often referred to as the "Field Wiring" or
“Cabling”.

If the Field Wiring is not designed and installed in an appropriate manner, Noise or
Line Interference can be induced into the Vibration Monitoring System. Since the
induced noise is typically an alternating waveform, the Monitoring Instrument will
interpret this signal as false vibration. The Vibration Monitoring System will then
not function as a reliable and credible protection or information system.

STI Vibration Monitoring Inc. Phone: +(281) 334-0766

1010 East Main Street Website: https://stiweb.com
League City, Texas 77573
 Condition Monitoring Custom Products

The Challenges

Low Level Signals

Vibration monitoring systems utilize the low level (voltage) output signals available
from vibration. These signals represent the actual vibration or motion of the
machine's shaft or bearing housing.

The following table provides a comparison of vibration transducer signal levels

expected from a machine running at 3600 RPM.

Sensor Type Expected Sensor Scale Factor Output Level

Vibration
Accelerometer 0.1 g 100 mV/g 10 mV
Velocity 0.2 in/sec 100 or 500 mV/in/sec 20 to 100 mV
Non-Contacting 1.0 mil 200 mV/mil 200 mV

As can be seen from this table, the signal level available from these transducers is
quite low. Base Line Noise especially in Power Plants, can be as high as 200 mV if
the Vibration Monitoring System is not properly installed. Since a running speed of
3600 RPM is the same as 60 Hz, any noise induced on the Vibration Monitoring
System by a power source will be interpreted as 1 time running speed vibration.
Increased fundamental shaft speed (running speed) is associated with many fault
conditions, like unbalance.

These transducer signal levels are also frequency dependent. When the machine's
designed running speed is increased, in general, the expected Displacement level
will decrease, the expected Acceleration level will increase, and the expected
Velocity level will remain constant.

Noise Sources
Noise or Line Interference can be induced in a Vibration Monitoring System in
several ways. There is always a source for the noise and numerous are available in
an industrial or power generation plant:

• AC Power Transients
• Ground Differentials
• Switching Circuits
• High Voltage Circuits
• Improper Load Balance

Noise can be induced in a Vibration Monitoring System through Electrostatic

(Capacitive), Electromagnetic (Inductive) or Conductive Coupling (Direct
Connection). All noise will be introduced into the monitoring system through one or
more of its external connections or Field Wiring.

STI Vibration Monitoring Inc. Phone: +(281) 334-0766

1010 East Main Street Website: https://stiweb.com
League City, Texas 77573
 Condition Monitoring Custom Products

The Solutions

Sensor Cabling / Field Wiring

Cables and cable assemblies are the most susceptible component in a Condition
Monitoring System. The instrument wire from the vibration sensor to its transmitter
or monitor should be either a twisted pair or triad cable depending on the sensor’s
requirement. These cables should be stranded, twisted, individually insulated,
shielded and with an overall jacket. The shields or drain wires must be insulated or
isolated from each other and the conduit. The use of multi‐conductor cable with a
single shield is not recommended due to its susceptibility to induced noise and line
interference.

The gauge or thickness of the instrument wire is determined by the distance

between the sensor and the transmitter or monitor. Long lengths of cable will
deteriorate the signal; this can be a problem when monitoring gear mesh
frequencies, blade pass frequencies or rolling element bearing frequencies.

The following table offers a guideline to determine the maximum cable length for
different types of sensors. This is based on an ideal installation where the cable is
properly grounded and installed in a dedicated conduit system.

Sensor Sensitivity Maximum Cable

Length
100 mV/g Accelerometer 100‐150’ (30 to 50 m)
500 mV/g Accelerometer 150‐500’ (50 to 150 m)
4‐20 mA Output Sensor >1000’ (300 m)

The cables that connect sensors to an on-line system limit both the maximum
observable frequency and the cable length. These limitations are due to the cable’s
impedance, which is a function of both frequency and capacitance.

The maximum sustainable frequency for a given cable is determined by the

following three parameters:

• The total line capacitance

• The sensor current
• The desired maximum signal amplitude

The maximum possible cable length for a given frequency and voltage range, and a
known cable capacitance can then be calculated.

STI Vibration Monitoring Inc. Phone: +(281) 334-0766

1010 East Main Street Website: https://stiweb.com
League City, Texas 77573
 Condition Monitoring Custom Products

The standard MIL spec cable assemblies (CMCP602

and CMCP603 series) are rated for IP68, a high
protection against dust and water ingress. The
CMCP602 and CMCP603 Cables Assemblies are for
both, 2 wire standard and 3 wire multi-parameter
Accelerometers in standard and high temperature
versions. MS-5015 and M12 Connectors along with
Seal Tight Push On and Locking Collar versions are
available. Hose and braided armor options are
available for installations not using conduit.

Shown above: CMCP602H and CMCP602HST

Junction Boxes
An important piece of hardware for installing Vibration Sensors are Junction Boxes.
These are typically installed close to the monitored point and within the length of
the Vibration Sensor’s Cable Assembly. The Junction Boxes should be mounted in a
convenient location for serviceability. Avoid mounting places under machine skirts
or other inaccessible locations when the machine is running. Junction Boxes contain
interfacing terminal strips and can include the Proximity / Eddy Current Probe
Drivers.

Shown above: CMCP265HD-SS-16 High Density Stainless-Steel Junction Box for

16 channels with DIN Rail Mounted 3-High Terminals, rated IP67 and NEMA 4X

A Junction Box is also the transition point of Flexible Conduit to the Vibration
Sensor and Rigid Conduit to the Monitor.

STI Vibration Monitoring Inc. Phone: +(281) 334-0766

1010 East Main Street Website: https://stiweb.com
League City, Texas 77573
 Condition Monitoring Custom Products

Conduit
For a quality Vibration Monitoring System installation, it is critical that conduit be
utilized on the Vibration Sensor and its associated Instrument Wiring. The use of
conduit greatly reduces the possibility of induced noise or line interference on the
signal path. The conduit system should be dedicated solely to the Vibration
Monitoring System, and no other wiring of any classification should be in the same
conduit.

Cable Trays, Wire Ways, or Instrument Trays are an unacceptable alternative to

dedicated conduit. This conduit must be routed as far as possible away from any
power cables. This is also the case when the Vibration Monitor is installed in a
cabinet. The Cable Assembly for the sensors must be separated as much as
possible from both Power and Relay Contact cables. All conduit must be installed
and grounded in compliance with the appropriate Articles of the National Electrical
Code, in effect at time of installation.

Instrument Wire Conduit and Power Cable Conduit parallel runs should be avoided
when possible. When parallel runs cannot be avoided, allow for appropriate spacing.

Shown Above: Conduit Example Installation

STI Vibration Monitoring Inc. Phone: +(281) 334-0766

1010 East Main Street Website: https://stiweb.com
League City, Texas 77573
 Condition Monitoring Custom Products

Rigid Metal Conduit

Rigid Metal Conduit (IMC) continuously bonded and made of ferrous (conductive)
material are highly recommended to be used between the Vibration Monitoring
system and the Junction Boxes located at the machine.

Flexible Metal Conduit

Flexible Coated Metal Conduit (Sealtite or Liquatite) continuously bonded may be
used from the Junction Box to the Vibration Sensor or machine entry point,
provided it is made of ferrous (conductive) material.

When installing Instrument Wire Conduit, the Conduit must not be overfilled with
Instrument Wires. As a rule, only 40% to 50% of the Conduit's cross-sectional area
should be filled with Instrument Wires.

Grounding/Shielding
Shields in signal cables reduces the coupling with other cables and minimizes the
intrusion of external noise. This protects the strength and fidelity of the signal of
interest. Grounding of shields, and the way in which they are grounded, has
consequences on their effectiveness. To provide proper shielding and prevent
ground loops, cable grounding schemes should be carefully considered and
implemented.

A "Single Point Grounding" scheme should be utilized when installing a Vibration

Monitoring System. This scheme of grounding means that all Instrument Wire
shields must be grounded at one end of the cable, and the other end left floating or
not connected. If the shield is not grounded, it will act as an antenna and increase
the induced noise on the signal path. If the shield is grounded at both ends, it will
allow ground differential (potential) current (ground loop) to flow through the shield
seriously increasing induced noise and voltage transients.

Shown above: CMCP402L cable (used for CMCP602L(ST) cable assemblies)

STI Vibration Monitoring Inc. Phone: +(281) 334-0766

1010 East Main Street Website: https://stiweb.com
League City, Texas 77573
 Condition Monitoring Custom Products

It is recommended that the Instrument Wire should be grounded at the Vibration

Monitoring System (Instrument Side).

Shown Above: Grounding on Instrument Side

Alternatively, it is possible to ground at the sensor side. Most sensors are designed
to allow for such a grounding scheme. Assuming the sensor is stud-mounted to the
machine and the machine is properly grounded, the shield is thus grounded to the
machine through the sensor, and the drain wire should not be connected to ground
at the instrument end. However, substantial ground differentials (potentials) can be
found between transducer locations on large machines or where multiple machines
are being monitored.

STI Vibration Monitoring Inc. Phone: +(281) 334-0766

1010 East Main Street Website: https://stiweb.com
League City, Texas 77573
 Condition Monitoring Custom Products

Clean AC Power

The AC Power source for the Vibration Monitoring System or any other Electronic
Instrument needs to be a "CLEAN" source. This implies that the source must be free
of power surges and transient voltages. A power conditioning device, such as a Sola
Power Line Conditioner, can be installed to alleviate these power source problems.
For installations with a switchable power source, an Uninterruptible Power Supply
(UPS) will be required.

The AC Power Source should have a manually operated switch device, or circuit
breaker, in line. The Power Source should be checked for the voltage tolerances at
50/60 Hz.

Relay Connections
When a Monitor's Relay Contact Connections are used for annunciation or
shutdown, these driven circuits must be free of noise or voltage transients. If these
circuits present problems, Slave Relays should be utilized to isolate the Vibration
Monitoring System from this known noise or transient sources.

Startup Connections
When Startup Contact Connections are used to initiate a Monitor's Startup feature,
the drive circuit (dry contact) must be free of noise or voltage transients. Again, if
these circuits present problems, Slave Relays should be utilized.

STI Vibration Monitoring Inc. Phone: +(281) 334-0766

1010 East Main Street Website: https://stiweb.com
League City, Texas 77573
 Condition Monitoring Custom Products

Checklist

• AC Instrument Power
o Proper Voltage
o Power Ground
o Common to Ground <5 Volt
o System Neutral to Ground = 0 Volt
• Junction Boxes Used and Accessible
• Solid Ferrous Metal Conduit (Monitor to J-Box)
• Flexible Conduit (J-Box to Transducer)
• Instrument Wire
o Individual Wires Used
o Insulated, Shielded, Twisted
o Proper Gauge
• Common Point Ground Scheme
• Shield Grounded on One End Only

Shown Above: Typical Layout Drawing

For more information and the complete data sheets, please visit us online:

https://www.stiweb.com

STI Vibration Monitoring Inc. Phone: +(281) 334-0766

1010 East Main Street Website: https://stiweb.com
League City, Texas 77573