Installation Manual

Bently Nevada Asset Condition Monitoring

50mm Differential Expansion

Transducer System

Part Number 131029-01

Rev. C (08/07)

50mm Differential Expansion Transducer System Installation Manual

Copyright 1995. Bently Nevada LLC.

All rights reserved.
The information contained in this document is subject to change without notice.
The following are trademarks of General Electric Company in the United States and other
countries:
Actionable Information, Actionable Information to the Right People at the Right Time,
ADRE, Bently ALIGN, Bently BALANCE, Bently DOCUVIEW SE, Bently LUBE, Bently Nevada,
Bently PERFORMANCE, CableLoc, ClickLoc, Data Manager, Decision Support, DemoNet,
Dynamic Data Manager, Dynamic Transmitor, Engineer Assist, FieldMonitor, FluidLoc,
flexiTIM, flexiTAM, Helping You Protect and Manage All Your Machinery, HydroVU, Key ,
Keyphasor, Machine Condition Manager 2000, MachineLibrary, Machine Manager,
MicroPROX, Move Data, Not People, Move Information, Not Data, NSV, Preformalign,
Process Centered Maintenance, PROXPAC, Proximitor, REBAM, Seismoprobe, ServoFluid,
Smart Monitor, Snapshot, System 1, System Extender, TDXnet, TDIXconnX, Tecknowledgy,
TipLoc, TorXimitor, Transient Data Manager, Trendmaster, TrimLoc, VAM, Velomitor,
Xlerometer

ii

Contact Information
The following ways of contacting Bently Nevada are provided for those times when you
cannot contact your local representative:
Mailing Address

Telephone
Fax
Internet

1631 Bently Parkway South

Minden, Nevada USA 89423
USA
1.775.782.3611
1.800.227.5514
1.775.215.2873
www.ge-energy.com/bently

iii

50mm Differential Expansion Transducer System Installation Manual

Additional Information
Notice:
This manual does not contain all the information required to operate and maintain
the product. Refer to the following manuals for other required information.

Installing the Transducer (AN028, AN013, AN079)

Proximity Probes and Related Accessories (AN028)
Guidelines for Grounding Bently Rotating Machinery Information Systems (AN013)
European CE mark of Bently Nevada 50 mm Differential Expansion Transducer System
(AN079)

Transducer Installation Accessories (145668-01, 141599-01, 141195-01)

Transducer Accessories (145668-01)
Proximitor/Interface Module Housings (141599-01)
3300 XL Proximitor Housings (141195-01)

Electrical and Mechanical Runout (AN002)

"Glitch": Definition of and Methods for Correction, including Shaft Burnishing to Remove
Electrical Runout. (AN002)
API 670, third edition, Section 4.1.2: Machine Shaft Requirements for Electrical and
Mechanical runout. Available from the American Petroleum Institute, Publications and
Distribution, 1220 L Street N.W., Washington D.C., 20005. Phone: (202) 682-8375.

Reference
Performance Specification for the 50 mm Differential Expansion Transducer System
(158739-01).
Product Outline Drawings: 50 mm DE system (130713), Armor Kit (131295-01),
Verification Kit (131037) and Brackets (131293, 131294, 131032, 131033, 131034 and
131035).

iv

Product Disposal Statement

Customers and third parties, who are not member states of the European Union, who are
in control of the product at the end of its life or at the end of its use, are solely
responsible for the proper disposal of the product. No person, firm, corporation,
association or agency that is in control of product shall dispose of it in a manner that is
in violation of any applicable federal, state, local or international law. Bently Nevada LLC
is not responsible for the disposal of the product at the end of its life or at the end of its
use.
This manual uses the following symbols:

Connect

Disconnect

Move one
Direction

Move the other

Direction

Observe

Torque

Record Value

Secure

50mm Differential Expansion Transducer System Installation Manual

Contents
1. System Description ........................................................................................1
1.1
General Overview.............................................................................................................................. 1
Application Advisory .................................................................................................................................. 1
Application Alert........................................................................................................................................... 1
1.2
Receiving, Inspecting and Handling the System................................................................. 1
1.3
Customer Service .............................................................................................................................. 2

2. Installation.......................................................................................................3
2.1
2.2
2.3
2.4

General Overview.............................................................................................................................. 3
Installing and Mounting of the Transducer ........................................................................... 4
Installing the Mounting Hardware............................................................................................. 5
Routing the Transducer Cable..................................................................................................... 8

3. Maintenance and Troubleshooting.............................................................9

3.1
General Overview.............................................................................................................................. 9
3.2
Setting Up the Verification Kit....................................................................................................11
3.3
Verifying Transducer Accuracy.................................................................................................12
3.4
Troubleshooting...............................................................................................................................16
3.4.1 Symbols for Measured Voltages..........................................................................................16
3.4.2 Definitions......................................................................................................................................16
3.4.3 Fault Type 1: Power source voltage is outside of typical levels ..........................17
3.4.4 Fault Type 2: Transducer output signal is clamped to positive rail ....................18
3.4.5 Fault Type 3: Transducer output signal is in a Not-OK condition ........................20
3.4.6 Fault Type 4: Transducer output signal is near the negative rail..........................21
3.4.7 Fault Type 5: Transducer output signal is clamped to the negative rail ..........22

4. Specifications and Ordering Information ................................................23

vi

Section 1 - System Description

1. System Description
1.1 General Overview
The 50mm Differential Expansion Transducer (50 mm DE) measures differential
expansion between the rotor and the stationary parts of the machine. The
transducer is environmentally rugged and designed to withstand the harsh
conditions commonly found inside machines (like steam turbines).
The system is completely enclosed in a single unit with a transducer cable. The
transducer cable has four connection points: system ground, transducer power,
transducer signal and transducer system shield wire. The complete system is
calibrated at the manufacturer for a target material of AISI E4140 steel. The
system measures displacement by using the eddy current principle and
provides a negative DC output voltage which is proportional to the distance
between the target and probe sensing surface. This transducer signal can be
applied to monitors, portable instrumentation or diagnostic equipment.

Application Advisory
The 50mm DE transducer system has been designed to measure the relative
position of parts inside a machine in the axial direction. The typical application
of this system is limited to differential expansion.

Application Alert
Although the terminals and connector on the transducer have protection
against electrostatic discharge, take reasonable precautions to avoid
electrostatic discharge when handling the transducer.

1.2 Receiving, Inspecting and Handling the System

The transducer and mounting hardware are shipped as separate units and
must be assembled at the installation site by the user. Carefully remove all
equipment from the shipping containers and inspect the equipment for shipping
damage. If shipping damage is apparent, file a claim with the carrier and
submit a copy to the nearest Bently Nevada office. Include part numbers and
serial numbers on all correspondence. If no damage is apparent and the
equipment is not going to be used immediately, return the equipment to the
shipping containers and reseal until ready for use.
Store the equipment in an environment free from potentially damaging
conditions such as high temperature or a corrosive atmosphere. See the
Specifications and Ordering Information section for environmental
specifications.
1

50mm Differential Expansion Transducer System Installation Manual

1.3 Customer Service

Bently Nevada maintains numerous Sales and Service offices worldwide. To
locate the office nearest you, visit our website at www.bently.com
<http://www.bently.com>. Here, you can also find specifications on all standard
product offerings.
Support for products and services should be directed to one of these
departments:
For product quotations, product applications, product ordering, scheduling onsite services, and questions regarding existing orders please contact your nearby
Bently Nevada Sales and Service Office.
For general product pricing, delivery or other ordering information contact your
local BNC office or contact Customer Service Department, Minden, Nevada, USA
Phone: 1-775-782-9913 Fax: 1-775-782-9259.
For technical questions or problems regarding installed BNC products, contact
our Technical Support Staff at techsupport@bently.com
<mailto:techsupport@bently.com> or at the following locations:
Technical Support (North America)

Phone: 1-775-782-1818
Fax: 1-775-782-1815

Technical Support (UK)

Phone: (44) 1925 818504

Fax: (44) 1925 817819

Section 2 - Installation

2. Installation
2.1 General Overview
This section contains a checklist of items that you must consider when you install
a 50mm Differential Expansion Transducer system. For detailed information
about designing installations for specific applications refer to documents 1, 2, 3, 4,
5, 6 and 10.
The Base Plate comes with three sets of holes (two holes per set). For a standard
installation, use the outer sets. The inner set of holes on the one end of the base
plate is intended for use in the case when the Base Plate needs to be cut down
due to space restrictions.

Mounting Hole Sets

Verification Kit:
-Verification
Kit Bracket

Base Plate

Sliding Plate

-Spindle
Micrometer
Transducer Cable
50 mm DE
Transducer
Sensing Surface

If you are using the 50mm DE

transducers in a redundant fashion (that
is two or more transducers mounted side
by side), clearance must be allowed to
reduce cross talk between the
transducers. See the figure for minimum
mounting separation.

76 mm (3.0 in)
203 mm (8.0 in)

50mm Differential Expansion Transducer System Installation Manual

2.2 Installing and Mounting of the Transducer

1

Measure the width of the collar. Record the value of "A".

Note: Only required for Complementary Input Differential
Expansion (CIDE) measurement. In CIDE arrangement, a
collar width dimension of less than 50.8 mm (2.00 in) can
cause noise in signal due to cross talk between
transducers. See document 9 for details.
2
Position the transducer(s) as shown:
Single Transducer
Configuration

CIDE
Configuration
58.4 mm + A *
(2.30 in + A) *
**

Sliding
Plate

Transducer

Sliding Plate

Transducers

Note: * These numbers ensure that the output voltage range will be
50.8 mm (2.00 in). Gap the transducers farther apart for
additional linear range - up to 63.5 mm + A (2.50 in + A).
** This measurement is made from the corner (or front edge) of
the metal enclosure.

Section 2 - Installation
3
Secure the transducer(s) in place with the
securing washers and screws.
See Specifications for torque requirements.

4
Secure the screws in place with safety wire.

2.3 Installing the Mounting Hardware

1
Design and install a bracket (as necessary) such that the supplied base plate can
be mounted as shown in the figure below. See the Specifications and Ordering
Information section for the Base Plate mounting hole configuration.
Axial position:

User-Supplied Bracket or
Machine Case

Base
Plate

Typical Position
Single Transducer Configuration:
B= 104 3 mm (4.1 0.1 in)
CIDE Configuration:
B= 130 3 mm (5.1 0.1 in)
5

50mm Differential Expansion Transducer System Installation Manual

Radial position:
Minimum Target
C = 101.6 mm (4.00 in)
Typical Position

D
C

D = 70.1 1.5 mm
(2.76 0.06 in)

Note: Refer to the Specifications section to

determine different recommended base plate distances D for collars shorter
than 102 mm (4.0 in). The linear range may be reduced for collar heights under
102 mm (4.0 in).
2
With the sliding bracket mounted on the
Base Plate, fasten the Base Plate to the
user-supplied bracket or the machine
case using bolts.

See Specifications for torque

requirements.

Section 2 - Installation
3
Verify accuracy for each
transducer in the installed position.

The Maintenance section starting

on page 9 shows how to verify the
transducer accuracy.

OUT (White)
10k
ohm
COM (Black)
-Vt (Red)

+
DVM
+ Power
Supply

Transducer position relative to cold

rotor position.

4
Set the position of the transducer assembly
relative to the machine's cold rotor position.

5
Fasten the Sliding Plate to the Base Plate
and tighten the bolts to the torque specified
in Specifications.

6
Secure the mounting hardware with safety
wire.

50mm Differential Expansion Transducer System Installation Manual

2.4 Routing the Transducer Cable

Route the transducer cable using the following guidelines. (Refer to documents 1
and 3).

Secure the transducer cable to supporting surfaces by using

mounting clips or similar devices.

Identify one end of the transducer cable by inserting labels under

the clear Teflon sleeves and applying heat to shrink the tubing.

Insulate the connection as required.

If the transducer is in a part of the machine that is under pressure

or vacuum, seal the hole where the transducer cable leaves the
machine by using appropriate cable seals and terminal boxes.

The transducer cable is manufactured so that it is "wick resistant"

which greatly reduces the oil wicking through the cable and ending
up in the terminal housing. The cable is not a pressure sealed
cable.

Bently Nevada has special hardware that makes routing cables to the 50mm DE
transducer system easier. Use the following wiring diagram to connect the field
wiring between the transducer and the monitoring instruments. (Refer to
documents 2, 3, and 5.)

Terminal
Housing

Sealtite
Flexible
Conduit

Rigid
Conduit

Transducer
Cable
Transducer
Field Wiring
Cable
Label

Low Pressure
Cable Seal
Machine Casing

To Monitor

Section 3 - Specifications and Ordering Information

3. Maintenance and Troubleshooting

3.1 General Overview
This section shows how to verify that the system is operating properly or identify
parts of the system that are not working properly.
Note:

The 50 mm DE transducer is a sealed

unit. DO NOT attempt to open, there are
no user serviceable parts inside. A
defective or malfunctioning transducer
should be returned intact to Bently
Nevada for failure analysis.

The transducer system does not require verification at regular intervals. You
should, however, verify operation by using the transducer accuracy verification
on page 11 if any of the following conditions occur:

components of the system are replaced or disturbed

the performance of the system changes or becomes erratic

you suspect that the transducer is not calibrated correctly

The transducer system is calibrated for target material of AISI E4140 steel. If
some other material is required for other special applications, contact your local
Bently Nevada office.
Transducer accuracy verification requires the following instruments:
digital voltmeter

fixed resistor, 10 k

24 Vdc power supply

micrometer kit

verification kit or extended range

Note: Required minimum accuracy for the test equipment listed above:
digital voltmeter: 4 digits
spindle micrometer: 0.01 mm or 0.001 inches ( 1 mils)

50mm Differential Expansion Transducer System Installation Manual

Transducer accuracy verification uses the test setup as shown in the following figure:

OUT (White)

COM (Black)
-Vt (Red)

10

10k
Ohms

Digital
Voltmeter
24 Volt
Power
Supply

Section 3 - Specifications and Ordering Information

3.2 Setting Up the Verification Kit

1
Pre-set the spindle micrometer to 48.75 0.01 mm or 1950 1 mils and lock in
place.

Contact Surface
Mechanical Lock

48.75 mm or
1950 mils

2
Install the spindle micrometer into the Verification Kit Bracket.
Make sure that the spindle micrometer's contact surface is flush with the front
surface of the Verification Kit Bracket.
After the spindle micrometer has been secured (finger tight) in place with the set
screw, unlock the spindle micrometer.

Verification Kit
Brackets Front
Surface

Detail Cross-section
View

Verification Kit
Bracket

Spindle Micrometers
Contact Surface

11

50mm Differential Expansion Transducer System Installation Manual

3.3 Verifying Transducer Accuracy

1

Digital
Voltmeter

Position the transducer relative to the collar by

moving the Sliding Plate (with the transducer and
mounting hardware already installed) so that the
voltmeter reads: -1.50 0.02 Vdc.

2
Install Verification Kit onto the Base
Plate so that the front surface is
flush with the Sliding Plate mating
surface. Secure the Verification Kit
to the Base Plate so that it does not
move during the verification
process. Secure it into place but do
not over tighten.

Make the two surfaces

flush with each other

3
Move the Sliding Plate so the edge of
the transducer is 35 mm or 1500 mils
from the collar.

Note: Do not use the spindle

micrometer to move the Sliding Plate.
35 mm or
1500 mils

12

Section 3 - Specifications and Ordering Information

4
Step: A Adjust the spindle micrometer
to the first value (n=1) listed in row n of
the table on page 15 in the column
labeled "Micrometer Adjusted Values".

Step: B Move the Sliding Plate back

flush with the spindle micrometer's
contact surface.

20.70 mm
or 850 mils
B

Step: C Record the voltage shown on

the digital voltmeter in the row n=1 of
the table on page 15 in the column
labeled "Actual Output Voltage, Va".

5
Step: D Adjust the spindle
micrometer for the next value listed in
row n of the table on page 15 in the
column labeled "Micrometer Adjusted
Values".
Step: E Move the Sliding Plate back
flush with the spindle micrometer's
contact surface.

23.25 mm
or 950 mils
E

Step: F Record the voltage shown on

the digital voltmeter in the row n of
the table on page 15 in the column
labeled "Actual Output Voltage, Va".
6
Repeat step 5 until you have recorded the voltage values for all rows n in the
column labeled "Actual Output Voltage, Va" of the table on page 15.
7
Use the following equations to calculate the average scale factor (ASF) and raw
deviation from straight line (DSLRAW) values. Enter these values into the
appropriate column in the table on page 15.

13

50mm Differential Expansion Transducer System Installation Manual

Metric
ASF =

Va1.25mm Va 29.30 mm
28.05 mm

ASF =

Va50 mil Va1150 mil

1100 mil

DSLRAW =

Vin Va n
0.3937 V /mm

English

DSLRAW =

Vin Va n
10 mV /mil

8
Determine the DSLSYS value. This is the calculated DSL for the system. First, two
parameters need to be determined: DSLRAW MAX and DSLRAW MIN. These values are the
maximum and minimum values from the DSLRAW section of the table on page 15.
DSLSYS =

DSLRAW MAX DSLRAW MIN

2

9
The last calculations are to adjust the DSLRAW values to DSLADJ values. Simply plug
each of the values into the equation and then update the appropriate column in
the table on page 15.

DSL ADJ = DSLRAW DSLSYS

10
If the measured accuracy of the 50 mm DE transducer is not acceptable, check
for the following situations that can degrade accuracy:

14

Target material not AISI 4140

Target surface too small (see collar height variations graph in Specifications)

Ambient temperature (see temperature response graphs in Specifications)

Cross-talk between transducers (see cross-talk graphs in document 9)

Variations in AISI 4140 material (see appendix in document 9)

Problem with the transducer (see Troubleshooting)

Section 3 - Specifications and Ordering Information

Metric
n

Actual
Gap
Values,

Micrometer
Adjusted
Values,

Actual
Output
Voltages
, Va

Ideal
Output
Value, Vi

Average
Scale
Factor,
ASF

Unadjusted
Value,

Adjusted
Value,

DSLRAW

DSLADJ

mm

mm *

Vdc

Vdc

V/mm

mm

mm

_______

________
________

________
________

1
2

29.30
26.75

20.70
23.25

_______
_______

-12.543
-11.539

3
4
5

24.20
21.65
19.10

25.80
28.35
30.90

_______
_______
_______

-10.535
-9.531
-8.528

________
________
________

________
________
________

6
7
8

16.55
14.00
11.45

33.45
36.00
38.55

_______
_______
_______

-7.524
-6.520
-5.516

________
________
________

________
________
________

9
10
11

8.90
6.35
3.80

41.10
43.65
46.20

_______
_______
_______

-4.512
-3.508
-2.504

________
________
________

________
________
________

12

1.25

48.75

_______

-1.500

________

________

English
n

Actual
Gap
Values,

mils

Micrometer
Adjusted
Values,

Actual
Output
Voltages,
Va

mils *

Vdc

Ideal
Output
Value, Vi

Vdc

Average
Scale
Factor,
ASF

Unadjusted
Value,

Adjusted
Value,

DSLRAW

DSLADJ

mV/mil

mils

mils

_______

________
________
________

________
________
________

1
2
3

1150
1050
950

850
950
1050

________
________
________

-12.500
-11.500
-10.500

4
5
6

850
750
650

1150
1250
1350

________
________
________

-9.500
-8.500
-7.500

________
________
________

________
________
________

7
8
9

550
450
350

1450
1550
1650

________
________
________

-6.500
-5.500
-4.500

________
________
________

________
________
________

10
11
12

250
150
50

1750
1850
1950

________
________
________

-3.500
-2.500
-1.500

________
________
________

________
________
________

Note: * The micrometer adjusted values are used because of the spindle
micrometer's numbers orientation. If your spindle micrometer is orientated in the
opposite direction, then the Actual Gap Values can be used.
15

50mm Differential Expansion Transducer System Installation Manual

3.4 Troubleshooting
This section shows how to interpret a fault indication and isolate faults in an
installed transducer system. Before beginning this procedure, be sure the system
has been installed correctly and all connectors have been secured properly in the
correct locations.
When a malfunction occurs, locate the appropriate fault, check the probable
causes for the fault indication, and follow the procedure to isolate and correct the
fault. Use a digital voltmeter to measure voltage. If you find faulty transducers,
contact your local Bently Nevada Corporation office for assistance.
The troubleshooting procedures use measured voltages as shown in the following
figure and table:
VPS
Transducer Power
Common (ground)
Transducer Signal

-Vt
COM
OUT

VSIG

3.4.1 Symbols for Measured Voltages

Symbol

Meaning

Voltage measured between...

VSIG

Signal voltage from the

transducer

OUT and COM

VPS

Power supply voltage

Power Source and Common

(-VT and COM, respectively)

Note: VSIG, and VPS are all negative voltage values.

3.4.2 Definitions
Symbol
A>B
A<B
A=B

16

Definition
"A" value is more positive than "B"
"A" value is more negative than "B"
"A" same value (or very close) to "B"

Section 3 - Specifications and Ordering Information

3.4.3 Fault Type 1: Power source voltage is outside of typical

levels
VPS > -17.5 Vdc or VPS < -26 Vdc
Possible Causes:

Faulty power source

Faulty field wiring

Faulty Transducer
VPS

17

50mm Differential Expansion Transducer System Installation Manual

3.4.4 Fault Type 2: Transducer output signal is clamped to positive

rail
VSIG = 0 Vdc

Possible Causes:

Incorrect power source voltage

Measure VPS:
VPS > -17.5 Vdc or VPS < -26 Vdc

Yes

Faulty
Power
Source

Yes

Faulty
Field
Wiring

No

Inspect transducer cable for problems:

Is there damage or other abnormalities?
No
Faulty Transducer

18

Short circuit in field wiring

Short circuit in the instrument connected to the transducer OUT

wire

Faulty transducer

Section 3 - Specifications and Ordering Information

Open in negative power source supply line

Fault Condition Type 1?

No

VSIG

Measure VSIG
VSIG = 0 Vdc?

No

Problem with
Instrument, or
Open Negative
Supply Line

Yes

Faulty Transducer or Short in Field Wiring

19

50mm Differential Expansion Transducer System Installation Manual

3.4.5 Fault Type 3: Transducer output signal is in a Not-OK

condition
-1 Vdc < VSIG < 0 Vdc

Possible Causes:

Incorrect power source voltage

Transducer is incorrectly gapped (too close to target)

Faulty Transducer

Fault Condition Type 1?

No

VSIG

Measure gap between transducer and target:

Is the gap less than 1.2 mm (50 mils)?

Yes

Adjust the transducer gap

so that it is greater than 1.2
mm (50 mils)

20

No
Faulty
Transducer

Section 3 - Specifications and Ordering Information

3.4.6 Fault Type 4: Transducer output signal is near the negative

rail
VPS < VSIG < -13 Vdc
Possible Causes:

Faulty Transducer

Fault Condition Type 1?

No

Transducer is incorrectly gapped (too far from target)

Adjust the transducer gap so
that it is less than 30.5 mm
(1200 mils)

VPS

VSIG

Measure gap between transducer and target:

Is the gap greater than 30.5 mm (1200 mils)?

No
Faulty
Transducer

Yes

21

50mm Differential Expansion Transducer System Installation Manual

3.4.7 Fault Type 5: Transducer output signal is clamped to the

negative rail
VSIG = VPS
Possible Causes:

Incorrect power source voltage

Faulty Transducer

Faulty instrument connected to transducer

Faulty field wiring (short between OUT and -VT)

Fault Condition Type 1?

No

VPS

VSIG

Measure VSIG:
VSIG = VPS?
No
Faulty Instrument,
Faulty Power Source

22

Yes

Faulty Transducer,
Faulty Field Wiring
(short between Vt
and OUT)

Section 4 - Specifications and Ordering Information

4. Specifications and Ordering

Information
On the following pages are the data sheets and specifications for the
50mm Differential Expansion Transducer and accessories.

23