Air Gap Sensor AGS
Contents
1. Figure 9 AGS 50 outline drawing 8 17 MIKROTREND AGS Installation and user manual 130425 4 Installation instructions 4 1 AGS Signal Conditioner unit installation guide Figure 10 AGS Signal Conditioner unit 4 2 Appropriate location for AGSC signal conditioner unit up to 10 meters from the sensor probe up to 100 meters from acquisition unit with 0 20mA loop if voltage output used interference free distance may vary prefer well ventilated dry area free of vibrations and stray magnetic fields ensure adequate ground for enclosure with minimum lenght of wire ensure access to 24 Vdc 0 15A Power Supply Whenever possible use auxiliary enclosure with door end hinge to additionaly shield AGS signal conditioner unit from environmental influences thermal changes etc 4 3 Grounding of AGS signal conditioner unit CAUTION WARNING Grounding is essential for system operation integrity as well as for protection against hazardous voltages For best grounding provide the shortest path possible between the AGS signal conditioner unit and the grounded structure MULTICORE CABLE SHIELD SHALL BE GROUNDED AT ACQUISITION CARD INPUT ONLY MULTIPLE GROUND POINTS WILL CAUSE NOISE PICK UP AND CAN DAMAGE CONDITIONER UNIT ELECTRONICS 4 4 Power supply connection Power to AGS signal conditioner unit shall be 24VDC 10 0 15A max Conditioner unit input has insulated DC DC converter allowing any pole to be2. grounded or floating power supply as well as daisy chain of several Conditioner units 4 5 Calibration The AGSP sensor probe and AGSC signal conditioner units are factory matched and calibrated for best performance However if needed may be calibrated at site For details please cantact www mikrotrend com 9 17 MIKROTREND AGS Installation and user manual 130425 4 6 AGSP Sensor probe installation guide CAUTION The AGSP sensor probe shall be handled with care Do not apply paint or silicone to the sensor surface Never pull or use excessive force on the sensor cable or preamplifier The sensor surface is treated with high quality insulation varnish it shall not be scrached as damage to semiconductive electrodes may occur 4 7 Placing the sensor Choose position for AGSP sensor probe considering number of sensors and machine poles True acurate rotor stator geometry can be obtained with only one Rotor mounted Air Gap Sensors and four Stator mounted Air Gap Sensors http www mikrotrend com wrm wireless hydrogenerator rotor monitor htm If Wireless Rotor AGS is not used than good practical results are achieved 4 sensors per generator for diameters of less than 7 5 meters 8 sensors per generators with dimeter 7 5 12 meters and 12 to 16 sensorsr for larger diameters Place sensors on the upper side of the stator as it will have higher excentricity than the lower side For stator height of more than 1 8 meters
3. 0 C Our prefered mounting technique with high flexibility and high holding force This is only metod recommended for Wireless Rotor AGS where high G forces are present Standard operation temperatures from 85 250 C up to 300 C A must for locations where stator surface coating has low adhesion to stator laminate Silicone sealant effectively compensates uneven surface tensions during high load periods on generator thus ensuring stable mounting of the sensor With paper adhesive tape mark border area about 5 mm larger on each side than sensor surface Apply Silicone sealant about 1mm thick evenly spread over entire back surface of the sensor Carefuly place sensor within paper covered opening and firmly press until sealant stops comming out Wipe of excess sealant with paper towel until clean and remove adhesive paper border Fix the sensor in position with adhesive tape Power Tape for at least 6 hours Full curing times up to 24 h shorter with higher ambient moisture 11 17 MIKROTREND AGS Installation and user manual 130425 C Two component glue short curing time LOCTITE MULTIBOND 330 continuous operation temperature not exceding 80 C If stator laminate coating is strong and stable You can use two component adhesive type LOCTITE MULTIBOND 330 It is quick and simple application but flexibility is not great and above mentioned precautions about surface stability and operating temperature shall be observed When generat
4. 4S Inverted edge mounted air gap sensor no NOT PAET All dimensions in milimeter SENSING SURFACE Not to scale 2 7mm x 0 8m AGS 4 Preamplifier Air Gap Signal Conditioner 220x120x80mm 10x70mm Multicore shielded cable 3 5mm x 10m AGS 4S Outline drawing 130422 Figure 5 AGS 4S outline drawing Not to scale AGS 7 5S Inverted edge mounted air gap sensor EE All dimensions in milimeter SENSING SURFACE Not to scale 2 7mm x 0 8m AGS 7 5 Preamplifier Air Gap Signal Conditioner 220x120x80mm 10x70mm Multicore shielded cable 3 5mm x 10m AGS 7 5S Outline drawing 130422 Figure 6 AGS 7 5S outline drawing 7 17 MIKROTREND AGS Installation and user manual 130425 pl et 87 2 DO NOT PAINT gt Preamplifier y1 2 5mm x 0 8m AGS 13 Air Gap Signal Conditioner 220x120x80mm 10x70 Multicore shielded cable iiaii 3 5mm x 10m AGS 13 Outline drawing 130422 Figure 7 AGS 13 outline drawing p p 207 2 NI DO NOT PAINT gt 4 3mm x 1 8m Preamplifier AGS 25 Air Gap Signal Conditioner 220x120x80mm 10x7 Multicore shielded cable mild 3 5mm x 10m AGS 25 Outline drawing 130422 Figure 8 AGS 25 outline drawing ma p4 AE 4 3mm x 1 8m AGS 50 Preamplifier Air Gap Signal Conditioner 220x120x80mm Multicore shielded cable 3 5mm x 10m 10x70mm AGS 50 Outline drawing 130422
5. Air Gap sensors should be placed on the lower side also Sensor shall be glued against stator laminations as deep as practical in the air gap or at stator edge if EDGE type of sensor probe is to be used In general this is beneath the second ventilation hole The preamplifier small cylinder shape integrated within the cable must stay outside of the air gap and outside of the endwindings if possible outside of the stator casing Stator Air Gap Sensors Rotor Air Gap Sensors Figure 11 Air Gap Sensor probe positions 10 17 MIKROTREND AGS Installation and user manual 130425 4 8 Preparing the stator surface WARNING CAUTION Thoroughly clean the stator surface use allowed cleaning liquid such as isopropanol alcohol disposable cotton rags and fine non metallic sandpaper DO NOT USE ACETONE OR OTHER SOLVENTS Use a clean rag moistened with isopropanol over the stator surface to remove oil and carbon deposits Epoxy coated or painted stator laminations check for mechanical stability If necessary polish the surface and or remove unstable particles with non metallic sandpaper Sensor s bottom surface shall be insulated from stator iron a thin coat of adhesive will provide suficient insulation After sanding once again clean stator surface with a rag moistened with isopropanol The glue surface should be flat without protruding laminations Slight unevenness can be tolerated 0 5mm Let the isopropanol evapo
6. MIKROTREND AGS Installation and user manual 130425 Air Gap Sensor AGS Installation and user manual MIKROTREND AGS Installation and user manual 130425 Contents Le DNs 3 2 ANN 4 2 1 PAGS selection DE va necteasioctae tou acne ddaninnnilan di eetSnacteanloeoeeesense he tendieseee 4 3 Technical specificationS anxrannnnnnnnnnnnnnnnnnnnnnnennnnnnnnnnnnnnnnennnennnennnnnnn 5 4 Installation INSTUCNUONS LusesserareesmGnK desk 9 4 1 AGS Signal Conditioner unit installation guide rrrrrrrornnnrnrrrorrverrrrrnnnnnnnrnrnrrnnnnnn 9 4 2 Appropriate location for AGSC signal Conditioner unit rrrnrarrrvrrvvrrrrnrnvrvrnvrrrrrnnnn 9 4 3 Grounding of AGS signal Conditioner unit rrrrrnrrrrnrrrnnnnnnnnnnrnrvrnrrrrnnnnnnnnnrnrrnnnnn 9 4 4 Power supply CONNECTION rrrnrrnrrrrvrrnnnrrnrrnnnrrrnrnnnrernnnnnrennnnnnrennnnnerennnnnesennnnnerennnnn 9 UMN 9 4 6 AGSP Sensor probe installation guide srrnrrrrrvvrnrnrrnnnnnnrrrrrrrrnnnrrnrnnnsnrrrrereennn 10 4 7 Placing the SCN SOM La avverarmesnmarevmvenmd ausameksnvjusasvamemmeiuandaiundung 10 4 8 Preparing the stator SUrfaCe rrrrrrnnnnnrvnnnnnrrvrnnnnrrvnnrnnrrnnnnnenrnnnnnnnrennnnnrennnnnsseennnn 11 29 Mounting NE SEN 4 een 11 4 10 True Air Gap and offset cccccssceeecceeesseeeeeceeeesseeeeeceeauseeeeeseeaaeeeeessenanseeeeesees 13 411 CbensalilbnuVarveavevv 97cievsvveiarmee eee 14 4 12 Connection to AGSC Conditione
7. contact capacitive type distance measuring sensor for measuring air gap in air cooled generators and electric motors Low profile sensor probe with triaxial cable preamplifier and shielded cable Edge mount type for wind generators with very small air gap High stability carbon particle semiconductive electrode made from glass epoxy fiber FR4 DC DC insulated power supply Optocoupler insulated output 0 20 mA 0 10V or 4 20mA 2 10V Wide operating temperature range with 3 accuracy Full Scale Deflection Sensor probe 20 140 C Signal Conditioner 20 50 C Immune to magnetic fields dust and oil vapours EMI RFI 3 17 MIKROTREND AGS Installation and user manual 130425 2 Application Capacitive type distance measuring sensor for air cooled generators and electrical motors High sensitivity high resolution up to 50 microns with oversampling Measuring of air gap rotor vibrations rotor symmetry power angle CAUTION AGS is not certified for and shall not be installed in hydrogen cooled alternators 2 1 AGS selection table In order to ensure 15 measurement headroom please select Air Gap Sensor according to the true air gap range per the following formula Lower air gap range Adhesive sensor thickness nonlinear meas range 20 FSD Error FSD Higher air gap range Adhesive sensor thicknes 80 FSD Error FSD AGS 755 AGS 13 AGS 5 5 25 AGS 45 Linear measuring Recommende
8. d for true 24 42 7 13 13 24 22 47 air gap range mm Linear output FSD 17 83 17 83 17 83 17 83 15 85 Table 1 Linear measuring distance from the sensor surface vs true air gap other ranges available per request 0 18 0 182 0 184 0 186 0 188 0 19 0 192 0 194 0 196 0 198 0 2 Time sec Figure 1 Image of AGS output signal zoom of two poles only 10 5 10 25 AirGap mm O j G Ude 1 I 1 1 1 I 1 1 1 1 1 i 1 I 1 I 1 1 a 0 0o25 DDE MO GA 0125 015 01 5 02 O225 O25 02 Gs 035 G35 0375 04 0945 045 0 48 Time sec Figure 2 AGS output signal one rotation 4 17 MIKROTREND AGS Installation and user manual 130425 Air Gap Measuring range 30mm 180 ge 20 Figure 3 Image of AGS output signal polar data 3 Technical specifications AGS755 AGS43 AGS Linear measuring range mm 15 75 26 13 10 50 from sensor surface ER a T Hi 13 24 Measuring range mm from sensor surface 0 4 0 8 4 Recommended true air gap mm 22 47 Linearity FSD 25 C 1 5 1 5 1 5 1 5 3 Linearity FSD 0 50 80 125 C 1 3 5 Linearity FSD 20 50 80 140 C 2 3 5 Output noise 0 5 0 20mA 0mA 0mm or 4 20mA 4mA 0mm with 500 Ohm termination resistor 0 10V 2 10V opto insulated Sensitivity 0 20mA output 0 4mA mm Sensitivity 0 10V output 0 2V mm Sensitivity 4 20mA output 0 32mA mm Sensitivit
9. et adjustement let AGSC Signal conditioner unit be powered for 20 30 minutes Slowly turn trimmer potentiometer labeled Offset adj untill reaching required output current voltage Normally very small rotation will provide large changes on output CAUTION DO NOT adjust other trimmer potentiometers factory adjustment only 4 11 Cable installation WARNING Beware of high voltages on the stator bars 5 22 kV Do not attach triaxial cable directly to the stator bars The triaxial cable preamplifier and multicore shielded cable must be protected by a flexible or semi rigid polyethylene PVC conduit CAUTION The triaxial cable shall not be modified Muticore shielded cable between preamplifier and signal conditioner unit may be shortened if neccesary Gently preshape the triaxial cable by hand to get the right form avoid to bend it beyond a right angle Immobilize the triaxial cable inside the air gap to prevent vibrations and or mechanical displacement hold the triaxial cable temporary with Cyanoacrylate type glue point glued to the stator laminations iron surface applly Silicone sealant along the cable in the air gap up to the exit making a strong permanent bond 14 17 MIKROTREND AGS Installation and user manual 130425 4 12 Connection to AGSC conditioner unit The figure illustrates how to connect the multicore cable to the AGSC conditioner unit Pole profile output gives instantaneous air gap value
10. f this happens during replacement of a new sensor slowly turn Offset adjustment trimmer potentiometer inside Conditioner unit until reaching desired output 2 Pole profile Output signal to low A If this happens during replacement of a new sensor slowly turn Offset adjustment trimmer potentiometer inside Conditioner unit until reaching desired output B If this happens during normal working conditions check Sensor or Triax cable for damages 3 50 or 100Hz Noise in pole profile signal A Check grounding scheme Ground loops shall be avoided B AGSC conditioner unit will tolerate aprox 0 1 Tesla of stray magnetic fields If stronger fields are present use aditional protection box made from ferromagnetic material or move to other location 6 Ordering information AGS Air Gap Sensor is delivered as factory calibrated sets containing P N AGSP sensor probe with integrated preamplifier and connection cable P N AGSC signal conditioner When ordering please use the following format AGS Measuring range 4mm 7 5 mm 13 mm 25mm 50 mm Installation type Side Edge S Output type 0 20mA 4 20mA Operating temperature 0 125 C 20 140 C 16 17 MIKROTREND AGS Installation and user manual 130425 7 Important notice Mikrotrend d o o and its subsidiaries reserve the right to make corrections modifications enhancements improvements and other changes to its products and services a
11. measured by the sensor It is optocoupled and insulated from sensor ground and also from power supply negative Output signal can be ordered as 0 20mA or 4 20m NOTE When 0 10V output is needed instead of 0 20mA 4 20mA a current to voltage conversion resistor of 500 ohms should be placed at the end of line near the acquisition unit lower noise level KES cr atm oa ore a leper ra ee res AGSC Air Gap Signal Conditioner i AFL Pale profile Leven Nic Yellow Nic HIC Multicore shielded cable Pi Er F Power supply 24V0C 0 154 P GND NOTE This shied Renna Optional 5000hm resister for conversion from shall be connected with blue wire 0 20m4 te 0 10 or 4 2 m5A to 2 TRV Shall be af the end of line f r lowest noise kval le T ps m Tv on a a nanea GAD kk Alternative color code DO NOT PAINT Triaxial cable AGS Wiring diagram 121018 Figure 16 AGS Wiring diagram Distance mm lout mA Vout V at 500 Ohm EE ee Oo EG O Table 2 AGS 25 0 20mA 0 8mA mm Output example Distance mm lout mA Vout V at 500 Ohm 0 1 4 1 2 O 4 2 8 72 1 36 gt 1 20 1 10 S Table 3 AGS 25 4 20mA 0 64mA mm Output example 15 17 MIKROTREND AGS Installation and user manual 130425 5 Troubleshooting Pole profile Output signal higher than 20mA or 10V Check the distance to pole surface is within measuring range I
12. or is under heavy load and if surface is not stable enough the sensor may come off due to tensions which adhesive cannot compensate Clean the back surface of the sensor with a rag moistened with alcohol Follow manufacturers instructions Curing times will vary with surface temperature 50 of the final strength is reached after 10 30 minutes full strength after approx 5 hours Figure 12 AGSP sensor probe installed at stator surface pictured left of magnetic field sensor 12 17 MIKROTREND AGS Installation and user manual 130425 Figure 13 Air Gap sensor probe installed at rotor pole 4 10 True Air Gap and offset The output of the signal conditioner provides the distance value between the sensor surface and rotor pole Offset is the distance between the stator surface and sensor surface including the thickness of the glue Offset glue thickness sensor thickness varies with sensor type and mounting metod True air gap is sum of measured and offset value Offset compensation shall be made at the monitoring system and displayed value will be True air gap distance Sensor surface Offset distance Stator surface Figure 14 AGS Offset distance 13 17 MIKROTREND AGS Installation and user manual 130425 factory adj A P Conn 2 Pole profile factory adj B N C N C ov factory adj C 24V Figure 15 AGSC signal conditioner adjustments NOTE Before attempting new offs
13. r unit r rrrnrrrnrrvrrvrrrrnnnnnnnrnrrrnnrnrrnrnnnnnnnrsnnnennn 15 Be TOUDESHOO IN rs 16 6 Ordering information ssssansnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnmnnn nnnm nnn 16 Ze UPON NONE cre RE EEEE EEEE 17 2 17 1 Overview MIKROTREND AGS Installation and user manual 130425 THIS INSTRUCTION MANUAL SHOULD BE READ CAREFULLY AND THE SAFETY INSTRUCTIONS OBSERVED BEFORE INSTALLING CALIBRATING OR USING THE EQUIPMENT DESCRIBED HEREIN Installation and maintenance must be performed by qualified personnel familiar with the construction operation and hazards involved with the equipment Installation and maintenance must be performed with the control out of operation and disconnected from all sources of power Care should be taken when servicing electrostatic sensitive components The manufacturer s recommendations for these components should be followed Ventilation passages should be kept open The means employed for grounding or insulating the equipment from ground should be checked to assure its integrity Care must be taken to avoid damaging any delicate components and to avoid displacing dust dirt or debris in a way that permits it to enter or settle into parts of the control equipment Enclosures should be inspected for evidence of deterioration Accumulated dust and dirt should be removed from the top of the enclosures before opening doors or removing covers High accuracy non
14. rate at room temperature for about 10minutes before proceeding with glue application 4 9 Mounting the sensor CAUTION The AGSP sensor probe shall be aligned with the plane area of the rotor pole A small missalignement may be compensated with offset adjustment The sensor measuring surface shall be entirely covered by the pole surface We recommend three metods for fastening the sensors each with different curing times and operating temperatures Commonly found Epoxy adhesive is not flexible enough The sensor may come off due to uneven surface tensions during high load periods on generator A Double sided tape 150 C Double Side adhesive 3M Scotch Acrylic Foam Tape VHB 4611 With glue thickness of 1mm a foam type tape will allow stator unevenness of up to 0 3 mm Alowed temperatures of 149 C for weeks and short time up to 230 C hours Clean the back surface of the sensor with a cotton rag moistened with isopropanol Place double sided adhesive tape on the back side of the sensor Remove protective foil and carefully place sensor in position without touching adhesive surface Using protective gloves or a rag press the sensor firmly against the stator surface Adhesive is pressure sensitive and reacts on the first applied pressure The sensor can be put in use imediatelly after gluing full strenght will be reached after 24 hours B Silicone sealant adhesive non acid neutral high temperature TEMPFLEX Loctite 5145 25
15. rd party products or services does not constitute a license from Mikrotrend to use such products or services or a warranty or endorsement thereof Use of such information may require a license from a third party under the patents or other intellectual property of the third party or a license from Mikrotrend under the patents or other intellectual property of Mikrotrend Reproduction of information in Mikrotrend data sheets is permissible only if reproduction is without alteration and is accompanied by all associated warranties conditions limitations and notices Reproduction of this information with alteration is an unfair and deceptive business practice Mikrotrend is not responsible or liable for such altered documentation Resale of Mikrotrend products or services with statements different from or beyond the parameters stated by Mikrotrend for that product or service voids all express and any implied warranties for the associated Mikrotrend product or service and is an unfair and deceptive business practice Mikrotrend is not responsible or liable for any such statements MIKROTREND d o o 4 Bizek 14 10000 ZAGREB CROATIA EUROPE Tel 385 98 504 838 e mail info at mikrotrend com www mikrotrend com 17 17
16. t any time and to discontinue any product or service without notice Customers should obtain the latest relevant information before placing orders and should verify that such information is current and complete All products are sold subject to Mikrotrend s General terms and conditions of sale http www mikrotrend com PDEF Selling Policy GT05c pdf supplied at the time of order acknowledgment Mikrotrend warrants performance of its hardware products to the specifications applicable at the time of sale in accordance with Mikrotrend s standard warranty Testing and other quality control techniques are used to the extent Mikrotrend deems necessary to support this warranty Except where mandated by government requirements testing of all parameters of each product is not necessarily performed Mikrotrend assumes no liability for applications assistance or customer product design Customers are responsible for their products and applications using Mikrotrend components To minimize the risks associated with customer products and applications customers should provide adequate design and operating safeguards Mikrotrend does not warrant or represent that any license either express or implied is granted under any Mikrotrend patent right copyright mask work right or other Mikrotrend intellectual property right relating to any combination machine or process in which Mikrotrend products or services are used Information published by Mikrotrend regarding thi
17. y 2 10V output 0 16V mm Typical frequency response 0 1000Hz 3dB other bandwidth optional Magnetic flux density withstand 1 8 Tesla Operating temp AGS probe 20 140 C Operating temp AGS preamp 20 80 C Operating temp AGS sig conditioner 20 50 C Storage temperature 20 80 C Power input 24Vdc 10 0 15A max 20 30 min 95 non condensing IEC 68 2 27 5 g peak 10 Hz to 150 Hz IEC 68 2 27 15 g peak 11ms EMC Sensor probe withstands 1 8 Tesla 50 60 Hz magnetic field Probe immunity magnetic fields dust and oil vapours without degradation of material AGSP probe dimension mm 51x25x0 8 68x29x1 1 112x29x1 7 232x32x3 2 175x60x4 1 AGSP cable length m AGSC sig conditioner dimension mm AGSC sig conditioner protection class Weight AGS probe cable 100g 250g Weight AGSC signal conditioner 1500g 1 AGSC signal conditioner at 50 C AGS preamp at 80 C AGS probe at 125 2 AGSC signal conditioner at 50 C AGS preamp at 80 C AGS probe at 140 C Output pole profile Relative humidity Vibration 220 x 120 x 80 wo cable inlets O 5 17 MIKROTREND AGS Installation and user manual 130425 Voutput V 0 5 10 15 20 25 1mm Linear measuring range Air Gap mm Figure 4 AGS Linearity Full Scale Deflection FSD definition 6 17 MIKROTREND AGS Installation and user manual 130425 Not to scale AGS
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