Condition Monitoring Custom Products

Accelerometer Selection Guide

How to choose the correct Accelerometer for Vibration Monitoring!

Analog accelerometers provide an output that is a continuous voltage proportional

to the acceleration. This technical note covers most of the aspects when selecting a
piezoelectric accelerometer.

The step-by-step guide is intended to explain the sensor options and for a better
understanding of the accelerometer specifications.

The mounting method used, and the sensor location can affect the operating
frequency range of an accelerometer. The advertised operating range is achievable
only by stud mounting, please refer to our Accelerometer Installation Guide for a
more detailed explanation.

Accelerometer Options
Sensor with Top Exit or Side Exit

The first choice is more of a preference. Side Exit Sensors require less clearance and
accommodate a flush installation. Due to their higher mass, they provide a lower
mounted base resonance frequency (22 KHz) than sensors with top exit (27 KHz),
but are still above the usual measurement frequency (10 KHz). Although the cost of
a Side Exit Sensor is about 10% higher, in recent years they became the leading
type in sensor sales.

Shown above: Top Exit and Side Exit Accelerometer

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

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

The most common connector for standard accelerometers is the 2 Pin MS 5015
(Military Style). Another option is the circular M12 style connector, which is used
primarily in factory automation applications.

Shown above: Top Exit MS 5015 & M12 Connector; Side Exit MS 5015 & M12

Connector versus Integral Cable

Selecting a sensor with integral cable can save the cost for the cable connector
assembly. The disadvantage is that when the cable gets compromised (nicked) the
entire sensor may have to be replaced. Sensors with integral cables are great for
submersible applications, due to their excellent sealing.

Shown above: Accelerometers with Overbraided & Integral Cables

For increased mechanical protection, choose a sensor with an overbraid integral

cable. The sealing might not be as good (check on the ingress protection, IP
rating) as when using a PUR jacketed integral cable (polyurethane: a halogen-free
and self-extinguishing thermoplastic elastomer).

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

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

Accelerometer Specifications
Acceleration Range and the Expected Vibration Level
The Vibration Level of the rotating machinery determines the Acceleration Range of
the sensor. Accelerometer specification often state this Measurement Range as the
Dynamic Range in [+/- g]; -a standard measurement range (for a sensor with 100
mV/g sensitivity) is +/- 80 g.
The highest vibration levels of the machine should never exceed the acceleration
range of the sensor, due to sensor overload that leads to signal clipping and
distortion.
➢ As a rule of thumb, the vibration level should be lower than 20% of the
maximum acceleration (peak g level), or smaller than 25 g.
➢ A quick measurement with a Data Analyzer or Vibration Pen will provide the
current vibration level.

The range can be extended by selecting a sensor with a lesser sensitivity, which is
explained next.

Sensitivity

Sensitivity is the ratio of change in acceleration (input) to the change in the output
signal (Voltage).
The sensitivity of industrial accelerometers typically varies between 10 and 500
mV/g; with 100 mV/g being the standard. The range of vibration amplitude levels
to which the sensor will be exposed during measurements drives the sensitivity
selection.
As a general approximation, if the machine produces high amplitude vibrations
(greater than 16 g rms) at the measurement point, select a low sensitivity (10 or
30 mV/g) sensor. If the vibration is less than 16 g rms, a 100 mV/g sensor is best.

General Relationship: Sensitivity – Range – Resonance Frequency

Sensitivity Measurement Mounting Base

Range Resonance Frequency
10 mV/g +/-800 g 33 KHz (1,980 kcpm)
30 mV/g +/-250 g 31 KHz (1,860 kcpm)
50 mV/g +/-160 g 29 KHz (1,740 kcpm)
100 mV/g +/-80 g 27 KHz (1,620 kcpm)
250 mV/g +/-32 g 26 KHz (1,560 kcpm)
500 mV/g +/-16 g 25 KHz (1,500 kcpm)

Higher sensitivity accelerometers, such as 250 and 500 mV/g are for special
applications such as slow speed machinery (6 t0 60 rpm) with low frequency or low
amplitude measurements.

➢ In general, higher sensitivity accelerometers have limited high frequency

operating ranges.

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

1010 East Main Street Website: https://stiweb.com
League City, Texas 77573
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Low-sensitivity sensors are for monitoring high frequency applications such as roller
element defects in bearings and measuring gear mesh fault frequencies.

Sensitivity Precision
The Sensitivity precision is given as a tolerance, typically +/-5% or +/-10%. The
sensor should be supplied with a Calibration Certificate that states the exact
sensitivity. This can be used to offset the tolerance by setting the actual mV/g
value in the data acquisition device (e.g., Data Analyzer, Control System).

Frequency Response
Frequency response, or Bandwidth, is the specification that shows the maximum
deviation of sensitivity over a frequency range.
The bandwidth is usually specified as a tolerance band, relative to the reference
frequency sensitivity (usually 100 Hz). The tolerance band can be specified in
percentage and/or Decibels (dBs) with typical bands being ±5%, ±10%, and ±3 dB
(with -3dB being 30%)
Bandwidth information reveals if the accelerometer can measure slow accelerations
and defines the upper frequency limit where the accelerometer will still be accurate.
If the frequency is higher than what the sensor can measure, the signal becomes
corrupted, and readings are unreliable.

Most vibrations of industrial machinery contain frequencies below 1,000 Hz (60,000

CPM), however signal components of interest often exist at higher frequencies. For
example, if the running speed of a rotating shaft is known, the highest frequency of
interest may be a harmonic (or multiple) of the running speed. The goal is to
determine the high frequency requirement of the application and choose a sensor
with an adequate frequency range, while also meeting sensitivity and amplitude
range requirements.

Typical Frequency Response for a 100 mV/g sensor, top exit, specified with
2 Hz (120 cpm) to 10 kHz (600 kcpm) at ± 5%
1.5 Hz (90 cpm) to 12 kHz (720 kcpm) at ± 10%
0.8 Hz (48 cpm) to 15 kHz (900 kcpm) at ± 3dB

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 flat section of the horizontal response curve in blue defines the usable area.

General Vibration of rotating machinery with running speeds of 300 rpm to 7,200
rpm can be measured including defect frequencies at a fraction (BPFO, Ball Pass
Frequency Outer Ring) and multiples (BPFI, Ball Pass Frequency Inner Ring) of
running speed.

Environmental Requirements

Environmental characteristics include temperature, maximum acceleration levels,

and humidity.

The hermetic seal standard on modern accelerometers helps prevent the intrusion
of contaminants or moisture.

The Operating Temperature of the accelerometer should match the requirements.

General Purpose Accelerometers have an upper temperature limit of 140°C (284°F)
and Premium accelerometers even go out to 150°C (302°F).

For higher temperature applications of up to 250°C (480°F), select a charge mode

accelerometer. The piezoelectric sensor with charge output and external charge
amplifier can be used at higher temperatures than those with internal electronics.

Noise Level

Noise levels can be defined in several ways. Some accelerometers will define
residual noise as a broadband RMS value, in [µV] or [µg]. This is calculated by
taking the root mean square of the signal without any mechanical excitation.

Some accelerometer datasheets provide a spectral noise parameter which will be

specified as µV/√Hz or µg/√Hz. When this value is multiplied by the square root of
the measurement bandwidth, this result is the nominal RMS acceleration noise of

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 sensor. Many accelerometers will specify this spectral noise density for different
ranges because noise levels tend to drop at higher frequencies.

Threshold [g rms] = Noise [mV] / Sensitivity [mV/g]

➢ To assure a low enough noise floor, -the lowest g level to be measured

should be 10 times the threshold level.

Other Considerations

Sensor Weight and Size constraints, check out Compact Accelerometers.

Machine Grounding, match cable connector assemblies with the applied

grounding method. Grounded at the Machine side, use Non-Isolated assemblies; or
standard grounding at the Instrument side, use Isolated assemblies.

Mounting, the best mounting method uses a threaded stud for top exit and captive
mounting bolts for side exit sensors. Select thread size of studs/bolts to fit
mounting requirements.

In Hazardous Areas, if there are flammable contaminants (dusts, vapors or gases,

fibers) present where the sensor will operate, the sensor must have the appropriate
hazardous location certification. The two methods of protection used in designing
electrical equipment for hazardous areas are intrinsically safe and explosion proof
housing.

There are more considerations, like corrosive chemicals or the presence of

electrostatic discharge, and intense acoustic or electromagnetic fields.

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

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

Common Specifications
Examples, -please refer to the individual sensor data sheets for specific information.
Technical Performance
Mounted Base Resonance: 27 kHz (nominal) top exit and 22 kHz for side exit
Sensitivity: 100 mV/g Standard, optional 10, 30, 50, 250 or 500 mV/g
Isolation: Base Isolated
Transverse Sensitivity: Less than 5%

Electrical
Electrical Noise: 0.1 mg max
Current Range: 0.5 mA to 8 mA
Bias Voltage: 10-12 Vdc
Output Impedance: 200 Ohms max.
Case Isolation: >108 Ohms at 500 Volt

Environmental
Sealing: IP68 and IP65 for sensors with Integral Overbraided Cable
Maximum Shock: 5000 g
Operating Temperature: 130°C, 140°C or 150°C maximum, depending on sensor
category
Approvals: CE Approved

Hazardous Location Ratings, Example

CSA/UL Class 1 Division 2 Groups B, C and D Approved
CSA/UL Class 1 Division 1 Approved with IS Barrier or Isolator

Mechanical
Case Material: Stainless Steel
Sensing Element: PZT/Compression
Mounting Torque: 5.9 lbs-ft (8 Nm)
Weight: 4.9 oz (139 gram) for top and 6.5 oz (185 gram) for side exit
Mounting, top exit: 1/4-28 UNF and M8x1.25 Mounting Studs Provided
Mounting, side exit: 1/4-28 UNF or M8x1.25 Captive Mounting Bolt

Example for Dimensions

Top Exit Side Exit Connector

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

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