User Manual - IRD Mechanalysis Limited
Contents
1. Figure 6 A typical vibration measurement datasheet 4 2 Incoming Inspection Vibration tolerances are often included in specifications of purchased components to prevent excess vibration in finished products The IRD306 Vibration Meter is ideal for inspection in receiving or on the assembly line 4 3 Field Service Field engineers and service men can quickly determine if vibration is the justifiable cause of a customer complaint The instrument avoids the expense of more costly equipment and is easily carried to the job 4 4 Final Assembly Testing Final vibration checks of finished products and assemblies before shipment assures compliance with production quality standards and customer satisfaction New or overhauled machines can be checked for vibration from troubles to faulty installation condition management solutions 8 IRD306 Manual V4 Aug14 IRD Mec hanalysis Lid 5 VIBRATION TOLERANCES Vibration measurements without a standard for comparison are seldom of any use There needs to be some guide to show how much is too much Table 1 provides a guide for Machine Tool Vibrations The values listed merely indicate the range in which satisfactory parts have been produced Actual tolerances must be determined by your own experience as to what vibration levels permit the meeting size and finish tolerance For General Machinery the guide shown in Figure 7 may be used Note the vibration displacement values are for a spec2. SPECIFICATIONS Measurement Ranges 7 Overlapping Displacement 0 3 000 microns Pk to Pk Velocity 0 3 000 mm sec Pk Frequency Range Displacement 300 to 24 000 CPM 5 Hz to 400 Hz Velocity 300 to 150 000 CPM 5 Hz to 2 500 Hz Accuracy Instrument 1 0 of full scale Input Inductive Velocity Sensor IRD544 Calibrated to National Standards Output Analog Moving Coil Meter display Power Requirements Internal Battery Environmental Battery Set 2 Nos of 9V 100mAH Dry Cells Operating temp 0 C to 55 C Storage temp 18 C to 60 C Weight amp Dimensions Instrument 184mm L x 114mm W x 83mm H Carrying case Instrument with batteries Carrying Case 195mm x 185mm x 110mm 0 8 Kg 2 4 Kg including meter and standard accessories The Vibration People of IRD Mechanalysis can be contacted at the following branches or your local distibutor Fax 91 0 11 2237 0778 Fax 91 0 33 2355 9214 Fax 91 0 44 2823 4702 SalesNR irdmech com SalesER irdmech com SalesSR irdmech com Tel 91 22 2852 0178 el 91 0 11 2237 3916 el 91 0 33 2355 2062 el 91 0 44 2823 0726 env 194 00 0950 1914 sales irdmech com IRD is the Registered Trademark of IRD Mechanalysis Ltd condition management solutions 19 IRD306 Manual V4 Aug14 IRD Mec hanalysis Lid 10 2 IRD544 Inductive Velocity Sensor Portable Measurement Part Number M45260 The model IRD544 inductive veloc
3. Bearing Demodulation or gSE amp Leak Detection Four Channel Vibration Analyser 4 Plane Balancing AE Bearing amp Lubrication Distress Fixed Variable amp Very Low RPM Decision Support Diagnostics KA AK KA SKK 2 6 26 2K EE EE 2 E E EE E E Ke 2k ke E 6 24S 6 E E E E Ke E E E 6 E EE E EE E E E E E EE E E E E E E E Ke E E EE E E E 2k Ke k k k k k k k kkk condition management solutions 29 IRD306 Manual V4 Aug14
4. 6214 6573 Fax 91 0 22 2832 1814 Email service irdmech com Email sales irdmech com Tel 91 0 22 2202 7430 Fax 91 0 22 2285 0480 Email ceo irdmec com www irdmechanalysis com condition management solutions 23 IRD306 Manual V4 Aug14 IRD Mec hanalysis Lid RMA Return Materials Advisorv Form ATTN Mechanalysis India Ltd National Service Centre 1 5 Marol Co op Industrial Estate Ltd Off Mathurdas Vasanji Road Marol Andheri E Mumbai 400 059 India 91 0 22 2852 0178 2906 FAX BACK RMA FORM 91 0 22 2852 1814 or Email to service irdmech com Fault details if applicable Please tick appropriate box Fixed Price Repair Exchange Units Standard Repair This is to advise that we are planning to dispatch the above instrument for Calibration Repair as detailed above on date Customer s Purchase Order No Date P O Value Rs if agreed eee AMC Contract No if applicable purchase order must be provided before inspection will commence unless an AMC Contract is in place When NSC receives the Return Material Authorisation it will issue an RMA number Only then send in the instrument with its RMA Nos tagged on the instrument for tracking purposes A PO must accompany the instrument referencing the RMA Nos Please complete the details below to enable us to process your requirements as quickly as possible Company Department Address City State C
5. Frequency of Vibration of a machine that has several rotating parts consider for example a belt driven blower The dominant frequency will reveal which part of the machine is causing the most vibration Vibration measurements taken with the model IRD306 are overall vibration readings or the vector sum of all the vibration at the point the sensor is applied Measurements taken on the motor bearings would include vibrations of the motor plus vibrations from the fan transmitted through the drive belt and mounting structure Conversely measurements taken on the fan bearings would include vibrations of the fan plus vibrations transmitted from the motor See Figure 8 In many cases the point with the most vibration would pinpoint which part has the trouble but not always log vibration amplitude Figure 8 Discrete machine frequencies show different defects The model IRD306 can be used to find the dominant frequency of vibration provided the readings taken are steady i e the meter pointer does not fluctuate more than about 10 Use the following sequence to find the dominant frequency 1 Measure and record the displacement D at a given point Be sure to use the exact Same measuring point holding the sensor steady for both the displacement and velocity readings 2 In the same manner and at the same point measure and record the velocity V 3 The Dominant Frequency can be found by dividing the velocity measurement V by the Displac
6. at NSC Calibrate Fixed Price Exchange Repair it Repair Unit Specific Fault ISO9000 12 month 3 months Parts Requirement Warranty Warranty Warranty HOW TO GET SERVICE 1 Before dispatching any instrument cable sensor etc it must be given an RMA number issued by the NSC see below 2 For a Return Material Authorization number RMA this can be downloaded from our web site www irdmechanalysis com 3 To discuss any instrument servicing issues please call Tel 91 0 22 2852 0178 or one of our Regional Offices Alternatively Email us at service irdmech com Complete the RMA and fax back to IRD Mechanalysis at Fax 91 0 22 2832 1814 When the RMA has been issued the Client sends the instrument with all accessories together with the Purchase Order making reference to the RMA Number 7 Upon receipt IRD will evaluate the instrument and make a recommendation to the Client if no instructions on type of service have been received earlier 8 Only when the repair has been completed and payment has been received will the instrument be returned to the Client 9 Warranties will apply depending on the Repair Category option LOCATIONS National Service Centre 1 5 Marol Co op Industrial Estate Ltd Off Mathuradas Vasanji Rd Marol Andheri East Mumbai Head Office Registered 47 48 Jolly Maker Chambers II Nariman Point Mumbai 400 021 INDIA 400 059 INDIA Tel 91 0 22 2852 01 78 Tel 91 0 22 2859
7. irdmech com Mumbai 400 059 7 C Chesney Nilgiri Apartments Tel 91 044 28230726 Chennai 65 Commander In Chief Road Fax 91 044 28234702 Chennai 600 105 Email salesSR irdmech com Tel 91 022 28520178 National 1 5 Marol Co op Industrial Estate Tel 91 022 28596214 6573 Service Ltd Off Mathuradas Vasaniji Fax 91 022 28521814 Centre Road Marol Andheri East Email mailto service irdmech com amp Works Mumbai 400059 Email service1 irdmech com condition management solutions IRD306 Manual V4 Aug14 IRD Mec hanalysis Lid INDEX OF ILLUSTRATIONS INDEX OF REFERENCE FIGURES Title Periodic Vibration measurements save valuable machine downtime Front view of IRD306 Vibration Meter IRD306 Vibration Meter Velocity Sensor standard package IRD306 Standard accessories IRD544 Inductive Velocity Sensor A typical vibration measurement datasheet IRD General Machinery Vibration Severity Chart Metric 8 Discrete machine frequencies show different defects 9 Step by step balancing vector diagram construction 15 Block Diagram of Calibration Setup for IRD306 Vibration Meter IRD Sensor Calibration Lab INDEX OF REFERENCE TABLES Tentative guide to vibration tolerances for machine tools PQ 7 Dominant machine excitation frequencies and most likely causes condition management solutions Il IRD306 Manual V4 Aug14 TABLE OF CONTENTS SNo Chapter description 1 10 INTRODUCTION 2 ri
8. repair technicians provide the highest quality service for your IRD products At our National Service Centre in Mumbai we stock a comprehensive supply of spare parts to ensure a quick turnaround BENEFITS and FEATURES For Mechanalysis India Ltd s customers the National Service Centre offers the following Fast in house turnaround options Expert factory technical assistance Industry competitive repair charges In house calibration of vibration sensors traceable to National Standards Regular cleaning and calibration to extend product life and reliability Instrument hire during repair period to minimize programme interruption 1 Year warranty on Product Exchange Programme Fixed Price Repair Whole Product 3 months warranty 90 day parts warranty on all repair and calibration services condition management solutions 21 IRD306 Manual V4 Aug14 IRD Mec hanalysis Lid PRODUCTS SUPPORTED The National Service Centre has the capability to support the following products Data Collectors IRD890 IRD Fast Track dataPAC 1250 dP1500 Also Commtest VBx series of vibration analysers and profiler Portable Instruments IRD306 IRD306C IRD306D IRD306DD IRD308 IRD350 IRD810 IRD811 IRD811 IRD811D IRD838 IRD880 IRD885 Protection Monitors 5802 5806 5815 5915 5800 Cards 6100 6600 Series IRD8700 Series IRD8800 Monitor Machinery Diagnostic Systems IRD9900 Machinery Protection Transmitters IRD71000 7200 7300 7400 Serie
9. 00 Hz lt 8 10Hz 20 average at 21 C Sensitivity 42 52 mV mm sec 10 Impedance R 2k ohms L 0 7 H at 21 C Maximum Amplitude 3175 microns Pk Pk to 70 Hz 30 g above 70 Hz Transverse Response Less than 5 average 10 to 1 000 Hz Orientation Any Horizontal Vertical or Axial Mounting 4 28 tapped hole in depth Groundinq Case and signal ground common Connector 2 pin Mil Spec Operating ranqe 40 C to 260 C Housing l Aluminium IP65 sealed Classification Class1 Div2 Weight amp Dimensions Weight 0 65 Ka Dimensions 50 8mm Hex base x 130 mm H Construction Aluminium The Vibration People of IRD Mechanalysis can be contacted at the following branches or your local disiibutor Chennai International 2852 Tel 91 22 2852 0178 Le 91 0 22 2852 0178 ret 91 0 11 2237 3016 el 91 0 33 2955 2062 el 91 0 44 2823 0726 en gy 09 0gm9 1814 Fax 91 0 22 2852 1814 Lane Grech aati Fax 91 0 11 2237 0778 Fax 91 0 33 2355 9214 Fax 91 0 44 2823 4702 sales irdmech com SalesNR irdmech com SalesER irdmech com SalesSR irdmech com IRD is the Registered Trademark of IRD Mechanalysis Lid IRD Mechanalysis Ltd continuously improves products it therefore retains the right to change the above specification without notice condition management solutions 20 IRD306 Manual V4 Aug14 IRD Mec hanalysis Lid Keeping you Going 11 Support Services Keeping you going is an IRD Mechanalysis commitment
10. 1 1 Purpose and scope of manual Getting you Started DESCRIPTION eee scene cn 2 1 General 2 2 Standard package OPERAIONS a ne 3 1 General 3 2 Preparing the IRD306 for use 3 3 Taking Vibration Measurements 3 4 Measuring Displacement 3 5 Measuring Velocity PLC BION Dias nee ne 4 1 Preventive Maintenance 4 2 Incoming Inspection 4 3 Field Service 4 4 Final Assembly Testing VIBRATION TOLERANCES DOMINANT FREQUENCY BALANCING a a eer FIELD MAINTENANCE cccccceeeeeeeeeeeeeeeeeeeeee 8 1 Operation Test of Batteries 8 2 Operational Test of Sensor Sensor Cable and Meter Circuit CALIBRATION 25 seoncan a serie ccanconcaama 9 1 Sensor Sensitivity 9 2 IRD306 Calibration Procedure 9 3 Sensor Calibration SPECIFICA TONS asarin ea 10 1 IRD306 Vibration Meter Velocity Sensor 10 2 IRD544 Inductive Velocity Sensor Portable Measurement IRD544 condition management solutions IRD Mec hanalysis Lid es 11 a 13 a 16 de 17 sn 20 III IRD306 Manual V4 Aug14 IRD Mec hanalysis Lid TABLE OF CONTENTS Continued SNo Chapter description Page Number Keeping you Going 11 SUPPORT SERVICES eee mms 22 Taking you Further 12 VIBRATION BASED CONDITION MONITORING 26 SOLUTIONS condition management solutions IV IRD306 Manual V4 Aug14 IRD Mec hanalysis Lid MANUAL MODIFICATION NOTE Applicable on
11. D Mec hanalysis Lid 4 APPLICATIONS 4 1 Preventive Maintenance data sheet The most useful application of the Vibration Meter is making periodic vibration checks for preventive maintenance purpose Many companies rely on the detection of a vibration increase as an early symptom of wear or mechanical trouble By detecting such a condition early repairs can be scheduled at a convenient time Thus maintenance costs and down time are reduced and product spoilage minimized Periodic vibration checks are recorded on a preventive maintenance data sheet like the one shown on Figure 6 T A 52 Ne 7 PERIODIC VIBRATION CHECKS PERIOD WEEKLY LR ET nn VIBRATION TREND CHART AACHINE 2 BOILER FEED PUMP LISP VEL ACCEL l 7 7 A Eou a 4 6 8 LOCATION OWER LEVE DATE ACH IBCH IC HIDCHIEC IFO CC HO etek yee RAGES ee Se aed OPERATING COND NORMAL 1 1410 4 A i al T INITIAL VIB LEVELS pisp JEL ACCEL A mo o e SY A dE C ID EI H HORIZONTAL H 1 19 1 19 1 271112 VERTICAL vV 12 1 11 16 08 AXIAL A 08 08 11 08 S H VIBRATION LIMITS PT D gt MT
12. IRD Mechanalysis Limite 0 The Vibration People gt he IRD306 Vibration Meter Operation amp Maintenance Manual IRD Mec hanalysis Limited 1 5 Marol Co op Ind Estate Ltd Off M Vasanji Road Marol Andheri E Mumbai 400 059 Tel 91 22 2852 2906 Fax 91 22 2852 1814 Email service irdmech com Web www irdmechanalysis com Customer Details Date Purchased IRD Serial Number s P O ref Organization End User Sensor Calibration Due IRD Mec hanalysis Lid IRD Mechanalysis Limited www irdmechanalysis com IRD Mechanalysis Limited continues to be the industry leading provider of Condition Management Solutions With over 35 years experience in machinery vibration and associated condition monitoring technologies the company designs and manufactures proven instrumentation suitable for rugged industrial environments A comprehensive range of products and services are available from the offices below Sagar Deep Plot No 11 LSC Saini Tel 91 011 22373916 Delhi Enclave Vikas Marg New Delhi Fax 91 011 22370778 110092 Email mailto salesNR irdmech com Tel 91 033 23559214 Kolkata 12 nd Floor VIP Road Fax 91 033 23559214 Kolkata 700 054 Se sce ests Email mailto salesER irdmech com 1 5 Marol Co op Industrial Estate Ltd Off Mathuradas Vasanji Road rer A UAE 28922906 Fax 91 022 28521814 Marol Andheri East i a Email mailto sales2
13. Product support is an essential aspect of any progressive business IRD Mechanalysis Limited is no exception the company has been supporting IRD s products for the past 35 years Indeed the acceptance and usage of these products by industry is directly attributed to the dedicated support IRD has provided IRD continues to invest in Customer Support Just keeping you going is not enough we have facilities to ensure systems match world standards Our instruments and systems are calibrated to National Standards IRD National Service Centre The very nature of industrial electronic instruments both portable and permanent demands regular calibration From time to time it becomes necessary to repair of damaged items such as cables sensors power supplies and occasionally electronic circuitry etc Mechanalysis is well equipped for such eventualities When equipment is in need of repair a reliable repair centre that is responsive convenient and cost effective is required Mechanalysis India Ltd offers in house as well as site calibration traceable to National Standards and repair services This also covers our partner s product range IRD also supports many obsolete products where components are still available or have been indigenised As the original equipment manufacturer OEM we are the most knowledgeable and the qualified to service our products Supported by more than 50 combined years of technical service experience our
14. anagement solutions 13 IRD306 Manual V4 Aug14 VI VII IRD Mec hanalysis Lid Draw a circle with a radius representing the original unbalance vector in micrometers Then draw a line vertically through the centre of the circle that intersects the circle The intersection at the top is point A at the bottom is Point B See figure 9A Using the same scale draw an arc with a radius equal to the vibration reading T1 The centre of the arc is at point A See figure 9B Using the same scale draw an arc with a radius equal to the vibration reading T2 The centre of the arc is at point B See figure 9C Note that arcs T1 and T2 intersect in two places Draw a line from the centre of the circle to one of the intersections of the two arcs Using the same scale measure the length of the line in microns Call this value R See Figure 9D To determine the correct weight to balance the part multiply O in micrometers by trial weight TW and divide by the resultant in micrometres Balance Weight O X TW R To determine the angular location for the balance weight measure with a protractor the angle between line A B and line R Call this angle M See Figure 9E Note The actual spot to attach the balance weight is either clockwise or counter clockwise An angle equal to the measure angle M from the spot where the trial weight was added for reading T1 Place the balance weight calculated in step V on the part at the measured angle M
15. clockwise from the spot where the trial weight was first added to obtain reading T1 If the vibration reading is not acceptable move the weight to spot M degrees counter clockwise from the spot where the trial weight was added to obtain T1 DATA Original unbalance O 100 Microns Trial Weight TW 70 Grams First Trial Wt Run TW 125 Microns Second Trial Wt run TW 125 Microns condition management solutions 14 IRD306 Manual V4 Aug14 IRD Mec hanalysis Lid 9E Figure 9 Step by step balancing Vector diagram construction condition management solutions 15 IRD306 Manual V4 Aug14 IRD Mec hanalysis Lid 8 FIELD MAINTENANCE Field Maintenance of model IRD306 Vibration Meter is limited to malfunctions which can be located and corrected without the use of electronic test equipment Simple test and correction procedures are provided in the operation test below If these tests reveal electronic trouble the Vibration Meter sensor and sensor cable should be returned to the IRD Works for repair and calibration If calibration equipment is available for the instrument calibration procedure is provided in the next chapter Prepare the IRD306 for taking vibration measurements as described in Chapter 3 The following tests will help determine if all segments of the instrument are performing their proper functions 8 1 OPERATION TEST OF BATTERIES The first position clockwise from the OFF position on
16. dition management solutions 3 IRD306 Manual V4 Aug14 IRD Mec hanalysis Lid Figure 4 IRD306 Standard accessories Standard Accessories Qty Part Number P N Inductive velocity sensor model IRD544 1 M45260 42 5mV mm sec top connector Cable Assembly for model IRD306 306C to IRD544 M24820 En Velocity Sensor 1 2m 4ft rubber insulated shielded Straight Probe for Sensor M11030 M50120 Carrying Case Battery Set 2 Nos of 9V 100mAH Dry Cells M30642 1 M43080 Manual Operating 1 The optional accessories are listed below Optional Accessories Part Number P N Magnetic Holder for model IRD544 Sensor M43320 Shaft stick for sensor model IRD544 IRD511 IRD521 M24750 IRD531 Magnetic Shield for IRD544 Sensor M60017 Manual Training IRD Mechanalysis Vibration M51001 Technology 1 MVT1 A brief description of the standard accessories is provided below A IRD544 Inductive Velocity Sensor The IRD544 vibration sensor as shown in Figure 5 is a rugged industrial vibration measuring sensor for use with portable measuring instruments In production for over 35 years it continues to be the World s most widely used velocity sensor Indian industry alone has more than 6000 in daily use The model IRD544 is one of the most reliable and environmental resistant sensors in condition management solutions 4 IRD306 Manual V4 Aug14 IRD Mec hanalysis Lid industry today The alum
17. ement Measurement D and multiply by the constant 19 120 The answer will be the Dominant Frequency of Vibration is cycles per minute condition management solutions 11 IRD306 Manual V4 Aug14 IRD Mec hanalysis Lid Dominant Frequency CPM Velocity V millimetres second x 19 120 Metric units Displacement D micrometers For example in Figure 8 if the motor runs at 1 750 RPM and the fan at 2 600 RPM and if measurements taken on the motor are displacement D 47 micrometers and velocity V 6 5 millimetres per second Then the Dominant Frequency is V 6 5 x 19 120 2 644 CPM D 47 2 644 CPM is nearest the fan speed The fan is the dominant part and is causing the largest vibration Generally the dominant frequency will be equal to the rotating speed of the part causing the vibration assuming that the trouble is unbalance In any event the dominant vibration frequency will normally be some multiple of RPM of the part After determining the dominant frequency the type of trouble present may be assumed from the following table Table 2 Dominant machine excitation frequencies and most likely causes DOMINANT FREQUENCY MOST LIKELY TROUBLE Unbalance and or misalignment If axial vibration is large Check for bent shaft or Misalignment 2 X RPM Looseness misalignment 3XRPM Misalignment Many times RPM Bad roller or ball bearings or gears Less than 1XRPM Oil whirl Less than 2 RPM Synchronous AC Line Electrical probl
18. ems frequency 2X Synch Frequency Torque pulses Bad gears Aerodynamic forces Hydraulic forces Mechanical looseness Reciprocating forces Many times RPM Harmonically related High frequency Not harmonically related Bad antifriction bearings Note This table is just a guideline for root cause analysis of a machine problem There are many other causes of vibration not listed To pinpoint all but the simplest requires a thorough analysis and interpretation of the vibration patterns of a machine using an IRD Vibration Analyser condition management solutions 12 IRD306 Manual V4 Aug14 IRD Mec hanalysis Lid 7 BALANCING In situ balancing is a routine procedure accomplished quickly and accurately with any IRD Vibration Analyser With its tuneable filter rejecting all other vibrations only the one from unbalance is shown on the amplitude meter simultaneously the strobe light fires on the component part to visually pinpoint the location of unbalance When an IRD Vibration Analyser is not available or it is impossible to use a strobe light the model IRD306 can be used for single plane balancing under the following conditions 1 UNBALANCE MUST BE THE MAIN CAUSE OF VIBRATION Check to see if other causes of vibration such as misalignment of couplings or bearings bent shaft bad antifriction bearings bad gears mechanical looseness etc are present 2 VIBRATION MEASUREMENTS MUST BE STEADY The meter reading must not
19. fluctuate or slowly drift up or down scale more than about 10 of range selected 3 THE DOMINANT FREQUENCY OF VIBRATION MUST BE THE SAME AS THE RPM OF PART BEING BALANCED Dominant Frequency CPM Velocity V millimetres second x 19 120 Displacement D micrometers If all three of the above conditions can be satisfied use the following PROCEDURES FOR SINGLE PLANE BALANCING Step1 With the sensor survey the part to be balanced for a point of maximum vibration Step2 Attach the sensor if possible at the point of maximum amplitude If the sensor is hand held make sure it is applied at the same point and in the same direction for all readings Step3 Measure and record the original unbalance vibration Call this reading 0 Step4 Choose a trial weight Carefully weigh and record the trial weight TW Step5 Add the trial weight at any location on the part to be balanced and run the machine Measure and record the vibration Call this reading T1 Step6 Move the trial weight to another location 180 from the first spot and at the same radius Run the machine Measure and record the vibration Call this reading T2 Step7 With the above data the amount of weight and the angular position necessary to balance the part may be determined A sheet of paper a ruler protractor and compass are required The sequence of steps is outlined below and the vector diagram drawn in the process is shown in Figure 9 condition m
20. ific frequency of vibration while velocity readings may be used regardless of the frequency Table 1 Tentative guide to vibration tolerances for machine tools Displacement of vibration as read Type of machine with pickup spindle bearing housing in the direction of cut Grinders Tolerance Range Thread Grinder 0 25 1 5 microns Profile or contour Grinder 0 75 2 0 microns Cylindrical Grinder 0 75 2 5 microns Surface Grinder Vertical Reading 0 75 5 0 microns Gardner or Besly type 1 25 5 0 microns Centre less 1 0 2 5 microns Boring Mill 1 5 2 5 microns Lathe 5 0 2 5 microns Note These values come from the experience of IRD MECHANALYSIS personnel who have been trouble shooting machine tools for over 10 years with the IRD MECHANALYSIS equipment They merely indicate the range in which satisfactory parts have been produced and will vary depending upon size and finish tolerance condition management solutions 9 IRD306 Manual V4 Aug14 Vibration Displacement Microns Peak to Peak IRD Mec hanalysis Lid GENERAL MACHINERY VIBRATION SEVERITY CHART METRIC Vibration Velocity mm sec Peak 5 Mechanalyss India Ltd Figure 7 The IRD General Machinery Vibration Severity Chart Metric condition management solutions 10 IRD306 Manual V4 Aug14 IRD Mec hanalysis Lid 6 DOMINANT FREQUENCY It is sometimes useful to know the Dominant
21. inium housing is waterproof dustproof and acceptable for use in Division 2 hazardous areas and operates up to 260 C Figure 5 IRD544 Inductive Velocity Sensor The inductive velocity transducer operates with a moving coil in a permanent magnetic field with eddy current damping It is suitable for a wide variety of manual and continuous monitoring applications due to its high output low impedance good frequency response and high operating temperature The sensor connects to the IRD306 meter through the assembled Sensor Cable to an IRD socket on the top end of the instrument Once a sensor is plugged in turn the meter ON and agitate the sensor to ensure the system is operating properly Note That without a sensor connected a residual reading might be shown due to stray Sensor B IRD544 SENSOR CABLE 1 21 M 2 NOS The sensor cable connects the VIBRATION SENSOR to the INPUT RECEPTACLE of the instrument Belden 8401 cable and MS 3106A 10SL 4S Amphenol connectors are used C STRAIGHT PROBE The Straight Probe is provided to reach out of the way places and is screwed into the end of the IRD544 sensor with the 14 28 UNF x 3 16 stud D Battery Set 2 Nos of 9V 100mAH Dry Cells E CARRYING CASE Not shown The CARRYING CASE is a rugged and reliable case having storage provisions for the instrument and all its standard accessories condition management solutions 5 IRD306 Manual V4 Aug14 IRD Mec hanalysi
22. ity sensor is an industrial vibration measuring device for use with portable instruments and rotor balancing It is environmental friendly generating its own power with high sensitivity outout and suitable for a wide variety of machinery types especially where displacement is important The sensor is sealed to IP65 approved for use in Class 1 Div 2 hazardous areas and operates up to 260 C In production for over 45 years it continues to be one of the World s most widely used velocity sensors Calibrated to traceable National Standards the sensor is supplied with a full frequency calibration test certificate It can be fully serviced only at the IRD Mechanalysis National Service Centre BILL OF MATERIALS Qty Part Number IRD544 Inductive Velocity Sensor 1 M45260 Optional Accessories Magnetic Portable Base model IRD544 Sensor recommended for routine portable measurements 1 M24823 Magnetic deflecting shroud reduces AC magnetic field by 100 1 1 M24825 Straight cable 1 2m rubber insulated shielded Mil to Mil Connectors for operation at 121 C 1 M24820 Dimensions amp Connections M16 Threads Se i a Se SENSITIVE AXIS A _ Liza b 28 une 190 5 55 69 Minimum Clearance Technical Performance Frequency Response 14 to 1 0
23. ly for model IRD306 bearing Serial Number 7 with Suffix C The model IRD306C now uses Nickel Cadmium batteries capable of charge discharge cycles in normal operation To obtain optimum performance and battery life the following care should be taken 1 Maintain batteries fully charged and avoid complete discharge 2 Recharge after each use and before storing 3 Recharge once each month even if the Vibration Meter has not been used 4 Recharge 14 18 hrs if Amplitude meter reads less than 0 8 on 0 1 scale condition management solutions V IRD306 Manual V4 Aug14 1 INTRODUCTION 1 1 Purpose amp Scope of Manual This instruction manual describes the IRD Mechanalysis model IRD306 Vibration Meter Velocity Sensor Also included in this manual are complete instructions on the preparation setup and operation of this instrument Specifications of the IRD306 meter and the standard accessories are provided in the subsequent chapters Information on the significance of the measured vibration amplitude levels in displacement velocity and acceleration are provided in the guideline severity charts attached at the end of the manual Condition in a machine that eventually causes breakdown and unnecessary repairs can be detected early by periodic vibration checks Figure 1 ie te if s re p i Figure 1 Periodic vibration checks can avoid costly machine breakdown This growth in the severity of mechanical deteri
24. n increase that may mean trouble is present or for comparison with previously established standards condition management solutions 6 IRD306 Manual V4 Aug14 IRD Mec hanalysis Lid 3 4 MEASURING DISPLACEMENT Vibration can be measured in terms of how far the part moves back and forth This is called the peak to peak displacement or simply the displacement The model IRD306 measures this displacement in micrometers One micrometer equals one thousandth of a millimetre 3 5 MEASURING VELOCITY The model IRD306 can also measure the vibration in terms of how fast the part moves This is called the peak velocity and is measured in millimetres per second Because velocity is a function of both displacement and frequency it provides an added sensitivity to high frequency vibrations For instance a vibration displacement of 10 micrometers results in the same meter reading when the frequency is 1800 CPM as it does at 18 000 CPM The corresponding vibration velocity is 1 0 mm sec at 1800 CPM but at 18 000 CPM the velocity is ten times as large i e 10mm sec This means that small vibration occurring at high frequency is easier to detect if velocity measurements are used Since machine faults such as bad bearings and gears cause vibration at high frequency velocity measurements are extremely valuable Displacement or velocity measurements are selected by the Displacement Velocity Selector condition management solutions IRD306 Manual V4 Aug14 IR
25. ng Hold the sensor perpendicular to the shaft of the machine Axial measurements are taken with the long axis of the sensor on the bearing housing parallel to the shaft centreline Starting at the least sensitive full scale range turn the Amplitude Range Selector clockwise to each position until a reading of at least 1 3 full scale is obtained on the Amplitude Meter This reading is the overall vibration at the point where the sensor is applied The meter has two sets of graduations or scales the top scale from 0 to 1 the bottom scale from 0 to 3 The setting of the Amplitude Range Selector determines which scale applies If the setting is 1000 100 or 10 use the top scale while reading the meter Placing the decimal point as indicated by the Amplitude Range selected Thus on the 100 setting full scale on the meter becomes 100 micrometers or 100 mm per second 0 6 on the meter becomes 60 micrometers or 60 mm per second If the Amplitude Range Selector is set on 3000 300 30 or 3 use the bottom scale placing the decimal point in the same way The indications are in micrometers displacement or millimetres per second velocity depending on the position of the Displacement Velocity Selector Vibration measurements taken with the model IRD306 are overall vibration readings Overall readings are the vector sum of all the vibrations at the point the sensor is applied Overall vibration readings are used for comparison with previous readings to detect a
26. no responsibility for the operation of instruments repaired or calibrated outside IRD or at an unauthorized service centre The following test equipment is required 1 Multi meter 2 Signal Generator 3 Frequency Counter 9 1 SENSOR SENSITIVITY On IRD544 Inductive Velocity Sensors with serial number prefix C or later the last three figures will be the milli volt level used for calibration of both Displacement and Velocity at 100 cps On IRD544 Sensors which have a calibration sensitivity label applied the noted sensitivity will be the milli volt level used for calibration of both Displacement and Velocity at 100 cps On sensors that do not have the sensitivity noted the sensitivity can be obtained by contacting IRD Mechanalysis Ltd State Sensor serial number and model number or if extreme accuracy is not needed 240 mV can be used This figure represents the model IRD544 s output at 100HZz at a 1 mil shake 314 in sec at 100 Hz 10 9 2 IRD306 CALIBRATION PROCEDURE The procedure for calibrating the model IRD306 is as follows 1 With the instrument turned OFF Zero the AMPLITUDE meter using the small adjusting screw located on the front face 2 Switch the AMPLITUDE SWITCH to TEST Meter should read between 0 8 and slightly off scale If not replace batteries 3 Turn the AMPLITUDE RANGE switch to the 30 position Turn the Disp Vel switch to Disp 4 Apply a signal to the input connector See Figure 10 5 Adju
27. ontact Name Telephone Mobile a U x z Email Users Name Designation Signature NSC RMA NUMBER ISSUED RMA condition management solutions 24 IRD306 Manual V4 Aug14 IRD Mec hanalysis Lid Taking you Further 12 Vibration Based Condition Monitoring Solutions IRD Mec hanalysis Ltd is a leading provider of condition management solutions with over 30 years experience in machinery vibration measurement IRD is credited with pioneering the concept of vibration based condition monitoring programmes in India With the advent of computerisation IRD has established and maintained over 250 automated vibration based CM systems and has a user base of over 2200 major Producers and OEMs in India IRD will continue to introduce new technologies to match your needs and reduce the cost of Condition Management IRD is now rapidly expanding its International Export Division globally We take you further by providing reliable easy to use rugged and a comprehensive range of vibration monitoring products amp solutions as depicted in the chart below that enables you to enhance your productivity and investment We look forward to your continued support and patronage CONDITION SERVICE TRAINING CALIBRATION MONITORING SOLUTIONS CONSULTANCY COMMISSIONING OFF LINE METERS FFT ANALYSER Overall Volume Vibration Levels Data Collector Sound amp Noise Two Channel Level Vibration Analyser 2 Plane Balancing
28. oration in a machine could be revealed by increase in vibration levels The portable self powered model IRD306 Vibration Meter Velocity Sensor provides the consistent means for making these important measurements This vibration meter measures machinery vibration in terms of Displacement microns and Velocity mm sec covering most machinery faults This rugged and proven portable vibration meter has been in use worldwide for over 30 years Over this time its circuitry has been enhanced to ensure stability accuracy and the highest reliability condition management solutions 1 IRD306 Manual V4 Aug14 IRD Mec hanalysis Lid Getting you Started 2 DESCRIPTION 2 1 General Thank you for investing in this IRD Mechanalysis Vibration Meter We trust that like many thousands of users before you will continue to enjoy optimum value from your wise investment IRD Mechanalysis Limited IRD is an independent System Integration Company that designs and manufactures condition monitoring system solutions The battery operated model IRD306 Vibration Meter Velocity Sensor uses the latest proven solid state circuitry to provide accurate measurement vibration over the frequency range of 300 to 240 000 CPM j Figure 2 Front view of IRD306 Vibration Meter Velocity Sensor All of the controls of the instrument are on the front panel and are shown in Figure 2 Brief description is as follows a Amplitude Meter The AMPLITUDE METER indicates
29. s Balancing Systems 245 246 dataPAC and Fast Track are trademarks or registered trademarks of IRD Mechanalysis Turnaround time and repair capabilities are dependent upon condition of equipment and spare parts availability at the time of the product assessment How the National Service Centre Optimises Clients Investments Annual Maintenance and Calibration ensures years of trouble free operation to maximize the investment in your condition monitoring equipment A complete in house supply of spare parts assures quick turnaround for product repairs State of the art Sensor Calibration automatically over the full frequency range traceable and up to date to National Standards of the UK IRD Mechanalysis Ltd ISO 9002 certification guarantees quality repairs and service Our highly qualified Repair Centre technicians supported by more than 50 combined years of technical service experience give you the best available service and results As the only authorized service centre for IRD Mechanalysis Ltd Products our National Service Centre provide the most knowledgeable experienced and committed support for all of our products We offer a IRD Product Exchange Programme Fixed Price Repair or Standard Repair and Calibration Only Services the applicable warranty benefits are given below condition management solutions 22 IRD306 Manual V4 Aug14 IRD Mec hanalysis Lid Service Options amp Process RMA issued Instrument arrives
30. s Lid 3 OPERATIONS 3 1 GENERAL One purpose of the Vibration Meter is to measure machinery vibration for comparison with vibration standards When the vibration shows an increase or exceeds allowable limits then trouble is present Since vibration is usually the result of troubles such as unbalance misalignment looseness or bad bearings the logical place to put the sensor for vibration measurement is on each bearing housing of the machine or if a bearing housing is not accessible and then put the sensor on the machine structure nearby 3 2 PREPARING IRD306 FOR USE 1 Screw the straight probe into the model IRD544 Vibration Sensor 2 Connect one end of the sensor cable to the sensor and the other to the IRD306 sensor input receptacle 3 Test the batteries Turn the amplitude range selector to test position This turns the instrument on Displacement Velocity Selector may be in either position Good batteries read 0 8 or above on the O to 1 scale of the Amplitude Meter Refer to the Field Maintenance Section for further information on batteries Approximately 10 seconds are required for warm up after turning the instrument on After that time the unit is ready for use 3 3 TAKING VIBRATION MEASUREMENTS Place the vibration sensor on the machine in the vertical horizontal and axial position at each bearing point The sensor should be held firmly against the machine with just enough pressure to prevent the straight probe from chatteri
31. st the oscillator output to the sensor output sensitivity The Amplitude Meter should now read 25 4 on the 30 micron scale If it does not disassemble the instrument and adjust the GAIN CALIBRATE R1 CONTROL until a 25 4 reading is obtained 7 Place the Disp Vel selector switch to Vel position and amplitude range switch to 10 range With same signal input Step 5 adjust the VELOCITY CALIBRATE CONTROL R2 for a reading of 0 8 on the 0 10 micron scale condition management solutions 17 IRD306 Manual V4 Aug14 IRD Mec hanalysis Lid MULTI METER SIGNAL GENERATOR 9 3 SENSOR CALIBRATION The calibration of the IRD544 sensor can be done at the state of the art Calibration Lab at IRD Works Mumbai Figure 11 o P hes P ALLA lt Mechanalysis WP _ Figure 11 IRD Vibration Sensor Calibration Lab This Lab has a state of the art TransCal system supplied by Beran Instruments UK It is an automatic digital full frequency sensor calibration system It undertakes calibration of a sensor throughout its frequency range The master reference sensor is traceable to National Standards Calibration Certificates are generated and stored for each sensor tested IRD has constructed an environmentally controlled Lab for all sensor calibration tests This service could be availed by all users irrespective of sensor manufacturer Further de
32. tails could be obtained from the IRD regional office or IRD Mumbai office condition management solutions 18 IRD306 Manual V4 Aug14 IRD Mec hanalysis Lid 10 SPECIFICATION 10 1 IRD306 Vibration Meter Velocity Sensor Part Number M30601 The IRD Mechanalysis model IRD306 vibration meter measures industrial machinery vibration in terms of Displacement microns and Velocity mm sec covering most machinery faults This rugged and proven portable vibration meter has been in use worldwide for over 45 years Over this time its circuitry has been enhanced to ensure stability accuracy and the highest reliability Supplied with the high temperature IRD544 inductive velocity sensor it can also be used for balancing machine rotors applying the Three Point Balancing Method BILL OF MATERIALS Qty Part Number P N IRD306 Vibration Meter Velocity Sensor 1 M30601 42 5mV mm sec top connector Cable Assembly for model IRD306 306C to IRD544 M24820 Velocity Sensor 1 2m 4ft rubber insulated shielded Magnetic Portable Base model IRD544 Sensor M24823 Stinger Al 225mm long for Sensor M24827 Vibration Meter Carrying Case for model IRD306 IRD306C M25349 Battery Set 2 Nos of 9V 100mAH Dry Cells M30642 Manual Operating M43080 a ee DE Optional Accessories Part Number P N Shaft Fish Tail Stick Absolute Vibration for IRD544 M24824 Magnetic Deflecting Shroud for IRD544 Sensor M24825 M51001
33. tantial meter reading is obtained The amount shown on the meter depends on the amount of stray electrical energy in the area the test is being made The meter will indicate higher if the test is being made close to a florescent light fixture Conversely the meter may not indicate at all if the test is made in an open field with no power lines close by The meter should indicate zero when the other end of the test wire is inserted into pin A of the sensor receptacle If it does not then the Sensor is probably inoperative lf the preceding tests are made close to an operating florescent light fixture and no meter indication is obtained disconnect the Sensor Cable from the meter Set the Amplitude Range Selector to the 3 Position Touch pin B of the sensor receptacle with the end of the Test Wire If the Meter indicates and goes to 0 when the other end of the test wire is touched to pin A Suspect The Sensor is probably inoperative If the test is made close to a florescent light fixture and no meter indication is obtained Suspect The meter circuit is probably not functioning condition management solutions 16 IRD306 Manual V4 Aug14 IRD Mec hanalysis Lid 9 CALIBRATION The calibration procedure described herein is supplied for the customer information No attempt to disassemble or calibrate the unit should be made except by an experienced qualified technician using the proper test equipment IRD Mechanalysis assumes
34. the amplitude range switch is the battery test position Good batteries show 0 8 or above reading on the 0 1 scale the upper scale only is used for battery test When the meter indication is below 0 8 in the TEST position replace batteries To gain access to the batteries remove the four screws located on the rear of the instrument The case containing the batteries will separate from the bezel containing the meter switches and printed circuit board Separate the case and bezel carefully Do not damage the interconnector wiring Observe the polarity of both replacement batteries 8 2 OPERATION TEST OF SENSOR SENSOR CABLE AND METER CIRCUIT Set the amplitude range selector to TEST Meter should indicate 0 8 or above If a reading below 0 8 is obtained see operational test of batteries above Place the Amplitude Range Selector in the 3000 position and Velocity Displacement Selector in the Disp position Grasp the Sensor in the hand and shake it back and forth A large amount of movement is not necessary A short fast shake will give better results The Amplitude Meter will register more than full scale and the Sensor Sensor Cable and Meter Circuit are operational If not disconnect the Sensor from the Sensor Cable turn the Amplitude Range to 3 and insert the end of a piece of insulated wire which is several feet long into the B contact of the Sensor Cable connector Turn the Amplitude Range Selector clockwise until a subs
35. the peak to peak Displacement or peak Velocity of vibration The METER has two scales O to 1 0 and O to 3 0 The scale used to read the vibration amplitude is determined by the position of the AMPLITUDE RANGE SELECTOR condition management solutions 2 IRD306 Manual V4 Aug14 IRD Mec hanalysis Lid Displacement velocity selector Either the Displacement or Velocity of the vibration may be chosen for measurement Displacement is indicated on the Meter in micrometers Velocity is indicated in millimetres per second pk c Amplitude range selector The AMPLITUDE RANGE SELECTOR determines the full scale meter range Full scale amplitudes from 3 to 3000 Micro meters or millimetres per second are covered in seven ranges 0 to 3 0 to 10 O to 30 O to 100 O to 300 O to 1000 and O to 3000 Positions marked 3000 300 30 and 3 are used with the bottom meter scale 0 to 3 0 Positions marked 1000 100 and 10 are used with the top meter scale 0 to 1 0 Each position indicates the full scale range of the meter for that setting D Vibration sensor receptacle The vibration sensor receptacle receives the connector on the Sensor cable from the vibration sensor 2 2 Standard package The standard package for the vibration meter is shown in Figure 3 The standard accessories which come along with the meter is depicted in Figure 4 and listed in the table that follows Figure 3 IRD306 Vibration Meter Velocity Sensor standard package con
Download Pdf Manuals
Related Search