Examiner 1000 Instruction Manual (English)
Contents
1. 3 MONARCH INSTRUMENT Instruction Manual EXAMINER 1000 Vibration Meter Electronic Stethoscope 15 Columbia Drive Amherst NH 03031 USA Printed in the U S A Phone 603 883 3390 Copyright 2008 Monarch Instrument all rights reserved Fax 603 886 3300 E mail support monarchinstrument com 1071 4400 114R jane Website www monarchinstrument com Use the chart below as a guide to judge the overall vibration severity of your equipment AN Safeguards and Precautions Refer to page 12 for further details VIBRATION SEVERITY PER ISO 10816 1 1 Read and follow all instructions in this manual carefully and retain this manual for future reference 2 Do not use this instrument in any manner inconsistent with these operating instructions or under any conditions that exceed the environmental specifications stated 3 This instrumentis not user serviceable For technical assistance contact the sales organization from which you purchased the product or Monarch Instrument directly In order to comply with EU Directive 2002 96 EC on Waste Electrical and Electronic Equipment WEEE This product may contain material which could be hazardous to human health and the environment DO NOT DISPOSE of this product as unsorted municipal waste This product needs to be RECYCLED in accordance with local regulations contact your local authorities for more information This product may be returnable to your distributor for recycling2. and how fast Lubrication analysis is the earliest warning of a developing problem Lube oil testing results can be trended with On Time software What are you Measuring Vibration is the behavior of a machine s mechanical components as they react to internal or external forces Since most rotating machinery problems show themselves as excessive vibration we use vibration signals as an indication of a machine s mechanical condition Also each mechanical problem or defect generates vibration in its own unique way We therefore analyze the type of vibration to identify its cause and take appropriate repair action With overall vibration monitoring VIB ISO using the Examiner 1000 analysis of the cause of excess vibration relates to the monitoring equipment s probe position either horizontal vertical or axial Horizontal Typically unbalanced shafts tend to cause excess radial horizontal and vertical vibrations depending on the machine support design Vertical Excessive vertical vibration can indicate mechanical looseness as well as imbalance Axial Excessive axial vibration is a strong indicator of misalignment It s important to note that these are general guidelines and that knowledge of your machinery and proper hand held probe techniques are necessary to accurately analyze the cause of excessive vibration Multi Parameter Monitoring Using different measurement types to monitor your machinery for changes This
3. allows for early detection of specific machinery problems that may not show under normal overall vibration monitoring For example ifa rolling element bearing has a defect on its outer race each roller will strike the defect as it goes by and cause a small repetitive vibration signal However this vibration signal is of such low amplitude that under normal overall vibration monitoring it is lost in the machine s rotational and structural vibration signals Acceleration Enveloping can measure these signals better than overall readings Use both measurement types for bearings and gearboxes As ENV values begin to decrease rely on VEL readings Overall Vibration Monitoring Monitors normal low frequency machine vibration Detects rotational and structural problems like imbalance misalignment and mechanical looseness Enveloping Amplifies high frequency repetitive bearing and gear mesh vibration signals for early detection of bearing problems but does not detect non repetitive rotational or structural events like imbalance misalignment and looseness Provides earliest detection of high frequency metal to metal contact or poor lubrication in problem bearings Establishing a Data Collection Route The Machinery Data Worksheet helps organize data for routine data collection Vibration readings are taken on the Points bearings established in your route and recorded using your naming convention on the worksheet Vibration speed tempe
4. information from machines as they operate to aid in making decisions about their health repair and possible improvements in order to reach maximum runability before any unplanned break down Machinery maintenance has evolved because of the demands to become more profitable through reduced maintenance costs Below is the progression of these maintenance philosophies e Break Down Maintenance e Preventive Maintenance e Predictive Maintenance Break Down Maintenance occurs when repair action is not taken on a problem until the problem results in the machines failure Run to failure problems often cause costly secondary damage along with expenses resulting from unplanned downtime and unplanned maintenance Preventive Maintenance occurs when a machine or parts of a machine are overhauled on a regular basis regardless of the condition of the parts While better than run to failure preventive maintenance results in excessive downtime due to unnecessary overhauls and the excessive costs of replacing good parts along with worn parts Predictive Maintenance is the process of determining the condition of machinery as it operates to predict and schedule the most efficient repair of problem components prior to failure Predictive Maintenance not only helps plant personnel eliminate unplanned downtime and the possibility of catastrophic failure but allows them effectively order parts schedule manpower and plan multiple repairs during scheduled downt
5. machinery the sensor s angle to the machinery and the contact pressure with which the sensor is held on the machinery e Location always collect at the same point on the machine Mark locations e Position Vibration should be measured in three directions A axial direction H horizontal direction V vertical direction e Angle Always perpendicular to the surface 90 10 e Pressure Even consistent hand pressure must be used firm but not so firm as to dampen the vibration signal For best results use the magnetic base If using the stinger probe is the only method available to collect data it is best to use a punch to mark the location for the probe tip to ensure a consistent coupling to the housing Optimum Measurement Conditions Perform measurements with the machine operating under normal conditions For example when the rotor housing and main bearings have reached their normal steady operating temperatures and with the machine running under its normal rated condition for example at rated voltage flow pressure and load On machines with varying speeds or loads perform measurements at all extreme rating conditions in addition to selected conditions within these limits The maximum measured value represents the vibration severity Stinger Mounted Vibration Sensor Magnetically Mounted Vibration Sensor load zone What Is Predictive Maintenance Predictive Maintenance can be defined as collecting
6. time Analyzing these along with other measurements provide insight into the condition of the machine and which components may be wearing or failing How to best monitor a machine s condition requires one to know which measurements to take and where and how to take them Sensors are placed at strategic Points on the machinery to monitor the machine s condition The EXAMINER 1000 processes the accelerometer s mechanical vibration energy into an electrical signal and displays the measurement value in numerical form for evaluation Commonly measured physical characteristics in Predictive Maintenance are e Vibration as explained above e Temperature e Oil Analysis Temperature As a bearing fails friction causes its temperature or its lubricant s temperature to rise While trending a bearing if the temperature rises followed by a vibration increase then it is safe to conclude their was a loss of lubrication which induced the mechanical failure If vibration increased first followed by increased temperature readings then a mechanical defect caused the lubrication failure Lube Oil Analysis Ferrography Monitoring oil condition warns of an increase in foreign substances such as water which can degrade the lubricating properties of the oil and cause bearing failures It also detects the presence of metallic particles carried into the oil stream These metallic particles are analyzed to determine which part of the machine is wearing
7. velocity Mass The measure of body resistance to acceleration Proportional to but not equal to weight mass weight gravity Measurement Point A location on a machine or component where all subsequent measurements should be made for accurate comparison Mechanical Impedance Ratio of applied force to resulting velocity during simple harmonic excitation The amplitude of vibration within a specified frequency range The absolute value zero to the maximum excursion on a dynamic waveform Also true peak and zero to peak Accelerometer Amplitude Frequency Integration Overall Peak Value Periodic Monitoring Measurements recorded at intervals of time Trend Comparison The most efficient and reliable method of evaluating vibration severity is to compare the most recent reading against previous readings for the same measurement Point allowing you to see how the Point s vibration values are trending over time This trend comparison between present and past readings is easier to analyze when the values are plotted in a trend plot A trend plot displays current and past values plotted over time Measurement records should also include a baseline known good reading The baseline value may be acquired after an overhaul or when other indicators show that the machine is running well Subsequent measurements are compared to the baseline to determine machinery changes Comparison with Other Machinery When several simi
8. 6 m sec Acceleration Enveloping A high frequency filtered data collection method expressed in ge A transducer which converts acceleration motion in to an electrical output The magnitude of vibratory motion Can be measured as peak to peak zero to peak or RMS Axial The direction parallel to the axis of rotation Baseline Recorded values taken when a machine is known to be good The standard which all additional readings will be compared to CPM Unit of frequency measurement cycles per minute Displacement A scalar quantity specifying the change of position of a body measured from the resting position Dynamic Force A force that varies with time Force Energy applied to a mass producing a deflection static force or motion dynamic force The repetition rate of a periodic event expressed in cycles per second Hz CPM RPM or multiples of running speed orders g s Units of acceleration referenced against the force of gravity 1g 32 1739 ft sec sec 1g 9 8066 m sec sec Gear Mesh Frequency A frequency generated by a gear Defined as the number of gear teeth on a gear times its shaft rotating frequency Hertz Hz A unit of frequency measurement cycles per second High pass Filter A filter that allows only those components above a selected frequency to pass The time based process of converting acceleration and velocity to velocity or displacement in sec ips Abbreviations for inches per second a measure of
9. call and comparison of events over time but is not a replacement for good maintenance practices Collecting machinery data is an aid to the maintenance professional which is used in addition to good maintenance practices Selecting and Classifying Machinery Setting up an effective Predictive Maintenance Program requires a careful study of the needs of the plant It is necessary to know each machine and its response to change The following is an example of machinery classification CRITICAL ESSENTIAL REDUNDANT Critical Machines expensive premium equipment generally gt 500 HP Usually less than 5 of all plant equipment Maintenance dollars per horsepower per year average 11 00 This category of equipment is very well maintained and monitored Continuous monitoring systems are better suited for this type of equipment Essential Machines medium size equipment 100 500 HP This group may be 30 40 of all the equipment in the plant Maintenance costs can average 22 00 per horsepower per year Less attention is paid to these machines even though their repair costs can be as high as critical machines Select some of these machines for your Predictive Maintenance Program Redundant Machines small redundant equipment usually lt 100 HP This group can be as much as 50 ofall machines in a plant and yet they are usually neglected By far the most expensive to maintain at 49 00 HP year this group will benefit the most from Predictive Ma
10. contact the distributor for details o E gt gt O o gt c 2 Smt i 2 gt Monarch Instrument s Limited Warranty applies See www monarchinstrument com for details Warranty Registration and Extended Warranty coverage available online at www monarchinstrument com EXAMINER 1000 SPECIFICATIONS Vibration Sensor Piezoelectric accelerometer 100 mV g with magnetic base probe and 5 foot cable to BNC Display LCD 3 5 digit measurement hold low battery indicator Measurement Acceleration 0 01 19 99 g RMS Range Velocity 0 01 19 99 in sec 0 1 199 9 mm sec RMS Envelope 0 01 19 99 ge peak Frequency Range Overall 10 Hz 10 kHz Envelope 0 5 kHz 10 kHz Output Sensor Excitation 18 Vdc 2 mA BNC Audio Out 3 5 mm mini plug 250 mW into 8 ohms 150 mW into 32 ohms Adjustable volume control with off position Power 2 AA cells Operating Time 20 hours continuous without headphones Weight Instrument 7 oz 0 19 kg Complete Kit 2 85 Ib 1 30 kg Dimensions 6 3 x 3 3 x 1 25 152 x 83 x 32 mm Operating conditions 14 to 122 F 10 to 50 C O GLOSSARY for vibration purposes Piezoelectric A material in which electrical properties change when subjected to force Process Measurements Variables such as temperature pressure speed and flow used to assess internal conditions of efficiency Radial Direction perpendicular to the shaft centerline Repeatabil
11. e Machinery Data Worksheet allows for record keeping of collected data The EXAMINER may be used with the On Time software to store data and perform trend analysis REPEATABILITY IS REQUIRED FOR ACCURATE TRENDING Establish a standard naming convention so you can communicate your results to the rest of maintenance Vibration readings are taken on the bearing caps or as close to the bearings as possible Always collect data the same way at the same point on the machine each time Vertical Direction for placing the Sensor For Vertical and Horizontal readings the sensor is placed in a radial position Axial Horizontal Also establish a starting point for each machine Begin from the OUTBOARD END of the DRIVE UNIT calling this point A Proceed to label Points bearings as needed until you have reached the outboard end of the driven unit POINT A B C D MOTOR PUMP
12. ecunsnreesesaeinicnntanamnasonceadiarasumoentencusuns 3 Overview of Data Collection Procedure 00 e 3 APPLYING THE EXAMINER 1000 What is Predictive Maintenance ccccceeseeeeeeeeees 4 Benefits of Predictive Maintenance c cceceeeeees 4 Why Measure Vibration 0 c cccccscceessinnenneseencnneeeanccenns 5 Selecting Machinery amp Measurements cccceeeeeeeees 6 Selecting Measurement Types 2 cceeeeesseceneeeeeesenees 7 Getting Started in your Plannt ccscs ccceeeeessseeeeeeeeeees 8 Establishing a Data Collection Route 9 What are you Measuring xxcic sccesasstittiecetaidiccictcdaneteccdiceaats 10 Measurement Techniques 0ecccceecceeeeeeeeeeeeeeeeeeeees 11 Evaluating overall Vibration Measurements 006 12 Evaluating Acceleration Envelope Measurements 13 GLOSSARY ntecrntinireciortiti i aieneienietnlan cana 14 Vibration Severity Chart per ISO 10816 1 l a 16 OPERATING THE EXAMINER 1000 Overview The EXAMINER 1000 is designed to be used with vibration limits established in ISO Standard 10816 to help you detect signs of malfunction or changes in rotating machinery during operation This is accomplished with overall vibration ISO VIB and envelope measurements Problems with bearings occur when there is a microscopic crack or flaw or when there is a breakdown in lubrication which leads to metal to me
13. ese are high frequency low amplitude events and a filter in the EXAMINER 1000 is set at 10 30 kHz to measure them Types of Measurements in the EXAMINER 1000 Velocity Good for frequency ranges 10 2000 Hz 600 120 000 RPM Acceleration used for higher frequencies or speeds above 2000 Hz 120 000 CPM Acceleration Enveloping uses a high pass filter to measure high frequency repetitive bearing and gearmesh vibration signals Used for early detection of developing bearing or lubrication problems Use this type in combination with the other types to detect changes in machinery Select Measurement Intervals Based on the classification of the machine its repair history and the amount of data required for a detailed trend analysis At the beginning of a Predictive Maintenance Program collect data frequently to build a rapid history of each machine Adjust your program as you go If measurement results are indicating signs of change measurements should be performed more frequently Getting Started in Your Plant Planning your work is very important to achieve success The EXAMINER 1000 is an overall vibration meter and electronic stethoscope It can be used as a stand alone device for the collection of vibration data for the purposes of trending or as a diagnostic instrument used to troubleshoot machinery defects In order to setup a trending program you must collect data on the same point with the same measurement type at a defined interval Th
14. ime Benefits of Predictive Maintenance Documented experience proves that plants which establish a predictive maintenance program are able to e Improve Machinery Reliability reduced unplanned failures e Reduce Maintenance Costs knowing the exact problem to fix e Increase Production optimize machinery capabilities e Lower Energy Consumption less vibration usually means less friction e Extend Bearing Service Life reduce vibration and lubrication failures e Improve Product Quality where less vibration improves finish The benefits are numerous and will vary depending upon the implementation of your Predictive Maintenance Program O Why Measure Vibration Vibration is considered the best operating parameter to judge dynamic conditions such as balance overall vibration bearing defects enveloping and stress applied to components Many machinery problems show themselves as excessive vibration Rotor imbalance misalignment mechanical looseness structural resonance soft foundation and gearmesh defects are some of the defects that can be measured by vibration Measuring the overall vibration of a machine a rotor in relation to a machine or the structure of a machine and comparing the measurement to its normal value norm indicates the current health of the machine The EXAMINER 1000 measures the vibration of a machine while it is operating Trending these measurements shows how a machine s condition changes over a period of
15. intenance practices At many facilities this group consumes 80 of the annual maintenance budget If you want to have an immediate impact begin with these machines Also include machines with known problems or a history of problems Personnel Safety is always the first priority in selecting machinery to monitor Selecting Measurements Establish measurement types that most accurately reflect the condition of the equipment Different causes or mechanisms are acting on the machine various types of measurements have been developed to measure each type of mechanism Those mechanisms are Stress A force on the machine or components which deflects the part Best measured in Displacement The Examiner 1000 does not measure Displacement as it is a very low vibration frequency below 10 Hz 600 RPM Fatigue Repeated cycles of stress on a component If you bend a part back and forth enough times it will fatigue As a general rule fatigue failures result from vibration frequencies 10 2000 Hz and Velocity measurements are used Velocity will be the primary measurement taken Force Mass x acceleration Measured in Acceleration Acceleration is the rate of change of velocity Acceleration is used for high frequencies above 2000 Hz 120 000 RPM Bearing defects and gearmesh frequencies are usually found in this range Impact forces The result of fatigue Impact forces are cyclical events which can be detected with Acceleration Enveloping Th
16. ity A measure of the deviation between successive measurements made under the same conditions RMS Peak Vibration x 707 in s or mm s Rolling Element Bearing A bearing consisting of balls or rollers operating between fixed and rotating races Route A sequence of measurements arranged for convenience during acquisition Sensitivity Used to describe a transducer s electrical output for a unit variation of the mechanical quantity measured Stress Force per unit area Synchronous Frequency components that are an integer multiple of running speed Transducer A system consisting of a sensor and signal conditioner to convert a physical quantity into an output for display monitoring and analysis Transmission Path The path from source excitation to sensor Trending The plot of a variable over time used as an indicator of change Velocity A vector quantity of the time rate change of displacement Vibration Conversions D 19 10 x 10 x VIF D 70 4 x 10 x A F V 52 36 x 10 x DXF V 3 68 x 10 x A f A 14 2 x 10 x D x F A 0 27 x 10 x Vx F where D Displacement mils peak to peak V Velocity in s zero to peak A Acceleration in s zero to peak F Frequency cpm TABLE OF CONTENTS OPERATING THE EXAMINER 1000 OVETVISW er 1 Controls and FUnctions cccccccceceee ceeceeeeeeeeeeeeeeeeeeeees 1 Rear Panel Batteries and Connections cceee 2 Parts of the System evsces
17. lar machines are used under the same operating conditions evaluation can be carried out by measuring all machines at the same Points and comparing the results Evaluating Acceleration Envelope Measurements Use the same techniques of comparison as for Overall Vibration readings Remember acceleration envelope is an advanced early warning of a developing problem High values do not necessarily indicate bearing failure They can also indicate A Lack of lubrication or decreasing oil viscosity due to high bearing temperature caused by overload or external heat source B Breaking of the lubricant film by excessive imbalance misalignment or housing deformation Loss of boundary lubrication C Arubbing seal or cover D Gear mesh interaction bad lubrication defects E Dirt or particles in the lubricant or a seal or filter problem Use trend Comparison similar to overall vibration to establish severity levels Accelerating Envelope readings tend to decrease as Overall Vibrations readings increase This happens when the defect in the bearing is becoming more severe and the frequency it generates becomes lower which makes it better read with the Velocity type readings Audio Comparison with Other Bearings on the Same Machinery When several bearings are used under the same operating conditions evaluation can be carried out by listening to the audio signals to determine changes This method will help to locate the defective bearing quickl
18. rature pressure or any process data may be recorded using this type of systematic approach Steps for Route collection 1 Determine the machines which require data collection 2 Define each measurement type for data collection Points on each Machine Several Points will have numerous readings 1 e VEL and ENV and Temp 3 Establish a Route with the Machines grouped by physical location 4 Walk the Route collecting and recording data for each Point 5 Transfer data values to your On Time Trending software Recording Data for a Machine A B Cc D The vibration sensor is placed on each data collection Point The Point direction of the sensor and the value are recorded on the Machinery Data Worksheet MOTOR PUMP example of Machinery Data Worksheet Point AVV is taken on the outboard end of the motor in the vertical position with a velocity type reading Machine Identification Water Pump 707 Machine Description AC motor 1800 RPM flexible a Ea Te dy Jan 2 1999 0 06 in s Jan21999 A H V__ 0 04 in s Jan 2 1999 0 03 in s Jan21999 B V V__ 0 07 in s Jan21999 B JH V__ 0 05 in s Jan2 1999 B v Env 0 001 as ey ee a O AHV Point A in the horizontal position with a Velocity type Selecting Machinery and Measurements Maintenance personnel have always made visual and hands on inspections of their machinery on a periodic basis Systematic data collection and trending allows for re
19. rksheet 6 To release the HOLD function press ON SELECT again 7 Repeat the above steps for each Measurement Point Evaluating the Overall Vibration Measurements Three general principles are commonly used to evaluate your vibration measurement values ISO 10816 Standard Comparison Compare values to the limits established in the ISO 10816 Standard See Vibration Severity Chart on page 16 Trend Comparison Compare current values with values of Baseline for the same Points over a period of time Comparison with Other Machinery Measure several machines of a similar type under the same conditions and judge the results by mutual comparison If possible you should use all three comparisons to evaluate your machinery s condition ISO 10816 and trend comparisons should always be used ISO 10816 Standard Comparison The ISO 10816 Standards provide guidance for evaluating vibration severity in machines operating in the 10 to 200 Hz 600 to 12 000 RPM frequency range Examples of these types of machines are small direct coupled electric motors and pumps production motors medium motors generators steam and gas turbines turbo compressors turbo pumps and fans Some of these machines can be coupled rigidly or flexibly or connected through gears The axis of the rotating shaft may be horizontal vertical or inclined at any angle Machinery class designations are Class Individual parts of engines and machines integrally connec
20. tal interaction The EXAMINER 1000 is designed to detect flaws or a lack of lubrication in bearings and gears at an early stage by measuring the high frequency impacts through acceleration envelope methods Vibration measurements are made by pressing the accelerometer sensor against designated Measurement Points on your equipment with either the stringer probe or with the magnetic base Controls and Functions ON SELECT Button Press this button to turn power on Power automatically turns off after ten minutes of non use After turning the EXAMINER on press the ON SELECT button again to select the measurement type Pressing and holding the ON SELECT button while collecting data will HOLD the display value indicated by the word HOLD in the display To release from HOLD mode press the ON SELECT button again DISPLAY The digital display shows the numerical value of the measurement An arrow indicates the measurement type selected The units of vibration are automatically displayed as the type of measurement is selected The user may work in either metric or imperial units in the V velocity mode Units of Type of Measurement Measure Type of Indicator Measurement Value of Measurement Low Battery Indicator Hold Reading Indicator GLOSSARY for vibration purposes Acceleration A scalar quantity that specifies time rate of change of velocity Expressed in either g s or m sec where g 386 1 in sec and 9 806
21. ted with the complete machine in its normal operating condition Production electrical motors of up to 20 HP 15 kW are typical examples of machines in this category Class Il Medium sized machines typically electric motors with 20 to 75 HP 15 75 kW without special foundations rigidly mounted engines or machines on special foundations up to 400 HP 300 kW Class Ill Large prime movers and other large machines with rotating masses mounted on rigid and heavy foundations which are relatively stiff in the direction of vibration measurement Class IV Large prime movers and other large machines with rotating masses mounted on foundations which are relatively soft in the direction of vibration measurement for example turbo generator sets especially those with lightweight ub structures Note These ISO 10816 Standard classes do not apply to prime movers or driven equipment in which the major working components have a reciprocating motion 12 Measurement Techniques In general vibration of anti friction bearings is best monitored in the load zone of the bearing Equipment design often limits the ability to collect data in this zone Simply select the measurement Point which gives the best signal Avoid painted surfaces unloaded bearing zones housing splits and structural gaps When measuring vibration with a hand held sensor it is very important to collect consistent readings paying close attention to the sensor s position on the
22. y Measure all machines at the same Points and compare the results Listen for increases in signal and for clicking patterns which indicate wear REAR PANEL CONNECTIONS CONNECTIONS VIBRATION METER ELECTRONIC STETHOSCOPE REFER TO OPERATORS MANUAL FOR INSTRUCTIONS NNECTION QUICK REFERENCE c9 CTIONS INSTRUCTION PANEL SENSOR IN AUDIO OUT V velocity mm s in s J A acceleration g w O E envelope ge gt Y sk Monarch Instrument 5 s 15 Columbia Drive gt 50 Amherst NH 03031 USA PRODUCT SERIAL NUMBER BATTERY COMPARTMENT Contains two AA alkaline batteries TOP VIEW AUDIO OUT 1 8 3 5 mm stereo mini plug SENSOR INPUT BNC Connector output 18 vdc 2 mA Parts of the System EXAMINER 1000 METER ON TIME SOFTWARE AND OWNERS MANUAL optional HEAD PHONES HOLSTER WAKES ACCELEROMETER WITH CABLE MAGNETIC BASE i STINGER PROBE Overview of Data Collection Procedure 1 Press the ON SELECT button 2 Press the ON SELECT button again to select the desired measurement type Place the accelerometer sensor on the machinery Measurement Point use proper probe technique as discussed on the following pages 3 Wait for the reading to stabilize then press and hold the ON SELECT button to HOLD the measurement Indicated by HOLD in the display 4 Adjust headphones volume level and listen for any distinct patterns or noises 5 Record the measurement value in your Machinery Data Wo
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