models mda 100, 200 & 400 bearinglifeguard user manual rev 2.0
Contents
1. User Name Password Re enter Password UserType C Technician C Analyst Engineer Free PDF documentation generator 1 1 Concept of Operations 11 Concept of Operations The bearing lifeguard program uses a database for persistent storage Prior to using the bearing lifeguard application the administrator must select and open the SQLite database Once opened the database tables must be initialized using the SQLite DButility application See Recreate Initialize in Software Installation The program uses 5 database tables to store information these are User Company Assembly Measurement Summary When first using the system and prior to having collected and stored any live data a default database exists with sample assemblies A supervisor may elect to erase any sample test data and start off clean Do this by selecting Table the dialog will destroy all files click on OK Easily create Help documents Setting up Assemblies After installation of DbUtility and BearingLifeGuard software click on DbUtility icon in Start All programs Bearing LifeGuard This brings up the DbUtility menu Select Table Edit Assembly This will bring up one of the assembly screens This confirms that database has been initialized and contains sample assemblies with test data Use the scroll bar to view the sample ID s stored Selecting any of the others will bring up the screens for examination or editing2. CFD Crest factor ratio of peak to rms acceleration where 1 acceptable and 10 early fatique cracking defects KFD Weighted value of Kurtosis acceleration factor where 1 smooth and 10 surface damage heavy impacts EDD Weighted value of demodulated acceleration envelope where 1 smooth and 10 Impacting damage Bearing Information for AssemblyID SAMPLE BEARING C LFF 4 12 0 11 20 2006 10 04 00 AM1 1 20 2006 10 04 34 AM1 1 20 2006 10 05 10 AM1 1 20 2006 10 05 40 AM1 1 20 2006 10 09 52AM 10 tis 0 11 20 2006 10 04 00 AM1 1 20 2006 10 04 34 AM1 1 20 2006 10 05 10 AM1 1 20 2006 10 05 40 AM1 1 20 2006 10 09 52AM CFD 3 59 0 11 20 2006 10 04 00 AM1 1 20 2006 10 04 34 AM1 1 20 2006 10 05 10 AM1 1 20 2006 10 05 40 AM1 1 20 2006 10 09 52AM KFD 10 00 0 11 20 2006 10 04 00 AM 1 20 2006 10 04 34 AMI 1 20 2006 10 05 10 AMI 1 20 2006 10 05 40 AMI 1 20 2006 10 09 52AM EDD 19 46 0 11 20 2006 10 04 00 AM 1 20 2006 10 04 34 AM 1 20 2006 10 05 10 AMI 1 20 2006 10 05 40 AMI 1 20 2006 10 09 52AM Free Web Help generator T imeHistory The time histories are line graphs of the raw or filtered acceleration data Select tabs along the top of the screen to view reading Time signal or spectrum Frequency spectrum Select the specific signal type and range by selecting one of the tabs along the bottom of the window The data displays are slightly different depending on whether the
3. Settings Processed Data Spectrum Reading 1 timestamp 02 16 2006 19 03 01 Forecast period 90 Days Estimated MT TF 14199 Hours Estimated Life 13062 Hours Probability of Failure 5 8 in forecast period Short term Probability 4 14 day Risk Estimate 576 CoAF 10000 Forecast Period Factors Discriminants MTTF BDF 10 Create HTML Help DOC PDF and print manuals from 1 single source Factors FACTORS BC Indication of actual bearing condition where 1 0 Optimum Like new and 10 Near failure LE Indicator of projected bearing life including effects of both BC and DF where lt 1 0 Optimum and 10 near failure DF indicates level of life reducing dynamic forces Ex Caused by imbalance and misalignment where lt 1 0 Optimum and 10 Danger Bearing Information for AssemblyID SAMPLE BEARING 0 11 20 2006 10 04 00 AM 1 20 2006 10 04 34 AM 1 20 2006 10 05 10 AM 1 20 2006 10 05 40 AM 1 20 2006 10 09 52AM 0 11 20 2006 10 04 00 AM 1 20 2006 10 04 34 AM 1 20 2006 10 05 10 AM 1 20 2006 10 05 40 AM 1 20 2006 10 09 52AM 0 11 20 2006 10 04 00 AM1 1 20 2006 10 04 34 AM1 1 20 2006 10 05 10 AM1 1 20 2006 10 05 40 AM1 1 20 2006 10 09 52AM Free HTML Help documentation generator Discriminants DISCRIMINANTS LFF Low frequency acceleration level where 1 2 optimum and 10 danger HFD High frequency acceleration energy where 1 optimum and 10 damage surface roughness
4. naan et Orne ery ree 21 22 nenn nn annn nn annene eneee 23 LL 24 26 SINI che cae 28 iue ubslce 28 riz viu NR c 29 Engineering MdG TNR Eom 30 OPE RATIONAL IN TS ascia drago vai 30 REP Ee NCES 93 ASSISTANCE SUPPORT Du ips trt fx 33 DATA COLLEC ees cents 33 General Gudelines oo eeeeeececececeseseeccececececeeeeneceececececeseenenacaececesecsenenenaecececeeesssnenecaeceeeeeess 33 GENERAL I NFORMATI ON 111Equipment Familiarization The system requires an electrical connection between the accelerometer located on the motor bearing housing load zone and the data acquisition hardware attached to the local computer There is no immediate electrical hazard associated with this connection However the user may be close to rapidly spinning machine elements It is often advisable to install the Vibration sensors permanently and run cables out to a BNC access switch box with barcodes to facilitate safe and rapid data collection 112Access Control The login name used by the program assigns the user privilege level Both the user name and password are case sensitive e g The user must successfully log
5. Forecast period days 90 RPM 3600 Estimated MTTF hours 2160 Estimated Life hours 1935 Probability of Failure in 63 forecast period Bearing service Short term Probability T recommended 14 day 6 Risk Estimate 6321 CoAF 1 0000 Free Web Help generator The user can select a forecast period 90 days is the default Other choices are 60 120 180 or 270 days Estimated MTTF is a Mean Time To Failure based on the last BC Bearing Condition reading Estimated Life reflects reduction in expected bearing life due to high dynamic force levels Estimated Probability of Failure is derived from the MTTF value such that when BC 10 the Probability of Failure 63 for the selected forecast period When forecast period time is changed the MTTF changes but the probability of failure POF remains constant The short term Probability of Failure is the estimated probability that the assembly will fail within 14 days The Risk Estimate is equal to the Probability of failure Cost of Actual unscheduled failure CoAF sometimes known as Avoided cost The value displayed in the text box labeled is the user estimated cost of actual failure in and is stored in the Assembly database Note that when a safety issue is involved cost is not an object However the supervisor may still use this feature by entering a very high estimated risk in monetary units Bearing Information for AssemblyID Baldor 3501 Drive x
6. If the assembly screens are blank use initialize to populate them To Initialize click on the SQLite DbUtility icon to produce the SQLite menu Table Edit Initialize Note the Entry Fields and how they are used to set up an assembly ID point HE EditAssembly Assembly Machine Point Demo Bearing 01 Organization ID LIGHT 10 RACE 1 Sensor Number 4ssembly Name n 7 Assembly Number Alarm Levels Probability of Failure 50 3 Motor Characteristics Rigid Mount V Variable Speed D efalt RPM 1725 V Gear Drive Teeth on Drive Dynamic Force Factor Accel Sensitivity Cost of Failure 8 Notch 1 Low Hz Notch 1 High Hz hoo ooo I Gear Ratio Cost of Repair 8 Notch 2 Low Hz Notch 2 High Hz foo n s Location Building Number Lab Floor 2 001 Floor Room Update p The machine point field identifies the location in the database and may be a barcode or a manually entered ID either numerical or text The company field contains the Host Facility number created in the DButility The Assembly Name amp number describes the machine and location of the sensor ex Pump 2 front drive bearing Sensor number l 2 etc Rigid mount Check if machine is bolted to concrete or solid foundation Variable Speed check brings up option of defining VFD noise suppression filters Gear Drive allows option of defining gear te
7. Recent 3 Desktop My Documents 98 My Computer a File name S LiteT est s3db Open a My Network Files of type SQLite files s3db Full featured Documentation generator Selecting the Data Acquisition Type Selecting a Data Acquisition Source Applys only to MDA 100 amp 200 This Data Acquisition Source selection screen Figure 510 is shown to an analyst or engineer The National Instruments DA QCard is automatically assigned to a technician Data Acquisition Source Seles DAQ Source C Simulator Existing Data File C National Instruments DAQCard Figure 510The user may elect to examine simulated sine or white noise random signals select existing data files or collect new data by activating one of the three and clicking Done The MDA 400 will show only PDA as the Source Easily create Web Help sites Main Screens From the MDA 100 200 main screen the user can access the help system collect new or review and search for previously collected data A technician can only collect new data and view Information Factors and Discriminants while an analyst or engineer can collect new data review or search as well as look at tab selected time waveform and frequency spectrums for previously collected data The Engineer Supervisor may also create planned program routes examine and edit the database and assign passwords If the user is assigned the technician privilege level the Review and Condition Sear
8. are generally answered within one or two business day Create iPhone web based documentation DATA COLLECTION Free iPhone documentation generator General Gudelines Please contact Technical Support bearinglifeguard com Free PDF documentation generator
9. charged Plug Unit into docking station and charge up for minimum of 12 hrs Subsequent charges until light on unit is green Then unit it is ready to go For convenience unit should be left in docking station on trickle charge when not in use 2 If battery is completely discharged and boots up to calibrate screen recharge and follow simple instructions on screen to Calibrate and reset the Windows program Be sure to press Enter on completion of Screen Calibration This resets Windows and the program settings Note if Auto Load program is installed when unit is turned off on with Power button the BearingLifeGuard data collection program will load automatically on Start Up Caution a cold or warm boot may cause loss of data and require reinstalling the program To reinstall Data Collection Program on 962 A Verify USB connection to 962 in Docking Station Activate Sync link Note In Setting up Active Sync when prompted select synchronize all files B From 962 PDA Installl 962 pocket PC drivers folder DAQmxbase CE setup exedouble click to load drivers on PDA C Open mobil device folder to view 962 files Copy and paste Data collection V8 to WINDOWS START UP folder on 962 In 962 Windows start up folder copy and paste Check PDA Windows Start up to verify LifeGuard progam Icon is present Suggeest Copy and paste to PDA opening display for convenience in restarting directly paste Lifeguard program icon to Windows prog
10. failure and the estimated POF 1 4Rotational Frequency Coefficient Settings L10 bearing life is stated in cycles to failure meaning that estimated bearing life in hours is inversely proportion to rotational frequency When rotational frequency is doubled life will be cut in half When rotational frequency is cut in half expected bearing life is doubled BearingLifeGuard diagnostics vary with frequency also and they roughly approximate the life change with rotational frequency Measured housing acceleration varies roughly as frequency squared Therefore we expect to compensate adjusting coefficients for systems with different rotational frequencies Experience indicates that default settings will satisfy most common situations in the range of 1800 to 3600 RPM To keep estimated cycles to failure approximately the same with RPM we suggest changing the forecast time period at 7200 to 45 days and 1800 to 180 days etc Experience will also dictate changes for specific situations In general we always recommend erring on the side of caution Coefficient are weighted and the weighting will change with rotational speed If there is doubt the specific time waveforms and spectra are available for examination by the engineer or analyst to confirm severity prior to shutdown Note On a variable frequency machine when possible data should be collected at roughly the same speed for trending consistency The discriminant levels vary w RPM suggested initial coef
11. limits the assemblies displayed to items preselected by a session planner 2 The Unplanned mode allows a user to view and select Ad Hoc any assembly stored in the database 3 The Review mode using a data tree created on collected points allows the user to immediately review the informational results for any selected point Other detailed data is also available in Review mode 4 The Search mode allows the Analyst or Engineer to select view only those units that exceed any one of three selected criteria Failure Probability Requires Service attention High Dynamic Force Shortening Machine life which also costs money or Financial Risk How much money To start collecting data a user clicks on either the planned or un planned button on the main window tool bar 1 1 1 1 1Data Collection Acquisition Modes In the MDA 100 and 200 there are two 2 data acquisition modes planned or un planned The planned mode lists only those measurements scheduled for a particular session while the un planned mode allows the user to sample data on any machine currently in the database The user can select the acquisition point using barcode scanner or by manually highlighting the measurement point on his Planned Unplanned tree display on his data collector A plan file is a text file which contains a list in order of the assembly ID s to be sampled one assembly ID per line A review mode Figure 512 in the 100 200 and 400 brings an assembly
12. scatter in the family to create useful norms Then if one finds that adjustments should be made to one or more coefficients the change can be made on all The patented Multiple Discriminant Analysis coefficients are provided to allow users to optimize the benefits of your BearingLifeGuard system Bearing Information for AssemblyID Demo Bearing 09 Settings Processed Data Readings to plot Analyst Engineer Engineering Demo Bearing 03 Last 5 Display Reading tt a ri v C2 KFD2 Scale MS C4 BDF Scale O Last 26 C5 DFF Gain O All C6 DFF HFF Contribution C DFF LFF Contribution C9 LEF DFF Contribution Peak Scale 51 HFD Scale 52 EDD Scale Easily create PDF Help documents OPERATIONAL HINTS 1 10perational Hints 12 Variations with RPM The MTTF and Life Estimates in BearingLifeGuard are based on remaining cycles to failure That is one hour on a 3600 RPM machine equals represents 216 000 cycles On an 1800 RPM machine it represents 108 000 Hence the 1800 RPM machine will have twice the estimated MTTF of a 3600 RPM machine in the same condition All vibration readings including the impact and RMS levels measured at the bearing housing load zone will vary with speed mounting bearing design installation and system orientation vertical horizontal The BearingLifeguard system is designed to allow adjustment to minimize the effect of these variables The system automatically adjusts the filter band for enve
13. to look at all the technical details Immediate Condition assessment report provided to Maintenance Supervisor This report provides all the information required to make a service decision If no action is taken and failure occurs it could cost over 5000 in interruption costs Bearing Information for AssemblyID Demo Bearing 06 Settings Processed Data Reading 2 Spectrum Time stamp 8 4 2010 6 37 24 PM Forecast period days 90 RPM 4 725 Estimated RMTTF hours mem Estimated Life hours 2501 Risk Cost exceeds Probability of Failure i ae i robability O allure in 53 4 Repair Cost forecast period Short term Probability 14 day 4 6 96 Risk Estimate Forecast Period 5339 CoAF 10000 Factors Discriminants RMTTF Free PDF documentation generator SpectrumHistory The spectrum plots are averaged results of selected number of time historiy samples in g rms User may view frequency and amplitude of selected spectrum peaks on top display bar as shown by right clicking and selecting view marker in drop down menu Drag the red diamond below to desired frequency To zoom display amplitude right click and select from drop down menu To expand section click and drag to outline portion to be observed Tab Select Raw Unfiltered incoming signal 3 Hz to 40 kHz WB Wide band 3 Hz to 15 kHz HF Filtered 4x rotation to 15 kHz VHF Filtered 15 kHz to 40 kHz De
14. tree and measurement and summary tables with test samples for use in training or familiarization training After training and practice the user may op to clear out the test assemblies and gain more space in the database By using the Re create feature which clears out all test assemblies and the measurement summary tables and allowing the user to start with a clean database CAUTION BOTH INITIALIZE AND RECREATE WILL ERASE THE EXISTING CONTENT OF YOUR DATABASE EE EditAssembly Seles Assembly Machine Point Demo Bearing 01 Organization ID E Assembly Name LIGHT ID RACE Assembly Number 1 Sensor Number o Motor Characteristics Alarm Levels Rigid Mount Variable Speed Gear Drive Probability of Failure 50 Defalt RPM E 725 Dynamic Force Factor 3 Accel Sensitivity 1 Cost of Failure 1 0000 Cost of Repair 1 000 Location Building Number kab Hs DINME NK Hes 0 0 scs pum Free CHM Help documentation generator DATABASE 11NO ENTRY Easily create HTML Help documents CREATI NG A USER The user table contains user names user password and user type There are three user types Technician Analyst Engineer Supervisor The most privileged user type is the Engineer Supervisor and the least is the Technician To create a new User Select New Enter new user name in field Create new password Select User Type access level for this User Save ES User Maintenance
15. tree with all points with collected data When a point is selected the Information Screen immediately appears giving the user quick assessment of a measured bearing point s condition The user can continue to examine all the additional data waveforms and spectra as necessary An additional Condition Search mode allows the user to search and display any assemblies exhibiting levels of Probability of Failure Dynamic Force levels or levels of high Financial Risk The user selects any of the three search criteria enters the level and initiates the search All units meeting any one of the criteria will be displayed in the database tree An operation or measurement is initiated by clicking on the appropriate program tool bar icon Figure 513 Full featured Documentation generator AssemblySelection 100 200 400 The assembly ID uniquely identifies the tree location to a single sensor location on a particular motor Note that there may be more than one sensor on a motor Selecting an assembly by clicking on the assembly ID will bring up the next screen which allows the user to change measurement parameters Figure 514 1 1 1 1 1The user selects an assembly by scanning ID point location barcode previously stored in the database assembly or by clicking the mouse on an assembly ID in the tree view window An assembly ID is the last item at each branch The window title indicates which operating mode was selected planned un planned or review The first
16. user is collecting or reviewing data When collecting data there will be a Time History for each data sample and a single averaged spectrum When reviewing data only the last reading of each measurement set and the ten sample spectrum associated with the last reading are shown To zoom time left click drag and outline the section to observe To zoom amplitude right click select desired zoom multiplier from drop down Tabs To view acceleration data Raw Unfiltered incoming signal 3 Hz to 40 kHz WB Wide band 3 Hz to 15 kHz LF Low frequency acceleration g or Velocity in sec Severity HF Filtered 4x rotation to 15 kHz VHF Filtered 15 kHz to 40 kHz DeMod Enveloped demodulated 3 Hz to 1kHz To view additional readings select settings and add highlight readings available in drop down New readings will appear as tabs on top bar 150 Milli sec acceleration time sample of defective bearing EB Bearing Information for AssemblyID Demo Bearing 06 Settings Processed Data Reading 2 Spectrum WB HF LE Raw VHF DEMOD Notes Settings Processed Data Reading 2 Spectrum Wideband Twenty five kHz frequency spectrum of same bearing NOTE Instantaneous amplitude or frequency may be displayed by right clicking mouse Time and spectral waveforms may be Zoomed by rolling center mouse control and or depressing button to move right or left No need
17. MODELS MDA 100 200 amp 400 BEARI NGLIFEGUARD USER MANUAL REV 2 0 Table of contents GENERAL INFORMATION trat ticae uc tutu dd 3 DISCLAIMER p 3 SOFTWARE endi 4 Setting up the 400 PDA PT 4 Setting up SQLite database a oa os ees sda eet So oe ees 6 RECREATE INMIALIZE aiio tcc can URB at t iE Pro EU Dein 6 DATABASE cT 7 Ey TN fece tra Ra UE Seu rue ipe E DRE eai UE 7 1 1 Concept of Operations nennen 8 Setting up Assemblies MM 9 1 1 1 Creating New Database ie Ee rao dnd 11 1 1 2 Removing a Database 11 rcp mM HE LOJON RR OO m T 11 Selecting the Data Acquisition Type cseceeeeeeceeeeeseeceateeeeceaeseeaeeaeeetseeaeeeseenseeeceataeees 12 Ma Seres icueticestimiebetaccatatetasu ntt UraE aud ceca Deere Se do SLE uin bebes tu ua iube 13 Collecting data 400 M 14 Data Collection Modes 100 200 0 eeeeseseesecceseeeeeceeeeeesceseeeeseeaeeeeseeseeeceeneseeeaneetaees 16 AssemblySelection 100 200 400 eesssseseeeseeenetee tnter 17 Acquisition Settings 100 200 Et eU ao a UR 18 SEARCH 100 400 atentos nen eee er eI MEUM IM E RI 20 Fay Ue ae NUI M CI M MI EM E 20 Bearing Information nenat 21
18. Mod Enveloped demodulated 3 Hz to 1kHz To view additional readings select settings and add readings available New readings will appear as tabs on top bar Wide band unfiltered frequency spectrum 1 hz to 25 kHz Bearing Information for AssemblyID Demo Bearing 06 Settings Processed Data Reading 2 Spectrum Wideband Veloci wB LF Raw VHF DEMOD Demodulated spectrum indicating periodic impact frequencies Bearing Information for AssemblyID Demo Bearing 06 Settings Processed Data Reading 2 Spectrum WB Raw VHF Easily create Web Help sites Settings The settings screen changes based on the user s privage level The differences can be seen by selecting one of the links below Technician Analyst Engineering Single source CHM PDF DOC and HTML Help creation Technician Mode All users can change the number of readings considered when plotting the factors and discriminants Bearing Information for AssemblyID Baldor 3501 Drive Settings Processed Data Readings to plot Last5 C Last 14 Last26 C AI Easily create Help documents Analyst Mode If the user is has analyst privileges they can view previously recorded data and select the number of prior collections to be viewed Last five to All The user must then hit Display r
19. When required the Analyst or Engineer may take the MDA 100 200 or a portable MDA 400 PC to the machine site and collect and observe all the vibration characteristics on location in real time The MDA 400 data collection is done by handheld Portable Data Acquisition PDA Computer with inserted accelerometer power supply and data acquisition capability A barcode scanner is used to identify the collection point and the data are collected and stored in Flash memory The PDA is placed in a docking station and the Supervisor uploads the data to the PC Once transferred the records are removed from the PDA and it is ready to collect more data Perform Measurement Quit MDA 400 PDA Data Collection Screen 111222333 Normal 600 7200 Enter Barcode ID Select Samples Collect 9 Level Vibratio 0 2 secs Process This Data ME Collect Again SKIP 5 YOU GET ANSWERS NOT SPECTRA Timestamp 11 21 2006 12 55 35 PM Forecast period days 90 RPM 33600 Estimated MTTF hours 2160 Estimated Life hours 1935 Probability of Failure in 63 96 forecast period P Bearing service vp ik Probability 6 recommended ay RiEs 66321 car 1000 Foctoss Osctearts Easily create Web Help sites Data Collection Modes 100 200 There are two 2 data collection modes for the MDA 100 amp 200 Planned and Unplanned and two 2 data Review and Search modes 1 The Planned mode
20. ch buttons will be dimmed and unavailable In the MDA 400 screen data resides on an external PDA The Main screen will initially contain only four tabs Transfer data from PDA Process Data Review Data and Condition Search Like the MDA 100 200 the MDA 400 provides the tab selected Time History Frequency spectrum demodulated time and spectra all with Zoom capability as well as the Information Summary Screen MDA 100 200 Planned UnPlanned Preview and Condition Search MDA 400 transfer data from PDA Process Review Condition Search MDA 100 200 Screen MDA 400 Screen Bearing LifeGuard He Planned Un Planned Review Condition Search Click on Planned or Un planned to collect data or press F1 for more help m a Bearing Lifeguard If File View a Hep i Transfer from PDA Process PDA Data Review Condition Search The Bearing LifeGuard system is configured so that users may elect to have the data collected by personnel with minimal vibration training who need only have familiarity with the facility the machine locations and have diligent observational and safety skills The data is stored in the database for review and examination by the supervisor When necessary an Analyst may need to be consulted but generally if properly configured all the information necessary to make a sound maintenance decision is available immediately The collection process is made user friendly and relatively uncomplicated
21. e data collection sequence The first record will be captured and a plot of the raw data will be presented to the user The user must accept the data by clicking Process this data in order to continue If the user closes the dialog or clicks Collect data again the data will be re sampled and presented to the user again If the user clicks on skip to next assembly the data collection for this motor will be bypassed Wideband 50 100 150 200 msec Once the data is accepted the remaining samples will be read without interruption and a progress bar will be displayed during the data collection process See IEPE BIAS FAULT the MDA systems are configured to measure bias levels on IEPE sensors to assure the user that the sensor is functioning properly The nominal bias range is approximately one half the constant current power supply level The MDA system is designed to check for bias level and warn the user if it is within the proper range typically 7 to 15 volts This is important to verify proper operation of the IEPE sensor When bias is out of range a user alert message is displayed warning the user This message may be ignored if user is aware that the connection is valid and an IEPE input is not being used i e A preconditioned sensor signal with zero bias level is connected as the source The user may elect Continue and the system will process the AC signal with a zero bias level The error message does not eff
22. eading tab and select the specific date that is to be displayed Usually the most recent This is accomplished by selecting a reading number using the pull down text box in the middle of the screen The reading number corresponds to the data which generated the bargraphs on the factors and discriminants screen Values range from 1 Optimum in the Green to 10 Near failure Red The date time of the data collection proceeds from left to right Right click and select show point values then holding cursor on the bar will show the specific reading magnitude and the date time data was collected mL Bearing Information for AssemblyID Baldor 3501 Drive Settings Processed Data Readings to plot Analyst Engineer Last5 Display Reading Last 14 xd Last26 C AM Full featured Documentation generator Engineering Mode If the user has engineering privileges they can view and alter the coefficient table to optimize performance for specific operating conditions Note Caution Supervisors are urged to view section on Operational Hints before modifying any of the default settings In general the defaults should be adjusted to compensate for machine RPM and other special characteristics However actual experience should be used to reach conclusions about making changes in coefficients for particular machines Example if a facility has 100 machines of the same type one can easily begin to look at variability and
23. ect the processing of the AC coupled portion of the signal Full featured Documentation generator SEARCH 100 400 The CONDITION SEARCH MODE allows a Supervisor to focus efforts and resources by quickly identifying machines that require attention The user chooses criteria for selecting specific ID locations for closer review Three criteria are provided which allow review of only those machine points that exceed specific Probability of Failure DF Dynamic Forces levels or Financial or safety Risk factors For example A Supervisor may wish to know which machines have a risk which exceeds 2000 and have POF levels in excess of 4096 By entering the numbers into the fields and disabling the the DF field by putting it over 10 only those machines with values exceeding those figures will be brought up for review in an assembly tree Bearing LifeGuard Window Help Planned Un Planned Review Condition Search ES Condition Search Forecast period days 90 Probability of Failure in 50 0 4 forecast period DFF Level 30 5 Search Risk 10 0002 Easy CHM and documentation editor Analyzing Data Analyzing Data The Bearing LifeGuard system has been designed to minimize the need for detailed vibration analysis The system is designed to allow a technician to identify the collection point via barcode connect and automatically power up the accelerometer initiate the collection process observe and validate the vibrat
24. ely or run for six months The information is provided and the assessment of the risk is left to the user Experience will provide guidance on the reliability of readings and allow the user to make appropriate adjustments if required 2 HIGH RISK ACTIVITIES The standard hardware used for the BearingLifeGuard system is not intrinsically safe For use in hazardous areas please contact the manufacturer The Software is not designed manufactured or intended for use or to be used as the sole basis for maintenance or repair decisions in environments in which its failure could lead directly to death personal injury or severe physical or environmental damage such as in the operation of nuclear facilities aircraft navigation or communication systems air traffic control direct life support machines or weapons systems High Risk Activities ACCORDINGLY WE AND OUR SUPPLIERS SPECIFICALLY DISCLAIM ANY EXPRESS OR IMPLIED WARRANTY OF FITNESS FOR HIGH RISK ACTIVITIES BY ACTIVATING THIS SYSTEM YOU AGREE THAT WE WILL NOT BE LIABLE FOR ANY CLAIMS OR DAMAGES ARISING FROM THE USE OF THE SOFTWARE IN SUCH APPLICATIONS Full featured Documentation generator SOFTWARE I NSTALLATI ON NO ENTRY Full featured Help generator Setting up the 400 PDA HELPFUL QUICK HINTS TO SET UP YOUR MDA 400 PDA HANDHELD COMPUTER 1 When unit is first received from DMC CT All BearingLifeGuard software and PDA drivers have been installed and unit battery has been
25. eth and ratios to reject gear mesh noise RPM Enter rotational frequency in rotations per minute Accelerometer Sensitivity mv g Cost of failure best estimate of financial cost of catastrophic or unscheduled breakdown Cost of repair best estimate of routine scheduled repair time and material Alarm Levels User entered settings limits for triggering user warning alerts displayed on Condition Information Screen Building Floor and Room are entered in last three boxes This information now identifies the measurement point so that any data collected at that point entered as ID will be available as a date stamped entry in the BearingLifeGuard program on the PC AA Easily create iPhone documentation 1 1 1 Creating New Database 1 1 1 Creating New Database In opening the DBUtility program a list of available databases will be displayed The user is requested to select the database to be used In File name enter the name of the new database to be used When entered the user will be taken to the new data base in the DB Utility program The user may than proceed to Initialize setting up a new database which creates a sample company and several demo assemblies which the user can than Edit add to or delete as required by entering new Companies Users and machine Assemblies with new ID s in the program When completed the New Database will then appear in the list for selection when either DBUltility or the BearingLifeGua
26. ficient settings roughly based on ISO10816 1 Note As coefficients are increased warning levels and readouts will be more conservative i e User will get earlier warnings recommendations are as follows For Supervisor Engineer level only Default Settings Coefficient RPM 200 400 60 100 1200 1750 5000 72 1200 min max 0 0 1500 2400 00 0 PEAK g 100 25 80 10 2 6 3 2 1 0 5 0 1 0 2 1500 200 30 a DNE ERR C4 BDF Scale 0 2 100 C5 DF Scale E 20 50 10 5 10 0 1 1500 150 30 see note C6 DF HF cont 0 2 0 2 02 0 2 0 0 0 6 C7 DF LF cont 0 7 4 C9 LE DF 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 1 0 5 S1 HF Scale 50 25 80 10 4 6 3 2 1 0 5 0 1 0 25 1500 200 30 S2 ED Scale 50 25 80 10 5 16 5 10 4 1 0 5 0 25 0 25 100 200 30 LF rms g x mass of housing General hints Read carefully Coefficients for approximate RPM are set by the Supervisor for each assembly to produce POF based on measured severity of surface defects The coefficients may be adjusted to compensate for anticipated variations in measured acceleration with RPM DF Peak g and High frequency RMS g HF for a given machine will vary roughly as the square of RPM When properly set they should produce 63 POF for a near failure defect condition Defaults are set based on measurements made with test machines running at 3600 RPM Forecast period is defaulted at 90 days Deemed a reasonable period for requi
27. he range of adjustment is not sufficient please provide feedback to DMC tech support and that request will be evaluated and if needed a change will be made on the basic package and sent free of charge to all users For machines operating outside the 200 to 12 000 RPMrange users are requested to contact techsupport bearinglifeguard com Important when an increase in any discriminant is noted it indicates a degrading condition and a need to monitor the machine more frequently to observe trend of problem indicated Easily create PDF Help documents REFERENCES 1 Rolling Bearing Analysis 3 Edition Tedric A Harris Wiley Interscience Publication 2 Torrington Fafnir Kilian Service Catalog 2001 Now Timkin Bearing Co 3 Shock amp Vibration Handbook Third Edition Cyril M Harris 4 ISO standard 10816 5 Mechanical Failure Prevention Society MFPT 62 Virginia Beach Virginia US Update on BearingLifeGuard project 6 Copyright 2010 Dynamic Measurement Consultants LLC 7 US Patents 8950 6495 4495 amp 7 606 673 Easily create Web Help sites ASSISTANCE SUPPORT The system is provided with a Quick Start User s Manual in addition to the Help Screen This is the first place to look for additional information In addition the program website has a Frequently Asked Question FAQ area if your question is not answered by one of the FAQ s you can e mail or contact technical support at techsupport bearinglifeguard com E mail questions
28. in to use the program The login process will terminate after 3 unsuccessful attempts 113Installation And Setup The software can be run in networked or standalone mode In standalone mode which is the default mode the SQLite data base server must be installed and running on the local machine For more information see User s Manual 1 8topping And Suspending Work The program can be stopped normally by clicking on the window close box or the exit button on the toolbar The program cannot be stopped or suspended normally during a measurement sequence Free PDF documentation generator DI SCLAI MER Disclaimer Please read carefully 1 Bearing failure may be initiated by a variety of factors and has been shown to be random in nature Failure patterns conform generally to a Weibull exponential probability distribution Bearing LifeGuard estimates are based on the results of diagnostic assessment of six widely accepted vibration analysis techniques carefully averaged and converted to metrics representing a range of optimum to severely degraded condition When at maximum they provide the user with credible evidence of severely degraded bearing surfaces The philosophy employed is to convey that information in a clear format to maintenance personnel so as to provide reasonable advance warning and encourage prompt action to avert catastrophic operational failure Given the statistical nature of failure the bearing could fail immediat
29. ing up SQLite database Initial Software Installation MDA 400 only There are four software components which must be loaded onto the computer in order to use the MDA 400 BearingLifeGuard system The components are 1 A compatible database which is used to store the captured information as well as the motor assembly parameters and location See below 2 The NI driver software for the data acquisition card 3 The BearingLifeGuard software for the 400 and the data collection exe file for the PDA data collection 4 Active Sync If not on PC After installation of BearingLifeGuard software in PDA Install folder activate DAQmx Base CE setup to install NI drivers and create link to PDA Using ActiveSync copy and paste MDA400 data collection to 962 in My Documents file Easily create HTML Help documents RECREATE INITIALIZE In opening the DBUtility program a drop down menu appears and offers and selecting Edit Table Assemblies Company measurement Summary Users Database Utility Connect EWEN Help Eee Re Create gt Company Initialize gt Measurement Summary Users The Edit function allows the User to go into the database and edit or add to assemblies companies or users etc It allows the Administrator to change the content in the Assemblies Company tables and Users and set the Information screen Alarm display levels Initialize Creates sample test assemblies for the new user populating the Unplanned assembly
30. ion waveform collect the data and move to the next point Notes may be taken if needed A point may also be accessed by highlighting it on the assembly tree On completion of the collection process the supervisor may review the data do a search to identify and further examine deviant points If there are none worthy of note the process is complete The data has been stored for future reference in the Bearing LifeGuard database Problem units revealed in the search process may be examined in more detail by the Analyst or Engineer by reviewing the ID Factors Discriminants or the time spectral or demodulated information to identify the cause and correct it Since information is available from six powerful diagnostic procedures the vast majority of problems will be quickly identified and rectified Free help authoring environment Bearing Information The Bearing Condition Information window is shown after a data set has been collected or when the user selects Review or Search from the program tool bar The window title indicates the current Assembly Identifier AssemblyiD In the example below the Assembly ID is Bearing 5 HVY ABR which is just a test sample The most recent reading for this Assembly is identified with a date and time stamp EE Bearing Information for AssemblyID BEARING 5 HVY ABR Settings Processed Data Timestamp 11 21 2006 12 55 35 PM Forecast Period Factors Discriminants MTTF Forecast
31. item in the tree identifys the database in use 5 Take Un Planned Reading Ele Data File MiB PICO AD 216 IE B Floor 2 3 B 001 eR Test Motor 0 5v amp 1 2 B Baldor 3504 Drive amp Test Motor 2 0v 1 amp 1 1 Baldor 3501 Free Midi Simulator White Noise g Building 1 Bg Floor 1 Room 1200 amp Constant Drive amp 2 amp 1 E Simulator FIX 00001 Variable Drive amp 1 amp 1 E Simulator VDF 00001 amp 2 E Simulator VDF 00002 Free iPhone documentation generator Acquisition Settings 100 200 OAcquisition Settings The default values for Motor Speed and Wide Band Detection are taken from the Assembly database The operator is given a chance to enter notes prior to starting the measurements The user selects the number of sample averages required the sample time 0 2 sec default the motor RPM is taken from the assembly set up but may be manually input by user To minimize imbalance and misalignment influences on bearing noise calculations by default the BearingLifeGuard system uses high frequency energy over four times rotational frequency to 15kHz The user may elect to use frequencies from 3 Hz to 15 kHz by checking Wideband Detection Once an assembly ID has been selected a new screen will pop up and display the default settings for the measurement set The default settings should be acceptable for most cases One general exception wo
32. lope detection and demodulation For RPM 1200 or greater it assumes an accelerometer resonance between approximately 16 kHz and 24 kHz For RPM below 900 it assumes that a high sensitivity sensor with a resonance between 8 kHz and 13 kHz will be used For machines operating below 700 RPM see Factory Following are some general guide lines and suggestions for adjustments that may be required in setting up assembly coefficients to optimize system performance Coefficients for POF amp DF level screen alarms as well as Cost amp Risk levels are made available in the SQLiteUtility and in the Settings screen located on the monitored point display screen The default settings are for rotational speeds of 3600 RPM 1 3The Forecast period Manufacturers failure estimates are typically given in number of cycles and then converted to hours at a given RPM for convenience Since the Bearing LifeGuard estimates are in hours the machine speed must be accounted for The fault detection coefficients are set up for 3600 RPM and therefore a machine running at 7200 or 1800 will reach the same number of cycles in half or twice the running time respectively So forecast period should be set accordingly from 90 to 45 or 180 days and 120 or 270 days respectively The forecast POF will not change but both the short term POF and the MTTF and MTTF E based on number of cycles will The financial risk remains the same because it is derived from the estimated cost of
33. ram display Turn unit off and on with power button to verify auto load If auto load fails go to Windows Start up and activate with Icon BearingLifeGuard will then load automatically on Start Up using red Power On button Note if unit is shut down and battery removed Repeat above procedure for Auto Load 3 Enable Barcode scanner by selecting Control Panel Scanner To KPD check Start Scan2Key when exit Test by depressing buttons on side of 962 housing Scanner will automatically enable at start 4 To check battery power go to Control Panel Power settings System defaults are one minute Idle three minutes System Idle four minutes Suspend Initial Computer Software Installation for PDA MDA 400 There are four software components which must be loaded onto the computer in order to use the MDA 400 BearingLifeGuard system The components are 1 A compatible SQLite database which is used to store the captured information as well as the motor assembly parameters and location See below 2 The NI DAQmxbase driver software for the data acquisition card 3 The BearingLifeGuard software for the 400 and the data collection exe file for the PDA data collection 4 Active Sync If not on PC 5 After installation of BearingLifeGuard software in PDA Install folder activate DAQmx Base CE setup to install NI drivers and create link to PDA 6 Using ActiveSync copy and paste MDA400 data collection to 962 in the My Documen
34. rd program are opened Easily create PDF Help documents 1 1 2 Removing a Database 1 1 2 Removing a Database SEE USER S manual Note It is recommended that only an IT supervisor be authorized to remove or modify an existing database Create iPhone web based documentation Logon The user must select a Database Name and enter a user name and password into the appropriate text box and then click on the submit button The Bearing Lifeguard program will terminate if an incorrect user name or password are entered three 3 times The User name and password are created in the DBUtility Table Edit Users Each user name is associated with one of three privilege levels technician analyst and engineer selected in the DButility The lowest privilege level is the technician and the highest is the engineer The privilege level limits what operations can be performed from the main screen and the settings screen x BEARING Note The user name and password are case sensitive and may be different than the computer login name and password The DBUitlity program allows the administrator Engineer Supervisor to modify the user name user password and assign a user s privilege level After Submit the Select a Database file screen is the first screen a user will see The database name is SQLite The user will select it and Open to start the program Select a database file X Look in 2 Database v 3 55 m ES C LFTESTDB SQL PDAData
35. red action for machines running near 3600 RPM Since L10 beaing design life is specified in cycles it is reasonable to estimate a machine running at 7200 RPM will fail sooner and that one running at 1800 or 1200 RPM will run longer with a given defect severity 90 days is approximately 5 year MTTF 45 days 2 5 yrs 180 10 years and 270 15 yrs 270 is suggested for machines running lt 600 RPM A supervisor will change the forecast period and coefficients accordingly In general user should adjust to satisfy individual risk tolerance and critical nature of the machine under test C6 User selected contribution of High Frequency energy to lower frequency Dynamic Forces 0 2 20 C9 User selected Dynamic Force reduction of estimated bearing life at DF max of 10 0 2 20 0 5 50 Estimated reduction in expected life due to excessive DF Note These setting recommendations are provided for guidance only User experience will be the most important guide If you tear down a bearing with surface condition that reflects lesser or more severe degradation than the discriminants may have indicated the engineer supervisor has the ability to go in and adjust the coefficients accordingly In general raising the coefficient will make the system more sensitive and provide earlier warnings They are intended to provide adequate warning and to allow the user the flexibility to optimize the diagnostic effectiveness of the system If a user discovers that t
36. ts file 7 Using BearingLifeGuard Set up install MDA software in host PC or Laptop Initial Computer Software Installation MDA 100 200 1 The NI DAQmx driver software for the data acquisition card 2 Net 2 0 dotnetfx 3 Install DBUtilitiy with setup program 4 Activate DBUtility Icon to open database selection screen Select SQLite to open database Create shortcut by right clicking on DBUtility icon Start All Programs Install the model 100 software from the BearingLifeGuard software disc on your PC SQLite is your default database Run the DBUtility 1 recreate all files oo 2 recreate users 3 edit table users add new users and passwords Set Access levels 4 edit table company change company 1 from default to your company add additional companies as needed 5 edit table assemblies add create new assemblies ID s machines buildings rooms floors as needed Define each point individually 9 Install the NIDAQ software Turn on PDA power and MDA program Connect and confirm w ActiveSync that the program is active and communicating with the DAQ card 10 Collect data and review Database Installation 1 A copy of SQLite database utility is included When installed it will create the SQLite database Subsequently when the DbUtility is opened it will display a database selection screen The user simply selects and opens SQLite Easy to use tool to create HTML Help files and Help web sites Sett
37. uld be motor speed which should be measured and entered when recording data on a variable speed motor In this latter case it is recommended that a consistant RPM be used each time a reading is taken so that conditions will be essentially the same from reading to reading The operator may enter comments for example a description about the motor appearance or performance information belt vibration loose foundation leaks etc into the notes area Any comments entered are stored in the database with the measurement data for this reading Any VFD or Gear Mesh notch frequencies used in the assembly point set up will be displayed The first block represents the number of samples to be captured and averaged The Duration determines the bandwidth resolution Example 1 0 2 5 Hz frequency bandwith Motor speed is obtained from the Assemby set up in the DB Utility or may be entered directly in this field block in RPM This figure will determine the 4X low frequency cut off used in the HF High Frequency energy measurement TakeMeasurementSet Seis BEARING 5 HVY ABR of Measurements ho Duration 02 Sec Motor Speed 3600 RPM Notes Wideband Detection Filter stack notch width 20Hz 1st order center frequency 3000 30 60 2nd order center frequency 6000 30 60 VFD frequency notches between 2100 to 2500 and 4000 to 4500 Collect Once satisfied with the information click on the Collect button to start th
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