A4910 – Lubri User's Guide
Contents
1. User s Guide am Whdashe A4910 Lubr WH Applications 7 Monitoring and control of lubrication process 7 Measurement of rolling bearing condition Ref No 12112009 ADASH spol s r o A4910 Lubri Contents IMT OGU GC HOM siss A E vet secgneseusansa 3 What Will You Get with Your Instrument 0 cece ceeseeeeeeeeeceneeeeeeneeseeaseeeeeseeseaneeseenseesoees 4 Instrument and Accessories ies iics dc sieicilccrawctetdiareantaiiasoanresie qroasnnnatastovanrntuaiienanunnd sumer nnmlssuaeusneanaa taauumarasauauarnsesoaias 4 ESTOS You SCN aie en taste eases E O 6 QUICK Stati scria a a A a a E 7 Two Possible Ways to Measure ccccccccceececeeeeeceeeeeseeeeeeeeeeeeeeeeseeeeeseeeseeeesseeeeeseueesseeeessneeeseeeeeas 7 istrument Preparation aisia a iia eaa a aa aE Ea a aA aiaa 8 Lubrication and MEASUPEMENL cccccccecccececeeeceeceeeceeeceeeeeeeeeesaeeseeeseeeseeeseeetaeeseeeseeeaeeeseeeaeeesaeees 8 Determining of Lubrication Interval and Amount of Lubricant ssccsssesseeseeeees 10 Goal of Maintenance in Lubrication ProCeSs ccccccceecccesceeaececaeececeeceeeecesseeeeseeeesseeessesessaes 10 Procedure for Lubrication OptiMIiSation cccccccccceecccceceeseeeeceeeceseeeeeeeeeeseeeeeseecesseeeesseeeeseeeeeeas 10 How Much Lubricant Needs to Be Added cccccccccescccesecceeecececeucecaueeceeeceeesaeeseueessueeseaeenaaes 11 instrument DESC HID TION sssrin2. ii Blinking signals a low signal level from bearing Picture on the left shows greasers signalling proper instrument start Middle picture shows measurement before lubrication and right shows measurement after lubrication Warning If the display stays off after switching on the instrument the batteries are weak change them 9 ADASH Ltd Czech republic tel 420 596 232 670 fax 420 596 232 671 email info adash cz For more technical and contact information visit www adash net www adash cz ADASH spol s r o A4910 Lubri Determining of Lubrication Interval and Amount of Lubricant Goal of Maintenance in Lubrication Process The goal of maintenance is a long lifetime of rolling bearings We need to optimise lubrication to achieve this To achieve the best possible state of lubricated bearings and save lubricant at the same time we need to determine regular intervals when we are going to perform lubrication Another question is the amount of lubricant for each of the lubrication points Starting points are intervals and amounts determined by a manufacturer We had performed a large amount of testing on bearings directly in manufacturing We have found that the intervals which are determined by manufacturers are always too long and that at the end of these intervals the bearings are not working under optimum condition Procedure for Lubrication Optimisation The A4910 Lubri instrument enables you to measure an act
3. 232 670 fax 420 596 232 671 email info adash cz For more technical and contact information visit www adash net www adash cz ADASH spol s r o A4910 Lubri for attachment at cooling ribs Both pads have an M6 threads for screwing on the sensor Pad Installation You will need the following angle grinder files sand paper degreaser spirits thinner measurement pads and glue The surface where you need to attach the pad needs to be prepared as follows remove paint corrosion and eventual unevenness by grinding degrease Both types of pads are being attached to a measuring location by METAL TECH SG glue See www thortex com product You can use other glues with similar properties It is dual component epoxy glue with characteristics suitable for this purpose The two components react chemically when handled and after proper mixing and drying create a hard material which is resistant to pressure temperature and humid environment In case of the simple pad proceed as follows With a sharp knife cut about 3 mm thick slice and by wet fingers work into homogeneous matter From this make about 2 3 mm thick cylinder and put it on a rough side of the pad Then press the pad onto the previously prepared cleaned spot and turn back and forth under steady pressure to glue it onto the machine Make sure the glue is being pushed out evenly around the circumference of the pad The purpose is to create as thin a layer o
4. cz ADASH spol s r o A4910 Lubri Before You Start ignoring any recommendations mentioned below may cause failure of the instrument Operating with power higher then 24 V can cause an accident 1 Never connect any other type of sensor than ICP into the socket marked ICP If unsure contact your supplier 2 Never plug the A4910 into 110 230 V voltage 3 To power the A4910 use batteries rechargeable batteries with max nominal voltage of 1 5 y 4 To power the A4910 use only alkaline or rechargeable NiCd NiMH batteries Regular carbon zinc batteries are not suitable WARNING Use correct battery polarity Incorrect polarity will cause destruction of the instrument 6 ADASH Ltd Czech republic tel 420 596 232 670 fax 420 596 232 671 email info adash cz For more technical and contact information visit www adash net www adash cz ADASH spol s r o A4910 Lubri Quick Start The aim of this chapter is to introduce you to A4910 Lubri and without reading a complete User s Guide try this instrument in practice Two Possible Ways to Measure A sensor a standard accelerometer with sensitivity of 100mV g and ICP power which needs to be mounted on a bearing housing is used to measure lubrication We have two possibilities how to do this 1 The sensor is mounted on a lubrication head This option enables a quick service since the lubrication head is transferred together with the sen
5. not much going on in the beginning which means that the lubricant is pushed toward the bearing however it is not there yet At the moment when the lubricant reaches the bearing the column decreases usually its upper red part disappears and only the green lower part remains and noise in the headphones decreases also We need to add a little more lubricant and if there is no further decrease we end the lubrication process If at the beginning of measurement the greaser in the lower right hand corner starts to blink then the signal from a bearing is very low We have either new or a very well greased bearing In this case we suggest using headphones to finish lubrication Before we start lubricating another bearing we piece to reset after the previous measurement It is ADASH Ltd Czech republic tel 420 596 232 670 fax 420 596 232 671 email info adash cz For more technical and contact information visit www adash net www adash cz ADASH spol s r o A4910 Lubri necessary since during bearing operation values showing bearing status are different for every bearing The values are different even for bearings of the same type used on different machines or under different loads Reset is done by a short push of the Mode button A lubrication value in the upper right display corner will start blinking during reset Complete switch off is done by a long push of the Mode button New measurement is signalled by A blinking
6. 32 670 fax 420 596 232 671 email info adash cz For more technical and contact information visit www adash net www adash cz ADASH spol s r o A4910 Lubri f 1 Push gently Battery compartment opening ADASH Ltd Czech republic tel 420 596 232 670 fax 420 596 232 671 email info adash cz For more technical and contact information visit www adash net www adash cz ADASH spol s r o A4910 Lubri Correct polarity Connecting of Headphones The instrument is equipped by a 0 5 W amplifier for listening to a bearing noise We can connect the headphones by a stereo 3 5 mm jack marked PHONES on the top of the instrument see picture in the sensor connecting chapter Suitable volume can be set by arrows A or Y When the instrument is switched on or off range is changed or the sensor is connected or disconnected a short unpleasant crack can be heard due to a transitional effect This is not a defect Be careful not to overload the headphone amplifier by excessive volume This will distort a signal in the headphones You can use any headphones with nominal impedance higher than 8 Q 15 ADASH Ltd Czech republic tel 420 596 232 670 fax 420 596 232 671 email info adash cz For more technical and contact information visit www adash net www adash cz ADASH spol s r o A4910 Lubri Measurement pad instalation Selection of Measurement Point Two conditions are important for exact measurement o
7. 910 Lubri Instrument Operation Mode button Mode button is used to switch the instrument on off and for measurement reset The button needs to be pushed for a longer time to switch off Buttons A and Y These buttons are use to control volume in headphones Arrow A increases volume arrow Y decreases it Error Indications Errors are indicated on an instrument display If there is a problem with cable or sensor the display will show ICP ERR see picture If we get an ICP ERR we need to check connecting cable broken or short circuit sensor If there is another internal fault the display will show CPU ERR see picture If the error constantly repeats itself contact your supplier or manufacturer Sensor and instrument power supply errors Changing Batteries To power the instrument use AA size alkaline batteries or NiMH rechargeable batteries with nominal voltage of max 1 5 V Use of regular carbon zinc batteries is not recommended The batteries are accessible after you open a small lid on a bottom of the instrument You can open the lid by pushing on its bottom side hinge side the upper side then opens easily see the picture DO NOT APPLY FORCE Correct polarity is shown in the picture Do not forget to switch the instrument off before you open the battery compartment lid Never handle the batteries when the instrument is switched on 13 ADASH Ltd Czech republic tel 420 596 2
8. a a ENE 12 Horument Operationen E e ceeueaeaers 13 E Or NOCAUT emote en eee rr er a Eee ee Oe ee eee 13 Chanongo i oye ia 2 i Rese semester rca ete rte er ane E R R 13 Connecting of FASC ACDINOINCS ssc ircs cosets css gacs ates oe aca eenntehcae a ceb ine eaeice sna cance ince eae aesdieeee 15 Measurement pad instalation cccccssseecesseeceesseeeenseeeenseeeeenseeeeeseeeonseeeesseesonseesoeseessoees 16 Selection f MEASUFEMENT POUT wees ceslitsccieiiedccteierns a a o catia ei 16 Preparation of Measurement Point ccccccecccceececeeeeeceeeeceeeeeseasesseecesecessaeeessaeeessaeeeseneesseaeenes 16 Typesof Measurement PACS iti cussstses cosiuenst aa e a o aE eerie 16 Pad MSU AU oN nan a A a eaten aeeonaiates 17 Bearing Condition Measurement for Diagnostic PUrPOSGG ccceeseeeeeeseeeeneeeeeeneeseees 19 Technical Specifications Adash 4910 Lubri c ceeceeseeeeseeseeeseeseeeseenseeeseenseeseeennees 20 2 ADASH Ltd Czech republic tel 420 596 232 670 fax 420 596 232 671 email info adash cz For more technical and contact information visit www adash net www adash cz ADASH spol s r o A4910 Lubri introduction There is an increasing demand for an instrument which is able to simply check lubrication of rolling bearings and also the condition of these bearings Every machine does have in its specifications how much lubricant every one of its bearings uses in a specific amount of operati
9. al AC signal 8 Q 0 5 W for external headphones listening to measured signal Power 2x1 5V AA alkaline batteries or 2x1 2V NIMH AA rechargeable batteries Consumption max 400 mA using headphones Dimensions 150 x 60 x 35 mm Weight approx 250 g 20 ADASH Ltd Czech republic tel 420 596 232 670 fax 420 596 232 671 email info adash cz For more technical and contact information visit www adash net www adash cz
10. ant Needs to Be Added The result of lubrication interval optimisation procedure is also the lowest value of a bearing condition Our goal is to reach this value by regular lubrication We add lubricant long enough to reach this reference value We need to realise however that a bearing is being worn out and so its working condition worsens That is why it is not possible to constantly reach during its lifetime its original reference value during lubrication The lubrication rule is then as follows Lubricate while the bearing condition value decreases then stop 11 ADASH Ltd Czech republic tel 420 596 232 670 fax 420 596 232 671 email info adash cz For more technical and contact information visit www adash net www adash cz ADASH spol s r o A4910 Lubri Instrument Description Input connector for lubrication sensor connector BINDER 712 Output headphone connector Stereo jack 3 5mm measured value Bar indicating lubrication state Volume up Volume down ON OFF Switch ADASH 4910 Lubri Batteries rechargeable batteries Adash 4910 Lubri Note The A4910 Lubri instrument has the LB TRUE RMS measurement method preset this method is capable of numerical evaluation of a bearing state 12 ADASH Ltd Czech republic tel 420 596 232 670 fax 420 596 232 671 email info adash cz For more technical and contact information visit www adash net www adash cz ADASH spol s r o A4
11. bricant is ideal This way it is ensured that we do not under or over lubricate When we use this instrument we can shorten recommended lubrication intervals since the instrument always exactly determines the ideal amount of lubricant needed As a result of using the A4910 Lubri instrument your machines will be maintained in their best lubrication condition The instrument enables you to make the whole lubricating process simpler and it normally reduces the consumption of very expensive lubricants 3 ADASH Ltd Czech republic tel 420 596 232 670 fax 420 596 232 671 email info adash cz For more technical and contact information visit www adash net www adash cz ADASH spol s r o A4910 Lubri What Will You Get with Your Instrument Instrument and Accessories The instrument case contains instrument A4910 Lubri lubrication and bearing condition sensor magnetic base for sensor coiled cable to connect sensor headphones 1 5V alkaline battery ADASH 4910 Lubri The complete lubrication set 4 ADASH Ltd Czech republic tel 420 596 232 670 fax 420 596 232 671 email info adash cz For more technical and contact information visit www adash net www adash cz ADASH spol s r o A4910 Lubri Application example 5 ADASH Ltd Czech republic tel 420 596 232 670 fax 420 596 232 671 email info adash cz For more technical and contact information visit www adash net www adash
12. ered into a computer If you want to successfully diagnose rolling bearing conditions use the following suggestions 1 Make a list of machines and bearings you want to measure Mark each measuring place 2 Measure every bearing at the same place under the same operational conditions 3 Mark the values only after proper bearing lubrication 4 Determine a reference value for each bearing Measure the reference value at a time when the bearing is in a good operational condition the best is after a successful installation of a new bearing 5 Record all measurements into a notebook or computer 6 We are capable to determine conditions of rolling bearings based on increasing values if there is an increase of 100 against a reference value we need to understand it as a warning and the bearing should be investigated in detail at the earliest opportunity if there is an increase of more than 400 a critical change in operational conditions of the bearing took place This bearing should be replaced as soon as possible 19 ADASH Ltd Czech republic tel 420 596 232 670 fax 420 596 232 671 email info adash cz For more technical and contact information visit www adash net www adash cz ADASH spol s r o A4910 Lubri Technical Specifications Adash 4910 Lubri lt 7 Technical Specifications Input 1x ICP powered accelerometer with 100 mV g sensitivity for measurement and recording of lubrication Output 1X monoaur
13. f glue as possible at the attachment location WARNING DO NOT PUSH OUT ALL THE GLUE Extra glue can be removed or smoothed around the pad Cover the pad by its cover When using T pad the amount of glue depends on the distance between cooling ribs so it is not possible to exactly determine this amount Just as with the simple pad you have to clean and degrease the space between ribs where the T pad is going to be attached This space needs to be filled by sufficient amount of glue so after inserting of the T pad only the cylindrical part of the pad would stay exposed Pack the glue around the pad then cover the pad with a cover 17 ADASH Ltd Czech republic tel 420 596 232 670 fax 420 596 232 671 email info adash cz For more technical and contact information visit www adash net www adash cz ADASH spol s r o A4910 Lubri Placement of measurement pads on a machine 18 ADASH Ltd Czech republic tel 420 596 232 670 fax 420 596 232 671 email info adash cz For more technical and contact information visit www adash net www adash cz ADASH spol s r o A4910 Lubri Bearing Condition Measurement for Diagnostic Purposes This instrument also takes measurements of rolling bearing conditions in addition to lubrication measurements For this purpose an actual value of bearing condition is displayed at the upper right side of the display It is possible to follow a time trend if these values are recorded or ent
14. f lubrication state Firstly to pick a suitable attachment place for the lubrication sensor i e place as close as possible to the bearing The bearing housing is ideal for this If this is not possible we should choose a part of a machine which is in as firm as possible contact with the bearing Covers etc are not suitable as measurement points the points have to be as rigid as possible The other condition is preparation of the measurement place gluing on a measurement base Note If your company performs vibration diagnostics on its machines you can utilize measurement points that have been created for this purpose for bearing lubrication measurements also Preparation of Measurement Point In order to obtain a quality measurement we need to properly prepare these places It is necessary in regularly performed lubrications to always attach a sensor the same way at the same place In order to perform bearing lubrication measurements we need to attach a sensor through magnetic base or even better screw it on For practical reasons most users use the magnetic base since screwing takes more time The magnetic base is a very strong magnet firmly screwed on to the sensor which is then magnetically attached to a surface of a machine The quality of the attachment significantly influences the measurement results If the sensor rocks or jumps etc the measurement is useless Also a thick layer of paint or corrosion lowers the usefulness
15. ion sensor with ICP power The sensor must be a standard accelerometer with 100 mV g sensitivity The instrument is equipped with its own source of ICP power for connected sensor The sensor needs to be connected at the right side plug using the supplied cable Then a magnetic base needs to be screwed on to the sensor connector to plug in headphones stereo jack 3 5mm connector to plug in the sensor Top view of the connectors Lubrication and Measurement If the instrument is ready we need to attach a lubrication head If a sensor is not a part of lubrication head we attach it by using a magnetic base to a formerly prepared and glued measuring base Do not forget to remove the cover of magnetic base which protects the magnet from weakening in storage Switch on the instrument by pressing Mode Provided that the batteries are OK the instrument display will show running bands and greasers red and green Then the instrument will automatically measure an actual lubrication state If your headphones are connected you will be able to clearly hear the bearing noise Using A and Y arrows you can increase decrease its volume On the left side of the display is a column whose height indicates a bearing lubrication state After the instrument is switched on it always reaches a maximum level We need to slowly start adding lubricant while monitoring the height of the column on the display and the noise in the headphones Usually there is
16. of a measurement The surface of the magnetic base is carefully ground and the same type of surface is needed on the machine This is of course practically impossible since we are only capable to create an evenly ground surface of 3x3 cm in a workshop Even if we were able to create such a surface it would not last since a quality of bearing housing steel for example is not high and it quickly succumbs to corrosion This renders the place unusable The solution is to use measuring pads They are small cylinders with diameter of approx 26 mm and 10 mm tall with ground surface They are made from magnetic stainless steel They are glued to appropriate places on a machine with a special glue which ensures perfect transfer of high frequency vibration The pad is covered by a plastic cover which is only removed at the time of measurement Another advantage of the cover is that in case of a machine being painted your measurement point is preserved Painting over the measuring pad destroys it All you need to do before gluing one of the pads is to degrease and roughly grind a machine surface in an appropriate spot The pads last indefinitely or until they are forcibly removed Types of Measurement Pads We supply two basic types of the measurement pads for measuring location preparation They are a simple measuring pad for easily accessible places on a machine and special T pad for electric motors 16 ADASH Ltd Czech republic tel 420 596
17. onal hours A task of each technician or engineer is to regularly check all the lubricated points and maintain lubricant at sufficient levels Either state lack or excess of lubricant are harmful for a rolling element bearing The result is always excessive stress on the bearing and consequently excessive wear Every lubricating point has a lubrication time interval in hours of service and also an amount of lubricant that needs to be replenished This manner of lubrication control has a significant disadvantage The amount of lubricant that any bearing actually needs for proper operation changes during its lifetime Longer lubricating intervals in the case of a new machine are usually not sufficient for a machine after several years of operation It is clear that it would be useful to be able to determine a state of a bearing somehow and replenish only as much lubricant as is actually needed Controlled lubrication increases bearing service life and lowers costs for lubrication and repairs We have collected a large amount of knowledge by researching machine long term operation and lubrication here at ADASH and we have applied it in developing the instrument A4910 Lubri It is simple to operate and user s training takes less than one hour The main use of this instrument is in the lubrication replenishment process During this process the instrument measures the actual lubrication condition of a bearing and tells the operator when the amount of lu
18. sor The disadvantage is a partial loss of sensitivity since the lubrication head attenuates the measured signal 2 The sensor is mounted next to lubrication point on a bearing housing measurement pad recommended This option enables a perfect measurement The disadvantage is a longer preparation since the lubrication head and sensor must be mounted separately 1 Sensor is on the lubrication head 2 Sensor is mounted next to lubrication point If vibration diagnostic measurements are performed on a machine then a measurement pad is already mounted This pad can be used also for lubrication measurements A procedure for mounting of a measuring base is shown at the end of this Guide T ADASH Ltd Czech republic tel 420 596 232 670 fax 420 596 232 671 email info adash cz For more technical and contact information visit www adash net www adash cz ADASH spol s r o A4910 Lubri Instrument Preparation The preparation of this instrument for measurement is easy All you need to do is to put in batteries and plug in the lubrication sensor and screw it on a magnetic base Remark The battery rechargeable battery space is behind a door in the base of the instrument Open the door by pressing its lower edge the edge with hinge then you can easily replace the batteries see chapter Instrument Description Battery Change Plugging in the Lubrication Sensor Lubrication measurements require plugging in a lubricat
19. ual working condition of a bearing a numerical value up on the display We can utilise this measurement for optimisation of lubrication using the following steps 1 We need to lubricate a machine thoroughly 2 Then we measure and record a reference value of the bearing condition 3 We need to repeat this measurement regularly in 1 10th lubrication intervals recommended by a manufacturer 4 If the condition value of the bearing increases to double of its reference value then further lubrication is needed and time from reference measurement to this new lubrication is our new optimum lubrication interval Remark In case that we overlubricate a bearing at the initial reference lubrication the bearing condition value can initially decrease until the amount of lubricant in the bearing reaches an optimum minimum value Than we use this time and value as our initial reference Example The manufacturer recommended lubrication interval is 600 service hours The reference value is 0 25g The control measurements are performed every 60 service hours see Table p60 026 The measured value reached double of the reference value in 240 service hours Optimum lubrication interval is then 240 service hours 10 ADASH Ltd Czech republic tel 420 596 232 670 fax 420 596 232 671 email info adash cz For more technical and contact information visit www adash net www adash cz ADASH spol s r o A4910 Lubri How Much Lubric
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