IRD Mechanalysis IRD811 Operation & Maintenance Manual

Vibration spike energy detector

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IRD Mechanalysis Limited

1/5,MarolCo-opInd. Estate Ltd

Off. M. Vasanji Road, Marol

Andhedri (E), Mumbai – 400 059

Tel: 91-22-2852 2906, Fax: 91-22-2852 1814

Email :

service1@irdmech.com

Web:

www.irdmechanalysis.com

IRD

Mechanalysis

IRD811

Vibration Spike Energy Detector

Operation & Maintenance Manual

Version 2.0

Limited

May 2013

Customer Details

Date Purchased:

IRD Serial Number (s):

P.O. ref:

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Page 1 Mechanalysis Limited IRD811 Vibration Spike Energy Detector Operation & Maintenance Manual Version 2.0 May 2013 IRD Mechanalysis Limited Customer Details 1/5,MarolCo-opInd. Estate Ltd Date Purchased: Off. M. Vasanji Road, Marol Andhedri (E), Mumbai – 400 059 IRD Serial Number (s): Tel: 91-22-2852 2906, Fax: 91-22-2852 1814 P.O.
Page 2 Mechanalysis Limited www.irdmechanalysis.com IRD Mechanalysis Limited continues to be the industry leading provider of Condition Management Solutions. With over 30 years’ experience in machinery vibration and associated condition monitoring technologies, the company designs and manufactures proven instrumentation suitable for rugged industrial environments. A comprehensive range of products and services are available from the offices below.
Page 3: Table Of Contents
Standard Package of IRD811 IRD 811 Standard Accessories IRD 811 Optional Accessories Front view of IRD811 showing all the controls, indicators & connectors A typical vibration measurement datasheet A general machinery vibration severity chart (Metric) A general Machinery Acceleration Severity Chart...
Page 4 4.6 In-Situ Balancing SERVICE 5.1 Field Maintenance 5.2 Spare Parts Listing 5.3 Instrument Calibration Procedures SPECIFICATIONS 6.1 IRD811 Portable Vibration Meter (Accelerometer) 6.2 IRD511 Accelerometer APPENDIX- A Keeping you going SUPPORT SERVICES Taking you further VIBRATION BASED CONDITION MONITORING SOLUTIONS...
Page 5: Periodic Vibration Measurement Save Valuable Machine
ENERGY Detector. Included in this manual are complete instructions on the preparation, setup, operation, and service of these instruments. Specifications of the model IRD811 and the major accessories are provided in Appendix A. Information on the significance of the measured vibration amplitude levels in displacement, velocity & acceleration and the procedures for evaluating SPIKE ENERGY measurements are well covered in the manual.
Page 6: Standard Package Of Ird811
Getting you started DESCRIPTION 2.1 GENERAL Thank you for investing in IRD Mechanalysis Vibration Meters. We trust that like many thousands of users before you will continue to enjoy optimum value from your wise investment. IRD Mechanalysis Limited is an independent System Integration Company that designs and manufactures condition monitoring system solutions.
Page 7: Ird 811 Standard Accessories
Manual Training - IRD Mechanalysis Vibration Technology 1 M51001 2.2 DESCRIPTION OF ACCESSORIES 2.2.1 STANDARD ACCESSORIES The standard accessories available for use with the model IRD811 are illustrated in figure 3 and are described below Figure 3 IRD 811 Standard Accessories A) IRD511 Accelerometer The IRD511 Accelerometer can be used in any position without loss of accuracy or sensitivity.
Page 8: Ird 811 Optional Accessories
IRD811 Vibration-SPIKE ENERGY Detector. Additional copies of the manual could be obtained from IRD Mechanalysis. 2.2.2 OPTIONAL ACCESSORIES The optional accessories available for use with the model IRD811 are illustrated in figure 4 and are described below. Figure 4 IRD 811 Optional Accessories...
Page 9 The threaded receptacle at the opposite end of the cable connects to the connector on the end of the IRD544 Sensor. This cable may also be used to connect the Model IRD811 to a vibration analyzer. C) Cable for IRD544 Sensor 8m The Extension Cable is 8 meters in length and when required, is connected to the external end of the standard cable to increase the overall IRD544 cable length to 29 feet.
Page 10: Front View Of Ird811 Showing All The Controls, Indicators & Connectors
Amplitude meter. In Metric units, the ranges extend from 1 to 3000 micrometers pk-pk, or mm/sec pk., In addition, the model IRD811 is also equipped with ISO ranges from 1 to 3000 mm/sec, RMS. The eight amplitude ranges that may be selected on each instrument model are listed in Table 1.
Page 11: Amplitude Ranges For Ird811
® IRD Mechanalysis Limited IRD811 O&M Manual Table 1 Amplitude ranges for IRD811 METRIC UNITS ISO UNITS microns pk –pk /mm/sec pk g’s pk mm/sec RMS 0 – 1.0 0 – 0.03 0 – 1.0 0 – 3.0 0 – 0.01 0 –...
Page 12: Measure Units, Ranges And Meter Scale Used In Ird811
® IRD Mechanalysis Limited IRD811 O&M Manual Table 2 Measure units, ranges and meter scale used in IRD811 METRIC UNITS Micrometer and Meter Scale g’s Meter Scale mm/sec Ranges Reading Ranges Reading 0 – 1 UPPER 0 – 0.03 LOWER 0 –...
Page 13: Amplitude Ranges For Ird811 Vibration Spike Energy Detector
The 6 Pin threaded connector at the opposite end is connected to the instrument. Set the AMPLITUDE RANGE selector on the IRD811 instrument to the position listed in the table below for the mode to be tested, then check that the Amplitude meter indicates a reading within the required limits.
Page 14: Accelerometer Mounting
® IRD Mechanalysis Limited IRD811 O&M Manual NOTE: The readout limit values reflect the combined tolerance of the instrument (+3%) and the calibrator (+1%). If the Amplitude meter indications are within the proper limits, then the instrument circuits and the sensor cable are functioning correctly. The sensor cable may then be disconnected from the Calibrator and the POWER switch set to OFF.
Page 15 ® IRD Mechanalysis IRD811 O&M Manual Limited The optional magnetic holder may also be used to secure the accelerometer to the rotating machine. The magnetic holder is attached to the pickup using the ¼-28x1/4- inch threaded hole and M6 stud. Silicone grease is normally applied to the mating surfaces.
Page 16 To connect an oscilloscope or tape recorder to the model IRD811, instrument a signal cable with a velocity sensor connector must be used. The output signal provided by the IRD811 instrument has a full-scale voltage level of 301 mV, rms, in Metric units. NOTE: FILTERED SPIKE ENERGY signal voltages are not provided at the output connector.
Page 17: Operation
® IRD Mechanalysis IRD811 O&M Manual Limited OPERATION 4.1 GENERAL The Vibration-SPIKE ENERGY Detector is designed to measure the overall machine vibration amplitude and the SPIKE ENERGY signal levels produced by moving- element bearing and high speed gears. All vibration readings obtained with the instrument should be compared to known standards of vibration for the type of machine, bearing, or gear being checked.
Page 18: A Typical Vibration Measurement Datasheet
® IRD Mechanalysis IRD811 O&M Manual Limited 4.3 VIBRATION MEASUREMENT The vibration should be measured in the vertical, horizontal and axial planes of each bearing housing. The vibration levels are then indicated on the AMPLITUDE METER. All pertinent rotating machine information, along with the vibration readings, should be recorded on a datasheet similar to the one shown in Figure 6.
Page 19: Tentative Guide To Vibration Tolerances For Machine Tools
® IRD Mechanalysis IRD811 O&M Manual Limited Table 4 Tentative guide to vibration tolerances for machine tools Displacement of vibration as read Type of machine with pickup spindle bearing housing in the direction of cut Grinders Tolerance Range Thread Grinder 0.25 - 1.5 microns...
Page 20: A General Machinery Vibration Severity Chart (Metric)
® IRD Mechanalysis IRD811 O&M Manual Limited ©2008 IRD Mechanalysis Ltd Figure 7 A general machinery vibration severity chart (Metric) The SPIKE ENERGY mode circuits are used for the detection of deteriorating and defective rolling element bearings and gear teeth. These circuits are completely independent of those which measure the RMS vibration components in the displacement, velocity or acceleration modes.
Page 21: A General Machinery Acceleration Severity Chart
® IRD Mechanalysis IRD811 O&M Manual Limited IRD Mechanalysis (India) Frequency (CPM) Ltd. Figure 8 General Machinery Acceleration Severity Chart 4.5 DETERMINING DOMINANT VIBRATION FREQUENCY If a single frequency is dominant in the machine vibration, the Vibration-SPIKE ENERGY Detector can be used to determine what this dominant frequency is. If the vibration level...
Page 22: Dominant Vibration Frequency Chart
The dominant vibration frequency can also be determined from the chart in Figure 9, by relating the vibration velocity and displacement values obtained on the Amplitude Meter of IRD811 instrument to this chart. The dominant vibration frequency value can often be used to determine the machine part causing the vibration.
Page 23: Dominant Machine Excitation Frequencies And Most Likely Causes
When the dominant frequency of the vibration has been determined, the data in table 5 can be used to help identify the specific problem. However, one must remember that only a preliminary identification of the vibration can be accomplished by using a model IRD811 instrument. A positive confirmation of the diagnosis requires a vibration analyser.
Page 24 ® IRD Mechanalysis IRD811 O&M Manual Limited manufacturer’s specifications. On some machines, methods such as bolting or welding the weights to various machine parts are used. In addition, provision for the removal of existing weights for balancing are provided in some cases.
Page 25: Sample Balancing Vector Diagram
® IRD Mechanalysis IRD811 O&M Manual Limited Construct a vector diagram as illustrated in Figure 10 by using the “O”. “T1” and “T2” value obtained in Step 2, 5 and 8 for the rotating machine being balanced. (A scaling of 10cm per microns of unbalance is used in this figure).
Page 26 ® IRD Mechanalysis IRD811 O&M Manual Limited EQUATION 2: REQUIRED CORRECTION WEIGHT = ‘O’ x “TW” (Value “O” was obtained in Step 2, value “TW” in Step 3 and value “R” in Step 13). NOTE: In Figure above the “O” value is 100 microns (original unbalance), the “TW”...
Page 27: Battery Replacement Details
Limited SERVICE FIELD MAINTENANCE The model IRD811 instrument generally requires very little field maintenance. The extent of the maintenance provided by the user may vary, depending on the availability of competent service facilities. The following service procedures can be easily performed in the field without the use of electronic test equipment: A.
Page 28: Instrument Calibration Procedures
The test equipment required for calibration of the model IRD811 instruments are listed below. Also, the circuit connections required is shown in Figure 12. The equipment should be installed with the test leads connected to the model IRD811 input receptacle as shown in this figure.
Page 29: Calibration Test Connections
® IRD Mechanalysis IRD811 O&M Manual Limited SIGNAL J101 GENERATOR Vibration Spike Energy Detector FREQUENCY COUNTER DIGITAL VOLT METER J102 Figure 12 Calibration Test Connections Preliminary steps Meter Adjustment – If necessary, adjust the Amplitude meter zeroing screw on the front panel for a “0”...
Page 30 ® IRD Mechanalysis IRD811 O&M Manual Limited NOTE: For SA instrument versions, ignore Steps 6 and 7. Set the DVM to measure AC voltage, and connect the test leads to the Analyser/Scope Output receptacle as follows : (+) SIGNAL – Pin B GROUND –...
Page 31 FREQUENCY – 10K Hz Adjust R155 (B/G Cal) for a reading of 0.5 on the Amplitude meter. ISO Mode Check (model IRD811 only) Check that the generator (+) signal lead is connected to Pin C and the ground to Pin A on the input connector.
Page 32 ® IRD Mechanalysis IRD811 O&M Manual Limited 4. Check that the Amplitude meter indicates a reading of approximately 25.4 micrometer. IRD544 DISPLACEMENT (1400 CPM) MODE CHECK 1. Check that the generator (+) signal lead is connected to Pin B and the generator ground to Pins A and F on the input connector.
Page 33: Specifications
Cable Assembly for model IRD811 to IRD511 accelerometer - 1.5m M60021 rubber insulated, shielded Stinger Al 225mm Straight for Sensor M24827 Battery Set, 3 Nos. of 9V, 100mAH Dry Cells for model IRD811 M30643 Carrying Case M25345 Manual Operating M21072...
Page 34 Carrying case: - 2.25 Kg (inc. meter, standard accessories) Spike Energy and gSE is a trademark of IRD Mechanalysis Inc. IRD Mechanalysis Ltd. continuously improves products; it therefore retains the right to change the above specification without notice condition management solutions...
Page 35: Ird511 Accelerometer
2-pin IRD-C-5015 Mounting ¼” – 28 UNF Female Options Integral cable, filters, temperature output, various connector assemblies, other sensitivities IRD Mechanalysis Ltd. continuously improves products; it therefore retains the right to change the above specification without notice condition management solutions...
Page 36 ® IRD Mechanalysis IRD811 O&M Manual Limited 7. Appendix A Use of Spike Energy measurement to detect defects in rolling element bearings and gears 1) SPIKE ENERGY CIRCUITS The SPIKE ENERGY detection circuits are designed to sense the amplitude of the microsecond range pulses caused by impacts between bearing elements which have microscopic flaws.
Page 37: Rolling Element Bearing Gse Severity Chart
® IRD Mechanalysis IRD811 O&M Manual Limited 4) OTHER SOURCES OF SPIKE ENERGY SIGNALS When taking bearing checks, it must be kept in mind that there are sources other than bearings which give off SPIKE ENERGY signals. Gears, cavitation, rubbing or striking of metal parts such as seals and coupling guards, are some of the more common sources which are likely to be encountered.
Page 38: Keeping You Going
At our National Service Centre in Mumbai we stock a comprehensive supply of spare parts to ensure a quick turnaround. BENEFITS and FEATURES For IRD Mechanalysis Ltd’s customers, the National Service Centre offers the following: • Fast in-house turnaround options Expert factory technical assistance •...
Page 39 • Balancing Systems: 245, 246, IRDB50 and IRDB150 dataPAC, Enpac, and Fast Track are trademarks or registered trademarks of IRD IRD Mechanalysis Turnaround time and repair capabilities are dependent upon condition of equipment and spare parts availability at the time of the product assessment.
Page 40 Regional Offices 4. Alternatively Email us at : service@irdmech.com 5. Complete the RMA and fax back to IRD Mechanalysis at Fax: +91(0)22-2832-1814 6. When the RMA has been issued, the Client sends the instrument with all accessories together with the Purchase Order making reference to the RMA Number.
Page 41 Limited RMA (Return Materials Advisory) Form ATTN: IRD Mechanalysis Ltd, National Service Centre, 1/5 Marol Co-op, Industrial Estate Ltd, Off Mathurdas Vasanji Road, Marol, Andheri (E), Mumbai 400 059, India. +91(0)22-2852 0178 / 2906 FAX BACK RMA FORM: +91(0)22-2852 1814 or Email to : service@irdmech.com...
Page 42: Taking You Further
Taking you further 8. Vibration Based Condition Monitoring Solutions IRD Mechanalysis Ltd is a leading provider of condition management solutions with over 30 years’ experience in machinery vibration measurement. IRD is credited with pioneering the concept of vibration based condition monitoring programmes in India.