FAG Detector III – The solution for monitoring and balancing
Contents
1. FAG Detector Ill The solution for monitoring and balancing Technical Product Information SCHAEFFLER GROUP INDUSTRIAL Principle Operation Condition based maintenance Condition based maintenance means identifying damage at an early stage defining planned repairs making optimum use of bearing life and achieving considerable reductions in costs FAG Detector III fulfils these tasks to an optimum degree and is also highly suitable for users without knowledge of vibration technology Preventing plant downtime There are many different reasons for unplanned downtime of machinery However a not inconsiderable percentage can be attributed directly or indirectly to imbalance or misalignment During operation imbalance can generate considerable vibrations that lead to secondary damage such as premature bearing wear or fatigue fractures This results in machine failure and thus unplanned production shutdowns FAG Detector Ill is a tool that can be used to not only identify but also easily and efficiently eliminate such conditions Bearing damage Imbalance and misalignment Reasons for unplanned downtime High functionality Simple handling FAG Detector Ill is an offline vibration monitoring system data collector and operational balancing device all in one By means of various sensors it can record the vibrations temperatures and speeds of machinery Step by step the device s so2. 105 King William Street Kent Town South Australia 5067 Australia Phone 61 8 8366 0700 E Mail Sales cmsa net au Internet www cmsa com au Every care has been taken to ensure the correctness of the information contained in this publication but no liability can be accepted for any errors or omissions We reserve the right to make technical changes Schaeffler KG 2007 April This publication or parts thereof may not be reproduced without our permission TPI WL 80 64 2 EF
3. ce PIS knows that customers wishing to change to the concept of continuous condition monitoring have differing needs and Services for FAG Detector III requirements Therefore PIS has a comprehensive portfolio of products and services containing both standard and customer specific solutions that are always developed in close partnership with the customer The F IS service portfolio for continuous condition monitoring covers the following areas e consultancy e installation e initial operation e system support e continuous and regular measurement wa a a u a uE It is of course the customer who decides which of the available services he wishes to use For example he can choose complete monitoring of his plant by F IS or to have his employees qualified for independent monitoring at their own responsibility through training Whichever service is selected the team of PIS experts is available at any time If you have any further questions on our services please contact us directly or visit our website sid a a a a ot a ot oJ Wd 98 04 07 Printed in Germany by Druckhaus WEPPERT GmbH Schaeffler KG Postfach 1260 97419 Schweinfurt Germany Georg Schdafer Strasse 30 97421 Schweinfurt Germany Service Hotline Phone 49 2407 9149 99 Fax 49 2407 9149 59 E Mail info fis services com Internet www fis services com Every care has been taken to ensure the correctness of the information con
4. d with 21 keys Illuminated graphic display LCD 128 x 64 pixels 551 mm x 33 mm 1600 measuring points plus 270 time signals maximum 300 time signals 230 x 70 53 x 45 53 mm tl x B x H approx 500 g including battery 0 C to 50 C working temperature Approx 6 to 8 hours continuous operation ABS IP 40 Two compartments black nylon carry strap EN61000 4 2 3 6 Free of charge firmware updates o on Internet Available languages German English Finnish French Italian Dutch Portuguese Swedish Slovenian Spanish and Turkish Trendline updates on Internet Suitable for Windows 2000 XP Available in German English French Portuguese and Spanish configuration of FAG Detector IIII via RS 232 interface bearing database of approx 20 000 bearings graphic presentation of measurement values and curve trend analysis presentation of time signals and FFT display of balancing in tabular and diagrammatic format configurable report generator Everything from a single source Customised monitoring solutions for everyone Everything from a single source customised monitoring solutions for everyone FAG Industrial Services F lS is a full service supplier in the field of condition based maintenance With the sourcing of high quality PIS products the customer thus gains access to a range of product related services see diagram Services Based on many years experien
5. e hand using 21 keys e Soft keyboard resistant to dust and spray water e Headset jack for acoustic noise assessment e Storage and display of up to 4 measurement values per measuring point for straight forward condition assessment e RFID reader retrofittable for readout of RFID transponders e Configurable report generator e E Mail service e Software e Sensor cable length up to 50 m Ordering designation and scope of delivery Detector Ill is available without and with automatic measuring point detection RFID The Balancing Kit and accessories are equally suitable for both devices Ordering designation DETECT3 KIT Scope of delivery e Basic device with rechargeable battery e Acceleration sensor with magnetic foot e Temperature sensor e Charger e PC data cable serial USB e User manual e Protective bag with holder for temperature sensor e PC software Trendline e Case Ordering designation DETECT3 KIT RFID Scope of delivery e As DETECT3 KIT e RFID Reader integrated in basic device e RFID tags Ordering designation DETECT3 BALANCE KIT Scope of delivery e Acceleration sensor with magnetic foot and sensor cable e Trigger sensor optical and inductive e Balance e Magnetic holder for trigger sensor e Extension for magnetic holder e Cable for trigger sensor length 10 m e Reflex mark for trigger sensor e Dongle for activation of balancing function e Case Accessori
6. equivalent conditions load speed etc are present After reference measurement measurements should be carried out at regular intervals bl aao aao 4000 amo amo mao maw maw n xam sao mao aan naw nan saan aanl saan taa aao ao aa co aco Presentation of measurement data in the Trendline software Route planning Bearing database Route planning The user can model the plant structure on a PC using the Trendline software Within these configurations routes can be defined for example for individual days of the week or by machine type Before measurement the selected route is transferred to FAG Detector III After a measurement round all the recorded data are transferred to the Trendline soft ware for evaluation analysis and presentation by means of diagrams and tables Trendline bearing database The integrated bearing database containing approx 20 000 bearings from various manufacturers allows considerably simplified and shortened analysis of the measured data In tandem with PIS Viewer the bearing database offers a perfect combination for assessing machine Bearing database condition Significant features can be recognised and allocated to the appropriate components at first sight A separate bearing list can be filed for each measuring point This offers the option of checking several bearing kinematic frequencies efficiently at one measurement po
7. es e Sensor extension cables of lengths of 5 m and 15 mare available on request e Further RFID tags are available on request Ordering designation for countries outside Europe FIS DETECTORIII KIT FIS DETECTORIII KIT RFID FIS DETECTORIII BALANCING KIT DETECT3 BALANCE KIT DETECT3 KIT Selection of parameters Selection of parameters Possible parameters and signal curves for each measuring point Measurement range resolution Parameter vibration velocity to ISO 10816 VDI 2056 broadband RMS value for vibration velocity for general assessment of machine condition to ISO 10816 Parameter vibration velocity freely selectable RMS value for vibration velocity e g for detection of imbalance and misalignment Parameter acceleration broadband RMS value for vibration acceleration e g for monitoring of gearboxes Parameter acceleration freely selectable e g for selective gear tooth monitoring RMS value of demodulated signal up to 100 1000 Hz e g for monitoring of rolling bearing condition Parameter demodulated signal freely selectable e g for selective monitoring of rolling bearing condition Time signal of vibration acceleration upto low pass cut off frequency 4096 or 8 192 values Demodulated time signal up to set low pass cut off frequency 4096 or8 192 values Frequency spectrum Fourier transform of time signal for vibration velocity up to set low pas
8. ff frequency lower limit frequency TP number of lines 2 56 3 100 mV g sensor 4 Quantity of values 4096 at 1600 FFT lines or 8192 at 3 200 FFT lines 0 5 Hz to 166 Hz Detector and PC On the PC the user can specify for each measuring point whether and under what conditions certain time signals are to be stored Three different time signals can be measured namely vibration velocity 0 1 Hz to TP scan rate 2 56 TP vibration acceleration 0 1 Hz to TP scan rate 2 56 TP and demodulated signal 0 Hz to TP scan rate 2 56 TP FAG Detector IIl can store up to 300 time signals Technical data Data collection Measurement ranges Parameters Window function Averaging i in frequency range Scan rate A D converter Frequency resolution Automatic measurement point detection Inputs Outputs 1 TP low pass cut off frequency Acceleration vibration velocity 0 1 Hz to TP 0 1 Hz to 200 Hz 0 1 Hz to 500 Hz Demodulated signal 0 Hz to TPY Low pass cut off frequencies 200 500 Hz 1 2 5 10 20 kHz High pass demodulated signal branch 750 Hz Temperature 20 C to 550 C temperature range as a function of sensor used freely configurable input 2 kHz to TPD RMS val for Vibration acceleration Ai Ase RMS value for vibration acceleration in freely definable frequency range ISO 10816 10 kHz to 1 kHz RMS value for vibration velocity Vea RMS value for vibration vel
9. ftware guides the user through the measurement and balancing procedure The user friendly software Trendline then allows easy and effective data analysis Any incipient damage can thus be detected at a very early stage As a result maintenance can be planned and machine availability can be increased FAG Detector IIl is thus the ideal entry level device into the world of offline plant monitoring Advantages of the system Parallel monitoring of vibration and temperature Static and dynamic balancing on site Optimised vibration data recording by means of RFID technology Wide range of options for analysis and presentation Simple and easy to use Excellent price performance ratio Areas of application Areas of application Machine vibrations are a good indicator for the condition of a machine FAG Detector III can be used to monitor machine vibrations according to ISO 10816 and the condition of rolling bearings by means of the demodulated signal detection method FAG Detector III is thus a highly suitable device for the detection of e imbalance and misalignment e rolling bearing damage e gearbox damage tooth sets Typical areas of application include the monitoring of e pumps e electric motors e fans machine tools e compressors e gearboxes e spindles e etc Measurement and analysis of machine condition FAG Detector III picks up vibration signals at predetermined measuri
10. int The bearing database can be expanded individually by each user to include further entries RFID Report Automatic detection of measuring points RFID With the new optional functionality of automatic measuring point detection recording of measurement values using FAG Detector Ill is faster simpler and more user friendly With the aid of RFID technology the device automatically detects the measuring points if these are equipped with RFID tags and jumps to the corresponding point in the configuration Measurement of the wrong assembly and erroneous allocation of measuring points are thus a thing of the past The employee only needs to start and store measurement using FAG Detector IIl no other action is required Nothing could be simpler The RFID technology can be easily retrofitted to existing FAG Detector Ill devices Run up coast down Run up coast down is used to determine resonance points Ina diagram Bode plot both the amplitude and the phase during run up or coast down are laid off over speed and presented in diagrammatic form in PIS Viewer The resonance ranges determined can then be marked diagrammatically and allocated to any balancing configuration In the worst case balancing in the resonance range can lead to machine damage 3 4 E Bochum E Kompressoraum fl Kompressor 1 1 Kompressor 2 VB ps1 r ps2 Bi ss3 rE ss rE Motor 4 TB MotB Kompressor 3 r
11. ng points and calculates the RMS values for vibration velocity vibration acceleration and the demodulation These characteristic values describe the condition of the machine and component and are presented in greater detail in the table on page 6 The sensor should be positioned as close as possible to the point to be measured In general it is attached to the machine by means of the screw mounted magnetic foot Measurement For the measurement procedure the user selects this measurement location in the configuration system of FAG Detector Ill and measurement is started At the beginning the speed is measured which should be constant during measurement at least 40 or 600 rpm for ISO 10816 The device records the sensor signals according to the selected bandwidths and calculates the parameters For each configuration FAG Detector IIl compares the measured parameters with the main alarm limit values defined for this measurement location Ifa threshold value is exceeded this is displayed directly on the device For conspicuous parameters the causes can be recognised from the demodulated and raw signal spectrum ole eo Fe kaw Eee Se With the aid of trend analysis the user can estimate when an alarm will probably occur When an alarm is triggered an alarm report can be automatically generated and printed out In order to allow comparison of values in offline measurement it must be ensured that approximately
12. ocity in freely definable frequency range frequency band as a function of TP Deff RMS value for demodulated signal Disa RMS value for demodulated signal in freely definable frequency range Crest factor speed temperature Hanning 1 9 FFT patanieters p per r channel Linear Max 51 2 kHz asa function of set TP 1600 3 200 lines 0625 Hz to 12 5 Hz asa function of set TPY RFID 13 56 MHz ISO 15693 compatible with RFID tags of stated specification 2 x BNC jacks multiplexer ICP 4 7 mA steplessly adjustable sensitivity AC DC 5V impedance gt 100 kQ 1 x AUX Tachometer input 5 to 24V lt 10 000 rpm rising or falling flank selectable IR temperature sensor 5V impedance gt 100 kQ freely configurable Battery charger Headset demodulated signal RS 232 for data transmission 38 4 kps 57 6 kps AUX supply for trigger sensor 5 V max 200 mA 12 V max 50 mA Technical data Measurement Balance units Weight units 1 or 2 plane balancing Weight positions Continuous 0 to 359 or discrete 4 to 99 positions Removal of weights yes no Peak peak to peak RMS g mm s inch s Hm mil gr OZ up to 99 999 99 gr or tozi Separate measurements Keyboard Display Memory Power r supply Dimensions sand m mass Temperature range Operating time B Housing o Protective bag EMC standards Firmware Software Temperature speed headset demodulated signal Soft keyboar
13. os i m ps2 rE ss3 rE sss TD Moto A BB Moto 8 BB Kompressor 4 GB Bremerhaven BB Schit By Macchinereaum Report generation Configurable report A very useful feature of the Trendline software is the expanded report generator This offers maintenance personnel in the company as well as external service providers using FAG Detector III the possibility of achieving seamless documentation of measurement results The report generator makes it possible to prepare different reports matched specifically to individual customer requirements All the information present in the system can be used for the report including time signals trend curves and alarm data z OE a I Time range Stat 1311 2006 x 15 2233 End 202207 s23 Number of days 101 Alam selection I Repot al F Repot slams VF Repot pe alams Char values Timesignal FFT I Show tends F Timesigna F FFT Cc al Selected Features Ordering designation and scope of delivery Operating benefits e Complete package e Static and dynamic balancing 1 and 2 planes e Monitoring functions ISO 10816 temperature general vibration condition rolling bearing condition data collector for up to 1600 measurement points storage of up to 300 time signals e Portable handy easy to use diagnostic device e Integrated database with approx 20000 entries e Operation with on
14. s cut off frequency Frequency spectrum Fourier transform of time signal for vibration acceleration up to set low pass cut off frequency ISO 10816 0 to 5 52 m s at 10 Hz 0 to 55 2 mm s at 1 kHz Veet 0 to 5 52 m s at 10 Hz 0 to 55 2 mm s at 1 kHz Aeff 0 to 37 g 0 to 37 g a Sea rarer E ey N Frequency range 10 Hz to 1 kHz Freely selectable up to set TP max 20 kHz 2 kHz up to set TP max 20 kHz Freely selectable up to set TP max 20 kHz Freely selectable up to set TP max 20 kHz Freely selectable up to set TP max 20 kHz 0 1 Hzto 20kHz2 0 1 Hz to 20 kHz2 0 3 Hz to 20 kHz 50 8 resolution TP 2 56 quantity of values 0 0625 Hz to 12 5 Hz 0 1 Hz to 20 kHz 2 resolution TP 2 56 quantity of values 0 0625 Hz to 12 5 Hz Display Detector and PC Te and PC and PC and PC a and PC and PC oe Frequency spectrum Fourier transform of time signal for demodulated signal or up to set low pass cut off frequency Measurement point temperature 25 9 resolution TP 2 56 quantity of values 0 0625 Hz to 12 5 Hz 0 1 Hz to 20 kHz Temp heen reg aa i aa aust Calculation from time signal for acceleration up to TP Detector and PC 30 to 10 000 rpm D TP low pass cut off frequency 200 500 Hz 1 2 5 10 20 kHz 2 Lower limit frequency as a function of set low pass cut o
15. tained in this publication but no liability can be accepted for any errors or omissions We reserve the right to make technical changes Schaeffler KG 2007 April This publication or parts thereof may not be reproduced without our permission TPI WL 80 64 2 EA 99 5 04 07 Printed in Germany by Druckhaus WEPPERT GmbH Schaeffler Canada Inc 2871 Plymouth Drive Oakville ON L6H 5S5 Canada Phone 1905 829 2750 Fax 1 905 829 2563 www fis services com Every care has been taken to ensure the correctness of the information contained in this publication but no liability can be accepted for any errors or omissions We reserve the right to make technical changes Schaeffler KG 2007 April This publication or parts thereof may not be reproduced without our permission TPI WL 80 64 2 EC 99 04 07 Printed in Germany by Druckhaus WEPPERT GmbH Schaeffler Group USA Inc 200 Park Avenue PO Box 1933 Danbury CT 06813 1933 USA Every care has been taken to ensure the correctness of the information contained in this publication but no liability can be accepted for any errors or omissions We reserve the right to make technical changes Schaeffler KG 2007 April This publication or parts thereof may not be reproduced without our permission TPI WL 80 64 2 ED 99 5 04 07 Printed in Germany by Druckhaus WEPPERT GmbH Condition Monitoring Services Australia A division of the Schaeffler Australia Pty Ltd
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