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23826 MANDELLO DEL LARIO (LC) ITALY Via Risorgimento, 9 - Tel. 0341/706.111 Tlx 380440 CEMB I - Fax (+39-341) 735.678
N402
Nr. 1165 - 1999.01
OPERATING INSTRUCTIONS
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Contents
page
INSTRUMENT DESCRIPTION ................................................................................. 5 ACCESSORIES ........................................................................................................ 5 SPECIFICATIONS .................................................................................................... 6 GENERAL RECOMMENDATIONS .......................................................................... 6 1 - PRESETTING OF INSTRUMENT AND SENSOR PARAMETERS .................... 7
1.1 - Presetting and general information menu ........................................................................................ 7 1.1.1 - Filter ................................................................................................................................... 7 1.1.2 - Unit of vibration measurement .......................................................................................... 7 1.1.3 - Unit of frequency measurement ......................................................................................... 8 1.1.4 - Transducer 1 ...................................................................................................................... 8 1.1.5 - Transducer 2 ...................................................................................................................... 8 1.1.6 - Transducer parameters ..................................................................................................... 8 1.1.7 - Display + Battery ................................................................................................................ 9 1.1.8 - Clock .................................................................................................................................. 9
....................................................................... 10 .................................................................. 10
........................................................................ 11
4.1 - Presetting and general information menu ..................................................................................... 11 4.1.1 - SYNC x N ........................................................................................................................ 11 4.1.2 - FIX .... Hz ......................................................................................................................... 12 4.1.3 - FIX ....CPM ...................................................................................................................... 12 4.1.4 - FILTRO OFF ................................................................................................................... 12 4.1.5 - FILTER ISO 2372 - 10Hz<F<1 KHz ................................................................................. 12 4.1.6 - FILTER - HDF BEARING WEAR .................................................................................... 12
5 - VIBRATION ANALYSIS
.................................................................................. 13
5.1 - Presetting and general information menu .................................................................................... 13 5.1.1 - To call an already acquired graph .................................................................................... 13 5.1.2 - Measurement ................................................................................................................... 13 5.1.3 - Display and accessory commands ................................................................................... 14
6 - FFT
................................................................................................................... 15
6.1 - General ............................................................................................................................................. 15 6.1.1 - Frequency range .............................................................................................................. 15 6.1.2 - Resolution (number of lines) ............................................................................................. 15 6.1.3 - Weighing window ............................................................................................................. 15 6.1.4 - Signal dynamics ............................................................................................................... 15 6.1.5 - Average results ................................................................................................................ 15 6.1.6 - Trigger ............................................................................................................................. 15 6.2 - Operation .......................................................................................................................................... 16 6.2.1- Presetting ........................................................................................................................ 16 6.2.2 -To make the measurement ................................................................................................ 16 6.2.3 - Impact test ....................................................................................................................... 17
.............................................. 18
7.1-Type of balancing .............................................................................................................................. 19 7.1.1 - Balancing on just one plane ............................................................................................ 21 7.1.2 - Balancing on two planes ................................................................................................... 22 7.1.2.1- Use of two measurers ................................................................................................... 22 7.1.2.2 -Use of just one measurer .............................................................................................. 23 7.1.3 - Balancing on three planes .................................................................................................... 23
......................... 24
............................................................................................... 27 ............................................................... 29
10 - MEMORIZATION OF PROGRAMS
10.1 - General
.......................................................................................................................................... 29
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10.2 - Presetting menu .......................................................................................................................... 29 10.2.1 -Read memory ................................................................................................................. 29 10.2.2 - Write memory ................................................................................................................. 29 10.2.3 - Rewrite memory n.xxx ..................................................................................................... 30 10.2.4 - Clear .............................................................................................................................. 30 10.2.5 - Clear the ENTIRE memory ............................................................................................. 30
11 - ERROR MESSAGES
..................................................................................... 31 .......................................................................... 31
15.1 - General ........................................................................................................................................... 33 15.1.1 - To change the roll of paper ............................................................................................. 33 15.2 - Printing of certificates - Presetting menu ................................................................................... 33 15.2.1 - Print-out with heading ..................................................................................................... 33 15.2.2 - Print-out of values only .................................................................................................. 34 15.2.3 -Certificate heading .......................................................................................................... 34
APPENDIX ................................................................................................................ 35
RATING CRITERIA BASED ON THE AMPLITUDE OF DISPLACEMENT OF THE VIBRATION ............... 35 QUICK INITIAL GUIDE TO THE INTERPRETATION OF A SPECTRUM ................................................... 40 TYPICAL VIBRATION SPECTRA REGARDING THE MOST FREQUENT FAULTS .................................. 42 CALCULATION FORMULAE FOR TYPICAL FREQUENCIES ASSOCIATED WITH BEARING FAULTS . 45
The following technical booklets are enclosed as an integral part of this instruction manual: - BOOKLET N 3: "Technical elements of rotor balancing"
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INSTRUMENT DESCRIPTION
1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) Seismic measurers Tool pocket Liquid crystal display Socket, measurer 1 Socket, measurer 2 Photocell socket Output RS 232 Main switch Alphanumeric keypad Thermal printer Magnetic bases
Fig. 1
ACCESSORIES
- Velocity transducer model dia. 40 10 < f < 1000 Hz - N.C. transducer model ARA 18 (optional) 1 < f < 1000 Hz - High frequency accelerometer (optional) 2 < f < 10 KHz - Low frequency velocity transducer (optional) 3 < f < 1000 Hz - Photocell complete with lead - Magnetic base for velocity transducer/accelerometer - Universal extension lead 10 metres (optional) for transducers and photocells - Roll of thermal paper code 4340 code 0060 code 2851 code 4099 code 4318 code 3051 code 4321 code 1869
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SPECIFICATION
- Measurement of vibrations with frequency from 1.5 to 8000 Hz (90 to 480000 cycles/min) - Type of measurement: RMS - PEAK - PEAK-TO-PEAK - HFD - Unit of vibration measurement m - mm/s - g - m/s2 - mils - in/s - Unit of frequency measurement: Hz - CPM - Measurers used and results obtained: ACCELEROMETER (displacement, speed, acceleration) VELOCITY TRANSDUCER (displacement, speed, acceleration) PROXIMITY INDICATOR (displacement, speed) - Filter on/off; selectivity 1 - 2 - 5 - 10 - 25% - Synchronization of filter through PHOTOCELL, PROXIMITY SENSOR or MANUAL MODE - Available functions: VIBROMETER, BALANCING, ANALYSIS, DATA LOGGER, FFT. - Printer, running on thermal paper, for balancing certificates, graphs of analytical results, trends, etc. - Provision for memorizing up to 120 programs with all the operational parameters. Each program can have an identifier title up to 20 characters long - Provision for memorizing up to 120 graphs acquired with the instrument - Serial output RS-232C for EXTERNAL COMPUTER, to allow subsequent data processing (optional program) - Clock with DAY - MONTH - YEAR - HOUR - MINUTES - SECONDS - Rechargeable batteries with back-up time of approx. 10 hours under normal operating conditions - Batteries recharged in about 5 hours - Provision for continuous operation running on mains power supply - LCD display 168 x 90 mm - Weight : 10 kg with standard accessories - Dimensions : 500 x 400 x 150 mm H.
GENERAL RECOMMENDATIONS
- The equipment runs on mains (220 V) or rechargeable batteries. Connect the mains cable provided on the instrument to a socket for recharging the batteries. - Instrument grounding (earthing) (not normally necessary as the N402 runs on batteries and the references of the measuring circuits are isolated against the outside). In special cases (where there are sources of electromagnetic interference, such as inverters, drives, etc.) it could be advisable to connect the central terminal of the mains plug to the N402 earthing system.. - The N402 has a protection class of IP55 with the case closed. If a similar protection class is required with the case open, the paper outlet opening of the printer should be protected. - The lead battery used has a guaranteed long life. If the equipment is to remain idle for a long period, it is advisable to fully recharge the battery at least every 4 months. - If the battery is partially charged, the instrument is able to operate correctly but printing is inhibited. - For connection of the transducers, use the leads provided as standard: connect the vibration transducers and the photocell to sockets 4 -5 and 6 respectively.
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1 - SETTING OF INSTRUMENT AND SENSOR PARAMETERS 1.1 Presetting and general information menu
- Press button : the following menu appears on the display:
FILTER UNIT OF VIBRATION MEASUREMENT UNIT OF FREQUENCY MEASUREMENT TRANSDUCER 1 TRANSDUCER 2 TRANSDUCER PARAMETERS DISPLAY+BATTERY CLOCK - The option select is highlighted by a dark line and wording in reverse video.
and
button.
1.1.1 Filter
- It is possible to define the characteristics of the filter used for all the measurements involving filtering of the vibration signal, e.g. Analysis, Balancing, etc. - After choosing this presetting, the current percentage width of the filter appears on the display. To change it, press the number corresponding to the required filter width from the 5 available ones (1, 2, 5, 10, 25%).
- Press button
to end.
N.B. A more accurate filtering (i.e. lower percentage) entails a longer wait time for the instrument to reach operating conditions, however greater measuring accuracy is achieved. For normal cases, use 1, 2 or 5% for balancing or analysis of phenomena requiring good frequency definition. While for rapid approximate analysis or when the harmonic examined is predominant over the background noise, use 10 or 25%.
N.B. Selection of the unit of measurement is obligatory when making comparison of tables of specific standards. However it is preferable to adopt the same unit of measurement used by the transducer; hence mm/s or in/s if a velocity transducer is used, g or m/s2 for an accelerometer, m for transducers of no contact type. The integration or differentiation operations necessary for converting the various units of measurement are carried out in analog mode for non filtered measurements and in digital mode for filtered measurements. Generally speaking, the filtered measurements are more accurate, especially at low frequencies.
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1.1.4 Transducer 1
This option serves to select the type of transducer connected to socket (1). The double series A and B allows using sensors of the same type but with different efficiency. The range of frequency to be processed (greater or smaller than 10 Hz) can be selected with keys 7 and 8. With frequency < 10 Hz instrument response is slower but the reading is more reliable starting from about 2 Hz also in the vibrometer mode without filter. - Press button to end.
1. 1.5 Transducer 2
Like transducer 1 but referred to socket (2).
- Preset the new sensitivity (mV/mm/s) for velocity transducer type A and press
- Preset the new sensitivity (mV/mm/s) for velocity transducer type B and press highlights the preset sensitivity A and B. - Press accelerometer. - Preset the new sensitivity (mV/g) for accelerometer type A and B, then press - The display highlights the preset sensitivity of accelerometer A and B. - Press to confirm or to pass onto to the no-contact transducer. to confirm the values and quit. Press
- Preset the new sensitivity (mV/mm) for no-contact transducer A and B. Press - Typical sensitivities for the standard transducers supplied are: VELOCITY TRANSDUCER ACCELEROMETER NO-CONTACT SENSOR = 21.2 mV RMS/mm/RMS = 100 mV RMS/g RMS = 520 mV RMS/mm RMS range 10 to 1000 Hz range 5 to 10,000 Hz range 2 to 1000 Hz
to quit.
For correct operation of the No Contact sensor of the inductive type used on the N402, it should be positioned at a distance of 1 to 5 mm (typically 3 mm) from the component to be measured. Furthermore the sensitivity of 520 mV/mm is referred to measurements on steel (st37) components. The use of other materials means reduction in sensitivity according to the following factors which can be used to modify the sensitivity of the sensor. Stainless steel 0.85 - Brass, bronze 0.55 to 0.60 Aluminium 0.40 to 0.45 - Copper 0.30 to 0.35
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- Press
1.1.8 Clock
- The display highlights the cursor to preset new values for : . Day . Month . Year . Hour . Minute - Type the new values and press .
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at the bottom of the page in the various measurements. Transducers are delicate devices, hence they should be used with care. Their compartment in the N402 instrument allows them to be transported without risk of damage. The transducers can be used: - by resting them manually against the vibration measuring zone after applying the extension rod. This system is suitable for approximate measurements with frequency limited to 1000 Hz. - with magnetic base. This allow improved frequency response and better repeatability of the measurement. - By fixing them via a tapped hole over the measuring point. This system is the most repetitive one, recommended for HFD measurements, and with frequencies greater than 1000Hz
corresponding keys to be pressed for the various functions. - Strike any key to quit. Use of the keyboard When the keyboard is used, certain buttons have a fixed function in whatever screen they may happen to be: = Return to previous page
= Allows alphabetic letters to be inserted (given in red on the button). This function can only be enabled in the screens where there is provision for entering alphabetic characters. When the selection is possible, and this button is pressed, the identical symbol appears at the bottom right corner on the display. When the button is pressed again, the buttons return to normal function.
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- When
- To memorize the measurement, press N.B. - Frequency of updating on the display depends on the mode of measurement chosen: with FILTER OFF, updating is made every second; in the FIX and SYNC modes, updating depends on the frequency being measured and the filter width; e.g. at 10 Hz (600 CPM) and with filter at 1%, the display is updated every 12 seconds, while at 1000 Hz, there will be 4-5 updatings every second. - In measurements with FILTER OFF, the value of the vibration only appears on the display, while with measurement in SYNC or FIX mode, also the frequency of measurement appears (sychronization frequency multiplied by 1 - 5). - During the course of a measurement, it could occur that when a key is pressed (e.g. [STOP] to stop the measurement) this key has to remain pressed for a few seconds before being recognized by the system.
4.1.1 - SYNC x N
- Press . The number of the harmonic to be measured appears.
(if just
= 1 is chosen automatically). N.B. The measurement can only be made with the photocell and filter inserted. The filter is tuned automatically to the frequency supplied by the photocell multiplied by the number selected N.
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- Type the value in the range (1.5 / 8000 Hz) and press
- During measurement, the set frequency can be changed by using - Measurement is made without use of the photocell
and
- Type the value in the range (90 / 480000 CPM) and press
and
is coherent with ISO standards 237/VDI 2372 regarding the state of vibration of the machines.
with cut-off frequency of 10 KHz. This filter serves for analyzing anti-friction bearings. A sensor of accelerometer type should be used with unit of vibration measurement in g RMS selected. When is
pressed, the instrument is automatically set to: RIL ACC. and U gRMS. To return to use with the velocity transducer and reading with other units of measurements, the presetting should be modified. - The transducer must be fastened through a tapped hole in the point as close as possible to the ball bearing. Faulty fastening or position will lead to unreliable values. Measurement in the HFD range likewise all similar measurements BCU, Spike Energy, etc. for analysis of anti-friction bearings, should be performed with the accelerometer supplied with the instrument fastened in the vicinity of the bearing under test. The measurement, in gRMS, does not give an absolute indication regarding the intactness of the bearing, rather it should be considered as reference for a comparison with measurements made subsequently or on machines with similar bearings. Deterioration of the bearing (scoring or chipping of the balls or races) is revealed as an increase in high frequency interferences (microshocks transmitted to the bearing structure) which produce an increase in the g RMS value measured by the accelerometer (for details, see Appendix 4).
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- Press
- Press
Hz (90 - 480000 CPM). Each time one of the two frequencies is varied, the display automatically shows the number of points which will be acquired and the expected acquisition time (if the number of points is too high or low, an error message will be sent and the analysis will not start). - Press to quit the menu.
N.B. The analysis is performed automatically in progressive mode in steps of the frequency calculated on the basis of the filtering width selected, commencing from the start-of-analysis frequency. The frequency step is such that measurement error over the limits of the actual step is held within 3 dB. Hence the frequency axis follows a logarithmic curve. The frequencies plotted along the abscissa correspond to the central frequency of certain bands identified by the references. The width of the vertical bands plotted in the graph depends on the width of the filter and frequency range selected. Such width is adapted automatically to enable a clear indication. For detailed analysis of beat frequencies or vibrations very close in frequency, a highly selective filter is essential. Hence it is advisable to identify the more significant frequency ranges through analysis using a wide filter (10%), followed by analysis in a restricted frequency range using a more selective filter for more accurate revealing of the individual harmonics. Thanks to this system, it is possible to correctly analyse phenomena such as beat frequencies difficult to analyze even with FFT analyzers.
appear in the top left corner of the display to indicate the presence of a graph in the memory. Press to display it.
5.1.2 Measurement
- Press to start the analysis: a graph appears with the value of the vibration in linear scale plotted on
the Y axis while the value of the corresponding frequencies in logarithmic scale is plotted along the X axis (abscissae). The current vibration and frequency values are shown in two screens in the lower left part of the display. - Press to stop the measurement at any instant.
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- After analysis, a moving right/left cursor (vertical line) appears upon pressing buttons When these buttons are kept pressed, the cursor moves at a higher speed.
- Press
to display a table containing the list of the first ten most significant vibration peaks plus
respective frequencies. - Press to return to the screen with the vibration graph.
- Press
to move the cursor to a position corresponding to one of the first 10 most significant
vibration peaks (the lower left screens highlight the corresponding vibration and frequency values).
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Consequently, in order to optimize the resolution, it is advisable to select the minimum frequency of greater interest as maximum frequency.
N.lines
This means that within above defined frequency interval there is an error in amplitude evaluation lower or equal to 3 dB. Hence the value recorded by the instrument is approximate owing to the finite number of samples. It is advisable to increase the lines used for improved accuracy..
6.1.6 - Trigger
It is possible to select a signal level which automatically triggers start of measurement.
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6.2 - Operation
6.2.1 Presetting
After pressing button a screen appears giving the current presetting. If a graph has already been
appears in the top left angle of the display to indicate the presence
to display it.
Press the number indicated in the menu to modify relative setting: 1 - MAX. FREQ. = Can be selected between 50, 200, 1000, 3000 Hz (3000, 12000, 60000, 180000 CPM). Use arrow keys to select; press to end selection.
2 - LINES
to select; press
to end selection. AVERAGES= Number of averages between the calculated values before display. Can be selected between 1, 4, 8, 16. Use arrow keys ; to select; press to end selection..
For correct FFT analysis, the signal level indicator should lie in the central zone of the bargraph :
Use the
and
keys to amplify.
In the event of excessive amplification, the overrange symbol appears above the Signal level bargraph. In this case, the [START] key is deactivated until the amplification is reduced. After acquisition, the graph is displayed with the results of the measurement. Control of the graph is through the same buttons described in SCAN. Furthermore it is possible, only for the FFT graph and only when the latter has a resolution of 400 lines (and therefore displayed in two different screens), to pass from screen 1 to screen 2 by pressing button and to pass from screen 2 to screen 1 by pressing .
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and
d) Press
, if the level of the signal exceeds the level of the trigger, the measurement will start
automatically. Impact test results are rarely repetitive as vibration level because the vibration is affected by how the stress has been applied. However the results are very useful for identifying the resonance and therefore the modes of vibration of a structure. Knowledge of the modes of vibration is an essential factor for identifying the intensification of certain frequencies of vibration when the structure is excited dynamically during regular operation of the machine to which the structure belongs. Caution! On the basis of point 1.1.2, it is advisable to use the same unit of measurement as the sensor when measuring with the Trigger activated in order to avoid problems and delays due to the time constant implicit in the analog signal conditioning.
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90
270
180
e) The calibration parameters regarding a given rotor can be memorized or called so as to have the unbalance at the first spin in the event of subsequent balancing operation on the same machine. Note that when using previously memorized data, it is essential to mount the transducers in the same position on the rotor (see Chapter Memorization of programs).
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1 - Automatic calibration
The balancing parameter acquisition is guided in an automatic sequence, as explained in paragraphs 7.1.1 and 7.1.2.
2 - Step-by-step calibration
If you use this option, you can choose which of the calibration cycles you want to run. First set the balancing parameters (number of planes, number of pick-ups, reference weight), as you would for automatic balancing. You will then see a submenu from which you can choose. According to how many planes you have entered, a list of the calibration spins necessary will appear. For example, if you choose two planes, the list that appears on the screen will be like this: 0 - No calibration weight 1 - Calibration weight on plane 1 2 - Calibration weight on plane 2 Press the number of the spin you want to run and then follow the instructions that come up on the N402 display. At the end of the individual spin, the equipment will return to this menu, where you can make another choice. Once a measurement has been made successfully, the lettering OK will appear next to the line in question. For example:
0 - No calibration weight 1 - Calibration weight on plane 1 2 - Calibration weight on plane 2 means that spins 0 and 2 have been run, while you are still short of the parameter acquired with spin 1. Whenever you find yourself in this menu, between one spin and another, it is also possible to press the [MEM] key to store the current state of the calibrations in one of the machines memories. In this way, the equipment can also be used for other types of measurement and, when you have completed them, you can call the calibration material up from the memory again to finish off calibrating the balancing machine. N.B.: when you call up an interrupted calibration process from the menu, you do not return to this menu automatically, but to the first balancing menu. You must therefore press [2] twice to choose the Step-by-step Calibration option again and then [START] twice to confirm the parameters that you had already stored in the memory. You will then find yourself back in this menu and can pick up calibrating where you left off before. As there is no difference between the parameters you acquire with the Automatic Calibration and the Stepby-step Calibration, you can also use the latter to correct any Automatic Calibration where one of the spins was not run correctly.
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3 - Manual balancing
You can use this function to calculate the consistency and the position of an unbalance if you know the vibration values (amplitude and angle). Also in this case, you must first feed in the calibration values, i.e. the vibration values picked up first without a reference weight and then with a known reference weight applied to the balancing planes. First press [3]. The machine will then proceed as for automatic calibration, asking you to feed in the number of planes and then the reference weights. After these parameters, it will ask for the vibration values relative to the spins without the reference weights and with the weights on the planes. When you have completed feeding these data in, the machine will show a residual unbalance that it calculates on the basis of the vibration supplied under measuring without calibration weight. If you want to feed in new vibration values, for example the ones you have read off after applying a correction weight, press [START] and then feed them into the menu provided. Now press [START] again and the machine will calculate the new unbalance value. As the calibration values for manual balancing calculated in this way are not compatible with those acquired directly by the pick-ups used for balancing the rotor in service conditions, it will not be possible for you to use them for measurements made with the pick-ups. For this reason, each time you press [START], the machine will show you the menu where you can feed in the vibration values. However, just like normal balancing, you can store these parameters in a memory and call them up again at a later date.
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- Press
N. planes = 1 N. measurers = 1 (however, the value preset as N. measurers is not used because when N. Planes = 1 is preset, the sensor connected to socket (1) is always used).
- Press
to go onto the next screen where it is possible to insert the master weight used and its position
- Press
to start the measurement which is carried out according to the sequence of instructions
appearing on the display. While the rotor is moving, the display gives, in the bottom lines, the value of vibration, unbalance angle and speed of rotation. Wait for the vibration value to become fairly steady before pressing again to commence the measurement. (Owing to the calculations necessary for continuous
be necessary to keep it pressed for a few seconds before the N402 gives the measurement). - At the end of the calibration cycle (2 spins), the value and position of the unbalance to be corrected is displayed, as according to previous note b); the corresponding vibration value is also displayed. - When further measurement spins are made (by pressing just allowing the required tolerance to be quickly reached. - The calibration parameters measured can also be memorized in one of the memories of the instrument (see Chapter Memorization of programs) so that they can be called later and used again. However for the parameters to still be valid, it is necessary to use the same measurer used in the calibration and place it in the exact position in which it was located when the calibration was performed. ), the instrument remains calibrated thus
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Press
- Press
to go onto the next screen where it is possible to insert the master weight used on
each plane and its position with reference to the light-reflecting label (see previous note d). - Press to start the measurement which is carried out according to the sequence of instructions
appearing on the display. While the rotor is moving, the display gives, in the bottom lines, the value of vibration, unbalance angle and speed of rotation. Wait for the vibration value to become fairly steady before pressing again to commence the measurement. (Owing to the calculations necessary for continuous
be necessary to keep it pressed for a few seconds before the N402 gives the measurement). - At the end of the calibration cycle (3 spins), the value and position of the unbalance to be corrected is displayed for correction planes 1 and 2, as according to previous note b); the corresponding vibration value is also displayed
- When further measurement spins are made (by pressing just allowing the required tolerance to be quickly reached.
- The calibration parameters measured can also be memorized in one of the memories of the instrument (see Chapter Memorization of programs) so that they can be called later and used again. However for the parameters to still be valid, it is necessary to use the same measurers used in the calibration, placing them in exactly the same position where they were located when the calibration was performed.
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Press
As regards the rest, the procedure is similar to the one for balancing with two measurers.
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If you want to change the setting of any plane, press the key with its number: a flashing cursor will appear on the Comp parameter on the row corresponding to the plane chosen. Feed in the new value and press [OK] (or just press [OK] if you do not want to change the value) to pass on to the next field, Ang1. When you have given the OK to the last value, the cursor will disappear and the parameters will be stored in the memory. These are the parameters you must feed in: Comp = Number of components of the vectorial decomposition. 0 = No vectorial decomposition on this plane (full rotor). 2 = Balancing with displacement of two known masses. from 3 to 255 = Number of components The value 1 is not used and is treated as 0. Ang1 = This value is only used if Comp is greater than or equal to 2. Otherwise, the display will read #### and it will not be possible to change it. If Comp>2, Ang1 indicates the angle of phase displacement between the photo-electric cell and vectorial component N 1, as in the following example:
Direction of rotation
90
270
180
Nr. 1165 - 25 Ang2 = This value is only used if Comp is equal to 2. Otherwise, the display will read #### and it will not be possible to change it. Ang2 indicates the current position of correction mass N 2. This value is only used if Comp is equal to 2. Otherwise, the display will read #### and it will not be possible to change it. Weight indicates the weight of the two correction masses (which must be equal).
Weight =
The values of Ang1 and Ang2 must be between 0 and 359. If you set 360, your setting will be interpreted as 0 and corrected to it. Any angles greater than 360 will not be accepted. The Weight values must be between 0.01 and 9999.99. When you have completed setting the parameters for each plane, you can return to the unbalance display by pressing the [PGUP] key. Note, however, that in this case the machine will not undertake the recalculation of the unbalance values to take the newly set parameters into account. If you want this recalculation to be done when you return to the unbalance readout, you should press key [0]. N.B.: While for classical vectorial decomposition (with 3 or more vectorial components) you must run the recalculation of the values after altering the parameters if you want to have the new unbalance values for each of the components, in the case of balancing by displacing the angles of two known masses it is important not to recalculate, but to terminate the setting with the [PGUP] key, otherwise the two angles you have just fed in would be changed again by the recalculation operation.
Remember that the unbalance will be displayed without the decomposition at the end of every balancing cycle. If you want to display the values calculated with the vectorial decomposition, you must press key [2]. To pass from the results of one plane to those of the other, press [ ] or [ ]. To return to the unbalance WITHOUT DECOMPOSITION, press [2] again. Here are some settings and how they would look when displayed: Example 1 Plane 1 with vectorial decomposition on 4 components. The first component is situated at 15 from the reference mark. The setting will be: Plane [1] Comp 4 Ang1 15 Ang2 #### Weight ####
An unbalance of 10 grammes with an angle of 180 will give us this readout: Plane: [1] Components: 004 Weight 2.59 9.65 Component 2 3 Angle 105 195
This indicates that the unbalance value on component N 2, which is situated at 105 from the reference, is 2.59 g., while the unbalance on component N 3, which is at 195, is 9.65 g.
Nr. 1165 - 26 Example 2 Plane 2 with Balancing with two known masses of 10 grammes each that are initially situated one at 90 and the other at 270. The setting will be: Plane [2] Comp 2 Ang1 90 Ang2 270 Weight 10.00
An unbalance of 10 grammes with an angle of 180 will give us this readout: Plane: [2] Masses: 10.00 Angle 1 Angle 2 119 240
This indicates that the first mass should be moved to 119 and the second to 240. N.B.: If the unbalance to be corrected is too high with respect to the masses used (e.g., if you are trying to balance an unbalance of 20 grammes by shifting two masses that weigh 5 grammes each), instead of the angles, the machine will display a message that tells you that you are making this mistake. In that case, you must adjust the piece to eliminate the majority of the unbalance by removing or adding material and then set the real position of the two masses again before repeating the measuring cycle. You must shift the masses to the angles indicated before running a new measuring cycle. As the computer will store the positions indicated for the masses in the memory and use them again for subsequent calculations, it follows that if the masses are not shifted, the results of these calculations will be out. The only way you can solve this situation is by picking up the real position of the masses and setting it again in the decomposition set-up readout, then pressing [0] to terminate the setting, so that the machine will recalculate the new balancing position.
Example 3 Plane 1 without vectorial decomposition and Plane 2 with vectorial decomposition on four components; the first coincides with the reference mark. The setting will be: Plane [1] [2] Comp 0 4 Ang1 #### 0 Ang2 #### #### Weight #### ####
Let us suppose we have an unbalance of 10 grammes at 180 on Plane 1 and one of 5 grammes at 270 on Plane 2. For Plane 1, this will give us: Plane: [1] Components: 0 Angle 180
Weight 10.0
because the vectorial decomposition is deactivated on this plane (Comp=0). If you press [ ], you can pass to Plane 2, which will look like this: For Plane 2: Plane: [2] Components: 004 Weight 10.00 0.00 Component 4 1 Angle 270 0
This indicates that the unbalance is all on component N 4, which is situated at 270 from the reference mark, while there is no unbalance to be corrected on the next component.
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9 - DATA LOGGER
You can use the DATA LOGGER function to acquire the vibration values as a function of time or of the rotation speed (Frequency). When you first enter the Data-Log function, the first page you will see enables you to choose the type of graph you prefer: 1 - Vibration / Time 2 - Vibration / Speed Press 1 or 2 to choose the type of measurement you prefer.
VIBRATION / TIME
The data logger serves for acquiring, at given time intervals, a series of measurements according to the presetting made in VIBROMETER mode. These measurements will then be displayed on a graph. Hence graphs will be obtained following the trend in vibrations Vs. time.
VIBRATION / SPEED
If you want to acquire the Vibration / Speed graph, you must use the photo-electric cell or a similar rotation sensor that enables you to detect the rotors speed in real time. Set the following parameters to make the measurement: 1 - Maximum speed 2 - Amplification The graph will always have a resolution of 200 points. 1) Maximum speed: You can choose a maximum detection speed to suit the rotor you are analysing. You can also choose the unit in which the speed is measured: either CPM or Hz, according to what you have set under Frequency measurement unit in the Set-up menu. The values you can choose from are 3,000 CPM (50 Hz), 12,000 CPM (200 Hz), 60,000 CPM (1,000 Hz) or 180,000 CPM (3,000 Hz). As the graph runs on 200 points, its resolution will change with the maximum frequency chosen:
Speed 3,000 CPM (50 Hz) 12,000 CPM (200 Hz) 60,000 CPM (1,000 Hz) 180,000 CPM (3,000 Hz)
Resolution 15 CPM (0.25 Hz) 60 CPM (1 Hz) 300 CPM (5 Hz) 900 CPM (15 Hz)
Nr. 1165 - 28 2) Amplification: Before the data acquisition, the rotor must be accelerated and an optimal amplification value will then be determined automatically. This value will then be kept blocked and used throughout the period it takes to acquire the graph. If the signal received from the pick-ups undergoes any noticeable variations during the acquisition period, for example when the structures own resonance frequency is passed or anything similar, this functioning mode may cause certain problems. For this reason, it is advisable to set a low amplification value, in order to avoid problems of saturation on the signal entrance stage. You can use this menu function to select the following amplification options: = Normal amplification = Amplification reduced by 1 step = Amplification reduced by 2 steps = Amplification reduced by 3 steps
While the values are being acquired, the entering signal is kept under constant control and a special symbol will remain visible in the top left-hand corner of the graph if any saturation has been detected in the amplification stages. It is then up to you to decide whether you want to accept the graph acquired as good or whether you prefer to repeat the measurement with a lower level of amplification. Note: The measurement saturation symbol will appear on the graph at the end of the detection process, but it is not certain to be there if other equipment functions are being run (VIBROM, FFT etc.) and the equipment will then return to display this graph. As the state of saturation cannot be stored in a memory, if you store the graph and then call it up from the memory, the saturation symbol will certainly not appear. Sequence of operations for acquiring a Vibration / Speed graph Set the Maximum speed and Amplification value on the basis of the type of measurement to be made. Press the [START] key and accelerate the rotor to the speed where you want to start measuring. During this time, the display will read the rotors Vibration and Speed values. If they are not being displayed, this means that the rotor is motionless or that the photo-electric cell cannot read the reference mark on the rotor. When the measurement start speed has been reached, press [START] again. The display will show the graph on which the vibration values detected will be plotted. When all the points desired have been acquired and plotted, press [STOP] to terminate the data acquisition. As the values are acquired on a continuous basis, you may have to keep the [STOP] key pressed for a few seconds before the N402 acknowledges that it has to stop.
Nr. 1165 - 29
next one of the 5 programs. To select a given program, preset its number and press
. The program
will be reloaded and the instrument is switched automatically to the presettings resident in that memory. If a graph is also associated with the memory, this graph will be reloaded as well and can be displayed by pressing button .
Nr. 1165 - 30 10.2.2 - Write memory This function appears in the menu and can only be used when is pressed from one of the functions
regarding VIBROMETER, BALANCING, SCAN, DATA LOGGER, FFT. When initial screen, this option does not appear.
and
next one of the 5 programs. To select which memory to use, preset its number and press
. Either a
free or already used memory can be selected. If an already used memory is used, its previous contents will be deleted. After pressing a request appears to enter the INFO field which can be a brief description (max. 20
. To end after
repressing
, press
If the memory contains a graph regarding the function being memorized and graph memories are still available, this graph will be saved as well. 10.2.3 - Rewrite memory n.xxx This function appears in the menu and can only be used when is pressed from one of the functions
regarding VIBROMETER, BALANCING, SCAN, DATA LOGGER, FFT. Furthermore it can only be used if the last memory called contained the same function which was being memorized. This mode of operation is useful when carrying out periodic checks on the operation of a rotor. For example, after calling a memory with the FFT of a given machine, a new measurement is made, and then merely by pressing new graph is memorized instead of the previous one. 10.2.4 - Clear memory This function serves for fully deleting a program from the memory. As in the case of the previous selected ones, the list of programs currently in memory appears from which the program to be deleted can be selected. After deleting the program selected, the system returns to the program menu. 10.2.5 - Clear the ENTIRE memory This function allows the ENTIRE memory of programs to be fully deleted. Once deleted, it is NO longer possible to recover the previously memorized programs. After choosing this option, request for further confirmation is made whether it is really wished to delete all the programs : - press for deleting, otherwise press any key to quit this function leaving the programs unaltered. the
Nr. 1165 - 31
11 - ERROR MESSAGES
ERROR
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 21 2227
MEANING
Vibration supplied by the currently used measurer is too high Vibration supplied by the currently used measurer is too high Error in the program memory Reading/writing error in the memory of permanent parameters Battery discharged Attempt to measure the acceleration using a transducer of the NO-CONTACT type Speed of rotation too low or photocell positioned incorrectly Speed of rotation too high or photocell positioned incorrectly Difficulty in reading the photocell signal Too many values acquired during ANALYSIS Error during the balancing calculations, probably due to incorrect calibration Hardware problems in the circuit Hardware problems in the circuit Writing not enabled in the memory of permanent parameters Error in the instrument presetting memory Battery voltage too low to allow use of the printer Error in printer operation N of FFT lines too high (preset the number again) Error in FFT calculations, reduce input signal amplitude or amplification
12 - INSTRUMENT RESETTING
This function allows reactivating the N402 instrument when, owing to excessive discharge of the battery, particular interference in the power supply or incorrect use of the instrument, the display contains illegible messages and it is not possible to reset correct instrument operation by switching off and on again. To perform the RESET: 1) Switch the N402 off.
2) Press keys
and
both together.
3) While keys
and
4) Release keys
and
Nr. 1165 - 32
13 - POWER SUPPLY
The instrument runs on mains power supply (220 V single phase; 50/60 Hz) or else on rechargeable batteries included in the equipment supplied.
Nr. 1165 - 33
When the instrument in rest condition, raise the lever as shown, insert the paper until it emerges from the top part, then shift the lever back to work position.
- Press
.0 - PAPER FEED .1 - PRINT-OUT WITH HEADING .2 - PRINT-OUT OF VALUES ONLY .3 - CERTIFICATE HEADING - Press one of the numeric keys to select the required mode (press to quit the function).
. When
15.2.1 - Print-out with heading - Press : the contents on the display are printed plus two lines of heading which can be read under
Nr. 1165 - 34 15.2.2 - Print-out of values only - press : the values on the display are printed.
15.2.3 - Certificate heading The certificates regarding balancing or vibration measurements and analysis can be customized by an alphanumeric heading on two lines compiled as required.
- Press
: the cursor moves to the beginning of the two alphanumeric lines of the potential heading.
- Press
: (the SHIFT symbol appears at the bottom right) and type the alphabetic characters.
- Again press
- Press
not inserted:
- Press
to form a space thus shifting forward all the text following the cursor.
- Press
- Press
Nr. 1165 - 35
TABLE A
MACHINE CATEGORIES BY CRITERIA OF JUDGEMENT
Group according to: ISO 2372/VDI 2056 I/K Characteristic Number 2.5 MACHINES
Machine parts that are closely related to the machine as a whole during normal working conditions. Grinding and boring machines. Electric motors (up to 15 KW) that need good balancing, e.g. dentists drills, aerosols, high quality electromedical and domestic appliances. Jet engine turbines and compressors. Fast compressors. Medium sized machines with electric motors from 15 to 100 KW, without any special foundations. Lathes. Milling machines. Machines and drives up to 300 KW with rigid construction, without any parts with alternating movement, resting on their own foundations. Mass produced electric motors with axis height less than 130 mm. The most common medium category for first approximation. This category includes machines not found in other categories. Large machines with rigid, heavy foundations, without any masses with alternating movement. Gas or steam turbines, turboblowers, large alternators. Normal motors in general and especially motors whose axis height is from 130 to 230 mm. Rigid (class A) ventilators. Parts of machine tools.
II / M
1.6
III / G
IV / T
0.63
Large machines with low-rigidity foundations, without any masses with alternating movement. Turbines, alternators, large motors, on light foundations or on board ship. Electric motors with axis heights from 230 to 330 mm. Hydraulic machines, centrifugal pumps. Normal ventilators. Turbine gears. High performance machinery: for printing, spinning or paper making. Machines with unbalanceable alternating masses, on foundations that are rigid in the direction of the greatest vibrations. Motors with crankshafts with six or more cylinders on their own foundations. Piston motors for automobiles, goods vehicles, transportation vehicles not set on insulators during tests. Machinery with unbalanceable masses, such as weaving looms, skimmers, centrifugal purification plants, washing machines if fitted to rigid baseplates without any shock absorbers.
V/D
0.4
Nr. 1165 - 36
Nr. 1165 - 37
da
ng
er
ou
no ta dm is si bl e
ac ce tta bl e
ad m is si bl e
go
od
ve ry
hu m an
go od
se ns iti vi ty
Fig. 24 Diagram for evaluating mechanical vibrations on the basis of the amplitude of vibration shift and frequency. This diagram is good for machines in category III, with characteristic number 1 (see Table 1). For other categories, enter the diagram by multiplying the experimentally determined vibrations measurement by the corresponding characteristic number.
Nr. 1165 - 38 Once you know the category, all you have to do is multiply the value found experimentally by the characteristic number of the same category to have a rough evaluation immediately.
da
e ng
ro
us
t no
e ibl ss mi ad
ad
iss
ib
le
RMS velocity
e bl tta ce ac
go
od
ry ve
od go
human sensitivity
QUALITY
Fig. 25 Graph for evaluating mechanical vibrations on the basis of the efficient speed of vibration and the characteristic number
Nr. 1165 - 39 Diagram showing the relationship between the vibration amplitude s() and the efficient speed (mm/sec) as a function of the frequency (Hz/CpM). From VDI 2056.
R M S
displacement amplitude in m
ve lo ci ty
hu m an
se ns iti vi ty
Nr. 1165 - 40
f = vibration frequency (cycles/min) s = shift amplitude (mm) v = vibration speed (mm/sec) a = vibration acceleration (g)
Unbalances in rotating bodies. Intensity proportional to unbalance. Rotor inflection. Axial vibrations sometimes sensitive. Resonance in rotating bodies. Critical speed near n with very high intensity. Roller bearings mounted with Recommend balancing the rotor on its own eccentricity. bearings. Disalignments. Considerable axial vibration also present, greater than 50% of the transverse vibration; also Eccentricity in pulleys, gears, frequent cases of f = 2n. 3n. etc. When the rotation axis does not coincide with the geometric axis. Irregular magnetic field in Vibration disappears when power is cut off. electrical machines. Stroboscope can be used to block belts and pulleys at the same time. Belt length an exact multiple of An unbalance vibration often also intervenes. the pulley circumference. Gear with defective tooth.
1) f = n
2) f n with knocking
Mechanical unbalance defect In asynchronous motors, the knocking is due to superimposed on irregular running. magnetic field. For high n, above the 1 critical level. Defective lubrication in sleeve Check with stroboscope. bearings. Precision journal movement (oil whirl).
3) f (0.40-0.45)n
4) f = n
Mechanical weakness in rotor. This is a sub-harmonic, often present but hardly ever important. Sleeve bearing shells loose. f = 2n, 3n, 4n and semi-harmonics also often Mechanical yield. present. There is strong axial vibration. Loose bolts, excessive play in the mobile parts and bearings, cracks and breaks in the structure: there are upper grade sub-harmonics.
5) f = 2n
Nr. 1165 - 41
FREQUENCY DATA
CAUSES
NOTES Frequency = n x number of spheres or rollers. Check with stroboscope. f = z n (z = number of defective teeth) Because of general wear, teeth badly made if z = total number of teeth. Often caused by mechanical loosening. f = n x number of blades (or channels).
6) f is an exact multiple of n
Roller bearings disaligned or forced in their housings. Defective gears. Disalignments with excessive axial play. Rotors with blades.
Damaged roller bearings. Excessive wear on sleeve bearings. Belts too tight. 7) f is much greater than Multiple belts not n, not an exact multiple homogeneous. Low load gears. Rotors with blades for fluid management (cavitation, reflux, etc.).
Unstable frequency, intensity and phase. Axial vibration. Completely or locally defective lubrication. Audible screech. Characteristic audible screech. Run between the belts. Teeth knock together because of insufficient load; unstable vibration. Unstable frequenzy and intensity. Frequent axial vibration.
Excessive play on sleeve 8) f = natural frequency of bearings. Belts disturbed by vibrations other parts from other parts.
Oil whip caused by vibrations in other parts. Check with stroboscope. Examples: eccentric or unbalanced pulleys, disalignments, rotor unbalances.
Multiple belts not 9) f unstable with knock- homogeneous. Unstable intensity. ing Belts with multiple joints.
10)
f = nc n nc
11) f = 2nr
12) f =fc<n
Belt with defective elasticity in fc is the belt frequency. one area. fc = D n/l (D = pulley diameter; l = belt length).
Considerable axial vibrations, more than 10% of the transverse vibration, may be caused typically by: - disalignment (more than 40%); - shaft inflection, especially in electrical motors: - defective thrust bearings; - elliptic eccentricity in the electric motor rotor; - forces deriving from tubing; - distorted foundations; - wear in stuffing box seals etc. - rotor side rubbing; - defective radial bearings; - defective coupling; - defective belts.
Nr. 1165 - 42
1. UNBALANCE
CPM
CPM
2. DISALIGNMENT
2 x CPM
5 x CPM
Nr. 1165 - 43
3. MECHANICAL LOOSENING/PLAY
4. BELTS
2 x belt frequency
5. GEARS
Side bands
Nr. 1165 - 44
6.
SLEEVE BEARINGS
2 x CPM
7.
ROLLER BEARINGS
8.
ELECTRIC MOTORS
Nr. 1165 - 45
The frequencies of bearings can be calculated if we know: S = number of shaft rpm PD = primitive diameter BD = ball/roller diameter N = number of balls/rollers = angle of contact The most common case: a - fixed external ring (rotating internal ring) S BD FTF = -- x [ 1 - ( ---- ) x cos ] 2 PD S BPFO= -- x N x [ 1 - ( BD ) x cos ] --2 PD S BPFI = -- x N x [ 1 ( BD ) x cos ] --2 PD S BSP = -- x ( PD ) x [1 - ( ( BD ) x cos)2 ----2 PD BD
b - rotating external ring (fixed internal ring) S BD FTF = -- x [ 1 ---- x cos ] 2 PD S BPFO= -- x N x [ 1 - ( BD ) x cos ] --2 PD S BPFI = -- x N x [ 1 ( BD ) x cos] --2 PD S BSP = -- x ( --- ) x [1 - ( ( BD ) x cos)2 ] --2 PD