2016_Vol.

2 & 3

balancing news
Information for the quality and performance of rotating equipment - From the Schenck Balancing & Diagnostic Systems Group
IN THIS ISSUE:
A little Maintenance Goes a Long Way......................................1
A Little Maintenance Goes
a Long Way Schenck Hosts High Speed Conference........................................5

A Repeat Performance for Schenck................................................5

Basic balancing machine maintenance will result
CAB 690: Gone But Not Forgotten..................................................6
in accurate readings and extended machine life.
Monitoring Hydropower Machines................................................7
With some basic horizontal balancing machine
maintenance you can extend the life of your Schenck Participates in EASA Conference..................................10
existing Schenck balancing machines as well as
Schenck Exhibits at IMTS...................................................................11
continue to attain accurate readings. Maintaining
the superior performance of your balancing Can We Chat?.........................................................................................12
machine will greatly reduce the chances of any
extended downtime periods, as well as the need
for additional balancing runs and unnecessary Often going unnoticed is the crown of the rollers.
corrections saving you money. The rollers must have a sufficient crown in order to
minimize the contact surface area *. This will
It is important to follow good balancing reduce friction as well as any associated noise. The
machine maintenance practices. Basic machine crown also provides a rotational degree of freedom
maintenance aspects can be overlooked, causing: necessary to provide accurate measurement
wear items to fail, increased friction and heat, or results. Crowned rollers, which are worn flat, will
noise in the system. All of which will interfere result in measurement error.
with the machine’s ability to transmit unbalance
forces from the rotor to the measuring system,
resulting in erroneous balancing results.

Recommended preventative maintenance of both

critical mechanical and electrical components are
as follows:

Roller Bearings
The roller bearings of the twin roller carriages are
subject to the most wear as they are the running
surface upon which the rotor’s journals run.
Roller bearings are without a doubt the highest
wear item. They are also critical in transmitting This will lead to more measuring runs and
the rotor’s unbalance forces accurately to the unbalance corrections, increasing the time needed
measuring system. for an operator to balance a rotor.
Bearing surfaces should be kept smooth. Pitting,
gouges, or burrs on the surface of the rollers *Note: This does not apply to certain specialized
can compromise the sensitivity of the measuring machines intentionally equipped with manufactured
system. These imperfections can be a source flat rollers. These machines incorporate a different
of mechanical noise and could also damage the style of pedestal, which places the rotational
journal surfaces of your rotor. freedom point somewhere other than at the rollers.

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 A roller has a sufficient roller crown if the rotor’s
journal is in contact with the middle 1/3 of the
roller’s width. A tip for identifying rollers with flat
surfaces is to apply a small amount of machine oil
to the rollers, then slowly hand-turn a rotor in the
machine.
Observe the track made by the rotor journal in the
oil film on the roller surface (wear pattern). The
track should be no wider than 1/3 the roller width.
A wider than 1/3 track indicates an insufficient
crown.
Additional roller bearing maintenance includes:
For rollers with enclosed bearings and lubrication
for life:
 After approx. 250 operating hours:
- Check rollers for tightness.
- Check rollers for play and
monitor regularly.
Replace rollers with tight bearings and bearings
with too much play as well as rollers with damaged
rolling elements, cages, and running surfaces.
For rollers with removable gaskets in the bearings:
After approx. 250 operating hours
- Check rollers for tightness.
- Check rollers for play.
In case of tight rollers: Dismount bearings, rinse
thoroughly and fill with new bearing grease. Fill
about 1/3 of the hollow spaces in the bearing with
grease.
In case of too much bearing play: Mount new anti-
friction bearings.
In case of damaged running surfaces: Replace
damaged rollers.
When pressing replacement rollers onto their axles,
never press through the bearing. Use a piece of
sleeving or tubing to press against the bearing
inner race.
After approx. 2000 running hours:
If rollers or roller carriages are found to be
damaged or worn, please contact Schenck’s
Service and/or Spare Parts Department for
directions on how to have rollers replaced, returned
for repair, or to schedule an on-site service visit.
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Keeping spare rollers on-hand will minimize
downtime, and ensure the best performance from
your Schenck Balancing machine.
Bearings that are still in good condition after 2000
operating hours should be rinsed thoroughly and
filled with new bearing grease. Fill about 1/3 of the
hollow spaces in the bearing with grease. Before
re-mounting bearings, after rinsing, check bearings
for usability. In general, a visual check is sufficient.
Check rolling elements, running surfaces and ball
cages for damage (cracks).
Keeping the journals of the rotor, and crown of the
roller lubricated is important.
*See Lubrication details further down in this article.
Note: Damaged bearings should be replaced
immediately.
Electrical and Mechanical Connections
Ensure all electrical interconnecting cables are
properly connected at regular intervals. Cable
insulation (sheathing) should not be cracked or
broken. Never interchange cable connections on
the back of the instrumentation for vibration pickups
1 and 2. The cable from vibration pickup 1 must be
connected to instrumentation pickup input 1, and
cable from vibration pickup 2 must be connected to
instrumentation pickup input 2.
Vibration Pick Up and Pick up rod
The vibration pickup is totally enclosed and designed
for years of trouble-free operation. However, should
it become necessary to replace a pickup, please refer
to your machine’s manual and/or call the Schenck
Service Department for assistance. Malfunctions
of the pickups are very rare. However, a complete
pickup and pickup rod should be available as a spare
part.
Periodically ensure that vibration pickup
connecting rods are properly assembled and
secured to the oscillating bridge. Improperly
assembled or secured vibration pickup connection
rods will result in unsteady balance indication
and erroneous measurements. Inspect for loose
pickups and loose pickup cable connections,
as this will also influence the sensitivity of the
measuring system.
Photoelectric Scanning Head (belt drive only)
The lens should be cleaned with a soft, lint-free
cloth. For repair of the photoelectric photo head,
it is recommended that you contact Schenck
Trebel for service assistance.
Belts
It is recommended to visually inspect the belt
every time the operator loads a new rotor into
the machine. Inspect for excessive wear along
the edges of the belt. This can be evidence of a
misalignment, causing side tracking of the belt.
Also inspect for drying and cracking along the
belt body. Excessive wear to the belt body from a
rough surface on the rotor or debris on the pulleys
may result in exposure of the belt’s reinforcing
fibers. The consequences of excessive belt wear
can be poor contact with the rotor, increased
friction, compromised belt tension and drive
capability, and most importantly, possible injury
to the operator. Excessive belt wear can also
cause damage to the rotor, balancing machine,
and shop surroundings. Belt wear and improper
belt tracking is a source of mechanical noise,
which can impair the sensitivity of the measuring
system. It is recommended that stock replacement
belts are kept on hand as spares so that down time
is minimized and there is little affect on productivity.
Lubrication
Supports:
It is recommended to grease the fittings for the
support moving pinion every 500 hours of operation.
Bed Assembly:
Keep support moving gear, rack, or chain clean and
lightly greased. Clean and lightly oil bed ways prior
to moving the supports.
Roller Carriage Assemblies:
Lubricate rotor journals with a few drops of oil
before each balancing run. We recommend using a
light machining oil per ISO VG 22, such as a Mobil
Velocite #10. If rotor is kept running for more
than two or three minutes, add extra oil during run.
Threaded portion of carriage height adjusting screw
should be kept clean and lightly oiled.
Drive Motor:
Drive motors are lubricated prior to delivery with
a high quality lithium base bearing grease. Some
drive motors are supplied with sealed bearings, and
do not require periodic lubrication.
If the drive motor is equipped with bearing service
point(s), the drive motor should be lubricated to
ensure that the bearings are properly lubricated
for the first twelve-months of service. When
lubricating drive motor bearings, be sure not to over
lubricate, over lubricating could damage bearing
seals. Lubrication of the drive motor bearings shall
be performed every twelve months there after.
For end-drive machines, with a transmission,
the transmission must be serviced at regular
intervals. This will extend the serviceable life of
the transmission and your balancing machine. The
oil should be checked periodically and changed at
regular scheduled intervals.
Initial Oil Change - After the first 250 hours of
operation, the transmission oil shall be changed.
The best time to change the oil is immediately after
the balancing machine has been operated while the
oil is warm.
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 The transmission has been serviced with MOBIL
DTE Heavy Medium Circulating Oil that meets
the specification requirements of ISO 68. When
servicing or changing transmission oil, it is
recommended that MOBIL DTE Heavy Medium
Circulating Oil be used, and if an equivalent is not
available, compatible oil can be used. Please refer
to your machines service manual for details.

In general, good housekeeping is recommended to

help maintain good measuring results and extend
the life of your balancing machine. Keeping the
bed ways free of dust and chips will help maintain
the alignment of the supports. Any debris in the
bed ways could prevent the operator from moving
the supports easily and setting them in position,
with proper alignment. The supports should move
freely along the bed length and not bind. They
should be locked in place so that they are not
skewed in relation to the bed ways. Inspection
of the bed ways and support alignment is critical
to ensuring the rotors unbalance forces are
transmitted accurately through to the measuring
system. Make certain that nothing is wedged into
the bearing supports that could restrict movement
of the pedestal support or vibration pickup rod.
During rotor unbalance correction, (for example,
during grinding of the rotor while on the machine
supports) the rollers, bed ways, chain for the
moving gear, and idler pulleys can be covered to
prevent grinding dust from entering these critical
machine components.
For belt-drive machines, keeping dust and debris
out of the drive pulley and the idler pulleys will
help extend the life of the belt and maintain
measuring accuracy. Debris on the pulleys can
affect the way the belt tracks over the pulleys and
over the rotor or tooling. This can cause noise in
the system. Any dust or chips can also wear at the
belt or cut into it; resulting in more frequent belt
replacements.
for questions concerning the testing of circuit
boards, our specialists for measuring electronics
are available to help troubleshoot and give advice.
An overall inspection of wear items should be
performed at regular intervals to help maintain
your horizontal and vertical balancing machine’s
measuring accuracy, prevent unexpected
downtime and provide a safe operating
environment for the machine operator. Regular
preventative maintenance, along with proper
troubleshooting, and spare parts availability, will
prove to be cost effectiv e to your operations and
you will continue to enjoy first-class balancing
results from your Schenck balancing machine.
Schenck Trebel provides periodic calibration
services based on your application requirements
and usage. Schenck also provides automatic
scheduling of calibration services to avoid missed
calibration deadlines and avoid unplanned
downtime of your equipment.

Schenck machines are designed and built to

withstand heavy industrial use. Your balancing
machines instrumentation will automatically
perform a self-diagnostic test every time the
instrument is powered up. Should a problem
occur, such as in the case of electronic
faults or a software problem in the measuring, or
To schedule a service or calibration visit, contact
our Service Department by e-mail at
service@schenck-usa.com, or by phone 1-800-
TREBEL-7 (1-800-873-2357).

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Schenck Hosts High Speed Conference

In June, users and operators of High Speed balancing facilities in the U.S. and members from
Schenck’s global High Speed product team came together in St. Louis to share ideas and discuss
new technologies and trends. Presentations included the new ISO 21940-12:2016 (11342) document
addressing procedures and tolerances for rotors with flexible behaviour, balancing techniques using
Residual Mod-al Unbalance, and Schenck’s new CABflex3 Flexible Rotor Balancing software suite.
A special thank you to MD&A for their generous hosting of their facility tour. Their new High Speed
balancing facility and balancing team are truly world-class, and we appreciate their support.

A Repeat Performance For Schenck

On September 22, Schenck Trebel competed in the 12th Annual Pratt & Whitney United Way Golf
Tour-nament. It was their second year participating in the golf tournament that took place at Bull
Creek Golf Course in Columbus, Georgia.

Last year’s tournament raised over $95k, with all of the net proceeds donated to the
Chattahoochee Valley United Way chapter. This year’s event exceeded last year, raising over
$100k !

Schenck Trebel played with a team of four of its employees, including Ulrik Frodermann, President
and CEO, Peter Ehlers, National Sales Manager, Mark Salak, District Sales Manager and Joseph
Alberto, Product Line Manager of Universal Balancing Machines.

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 CAB 690: Gone But Not Forgotten
From it’s introduction in the 1980’s, the CAB
690 became one of the most popular measuring
units from Schenck. The most recent deliveries
date back to 2001, other than some special
application units delivered in 2006.
Today, we are no longer able to fully service the
CAB 690, due to its core electronic parts being
discontinued on the market. Please take note of the
following, prior to considering an investment in
repairs to your existing CAB 690.
CAB 690
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6
Schenck will still support the CAB 690 after 2016
for as long as possible but cannot promise full
spare parts availability after that time.
The latest CAB 920 Smart Touch and CAB 925 Aero
provide all of the essential functions to fully
replace and exceed the CAB 690 functionality
with cutting-edge technology.
If you are the owner of a CAB 690 Instrument and
would like to consider a replacement instrument,
please contact us at sales@schenck-usa.com
The CAB 920 and 925 Aero, offer a Touch Screen
operator interface coupled with the latest
developments in measuring technology.
Monitoring Hydropower Machines
Today’s global installed hydro-power capacity represents about 20% of the world’s current electricity
generated.

Hydropower provides the largest part of the renewable energy sector. About 50% of the renew-
able energy in the USA is generated by hydropower.

The design of a hydropower plant is to convert kinetic energy of water into electric power. There are
three typical turbine designs: Pelton turbine (Lestor Allan Pelton, OH), Francis turbine (James B.
Francis, MA) and Kaplan turbine (Victor Kaplan, Austria) which are chosen based on head and fl ow
of the water.

A = Pelton turbine B = Francis turbine C= Kaplan turbine

The majority of larger turbines are designed in the vertical orientation with the generator on top of
the turbine. Some smaller turbines are designed in the horizontal orientation with either one turbine
runner or two turbine runners, one on either side of the generator.

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 Today, machine uptime is more important than ever before. Therefore, monitoring the machine
status has become absolutely necessary. There are two different levels of machine monitoring either
a) safety monitoring or b) condition monitoring.

a) Safety monitoring for hydropower machines, based on vibration monitoring

Safety monitoring systems for hydropower machines are using permanently installed equipment,
that measure the vibration overall values of all measurement points simultaneously and gives an
alarm / and / or shuts the machine down before a catastrophic failure occurs.

Since the majority of hydropower machines have journal bearings the most effective way to monitor
the machine is by measuring the shaft relative vibration by means of two displacement probes per
bearing plane. ISO 7919-5 provides recommendations for the type of equipment, what to measure,
where to measure and acceptable vibration levels for evaluation.

In addition ISO 10816-5 provides guidelines for measuring and monitoring the bearing housing vibra-
tion using seismic transducers, i.e. accelerometers or velocity transducers.

Both standards mentioned above are currently under revision and being combined into one standard
(ISO 20816-5) which will cover both applications in the future.

Figure1 - is an example of two displacement probes measuring shaft relative vibration.

Figure2 -is an example of one velocity transducer measuring bearing housing vibration.

b) C ondition monitoring for hydropower machines, based on vibration analysis and the influence
of operating parameters.

Machine condition monitoring is a step above safety monitoring and provides the user with early
fault detection and information on developing machine failures prior to a catastrophic failure
occurs.

ISO 13373-7 sets guidelines and specific procedures to be considered when performing vibration
diagnostics of various types of hydropower machines.

8 balancing news
 Figure1 Figure2

Hydropower machines are primarily influenced by

- Mechanical unbalance
- Hydraulically excited forces in the turbine runner
- Magnetic forces between stator and rotor in the generator
- Mechanical forces in the bearings

Machine vibration is further influenced by different operational parameters such as:

- Load
- Head
- Opening of wicket gate
- Bearing oil temperature
When performing condition monitoring it is essential to be able to separate the differences in vi-
bration caused by a failure mode from the differences based on operating modes it is necessary to
simultaneously record all vibration and operating parameters.

We are able to provide you with scalable solutions based on your particular needs for small and
medi-um sized hydropower plants. Typical solutions include all or some of the following:
displacement sen-sors for measuring shaft relative vibration, seismic sensors for measuring the
housing and /or bearing vibration, safety monitoring equipment and condition monitoring systems.
Depending on the size of the system and the number of turbines / sensors we can offer either the
small Compact Monitor or the larger 19 in rack based VC-6000 with up to 36 channels per rack.

Compact Monitor

Typical Turbine Sensor Positions

VC-6000

More information on condition monitoring , or contact us at sales@schenck-usa.com

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 Schenck Participates in the EASA
Fall Conference

On September 16th, 2016, Schenck Trebel

participated in the 77th Annual EASA Southeastern
Chapter Fall Conference. It was held
from September 16-17, in North Charleston,
South Carolina in the Chapter Members’ Excel
Apparatus Services, Inc. facility.

The conference included a strong focus on
technical training. Scheck Trebel had the
opportunity to host the event and teach their
Fundamentals of Balancing Seminar along
with hands on training. The demonstration
portion of the seminar was performed using a
6,500 pound capacity Schenck Horizontal
Balancing Machine.
This year’s Fall Conference along with
Schenck’s Fundamentals of Balancing Seminar
was a great success. Many thanks to the
Southeast EASA Chapter and Excel Apparatus
Services, Inc. for giving Schenck Trebel the
opportunity to participate. We wish all of the
attendees and companies participating in this year's
event continued success.

For more information on

Schenck’s seminars and
workshops, visit our
seminar page.

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Schenck Exhibits at IMTS 2016

On September 12-17, Schenck Corporation participated in the International

Manufacturing Technology Show (IMTS), one of the largest manufacturing and industrial
trade shows in the world, that takes place every two years in Chicago’s McCormick Place.

Schenck exhibited their products in a custom designed booth in the East

Pavilion at McCormick Place featuring their Pasio 15, HM30 and the Distec machines.

Rounding out Schenck’s product line were their portable balancing analyzers, the Smart
Balancer and their new Vibrotest 80 and Vibroport 80.

Schenck takes this opportunity to thank their Customers for visiting their booth!

Schenck looks forward to participating in the next IMTS Show that is scheduled for
September 10-15, 2018.

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 Schenck Happenings

Can We Chat?
Schenck now offes their customers the
convenience of Live Chat! June of 2016 marked
the launch of Schenck’s chat feature on their
website’s homepage.

Since it’s launch in June, we had over 300 chats

with our customers.

Schenck’s live agents have answered visitors’

questions about a wide range of topics dealing
with parts, service, sales, events and training, just
to name a few.

Schenck’s website chat feature is available during

our normal business hours. You may leave us an
email any time our agents are not available.

Visit Schenck’s website now and look for the

chat icon to engage with a live agent!

12 balancing news