FAG Detector III User manual

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© 2007-07-13 FAG Industrial Services
From software version 3.2.0

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Table of Contents
............................................................................ 7
1Welcome
............................................................................ 9
2General
.............................................................................................................. 92.1 About this documentation
.............................................................................................................. 9
2.2 Mode of functioning
.............................................................................................................. 12
2.3 Intended use
.............................................................................................................. 13
2.4 Scope of delivery
.............................................................................................................. 15
2.5 Characteristic values
.............................................................................................................. 17
2.6 Statement of Conformance to electrical safety and EMI requirements
............................................................................ 18
3Trendline 3
.............................................................................................................. 183.1 Program installation
................................................................................................. 18
System requirements3.1.1
................................................................................................. 19
Trendline software installation3.1.2
................................................................................................. 22
Detector Flash Updater installation3.1.3
................................................................................................. 24
MSDE installation3.1.4
..................................................................................................... 27
Registering databases at the MSDE/SQL server3.1.4.1
................................................................................................. 29
Uninstalling3.1.5
.............................................................................................................. 30
3.2 User interface
................................................................................................. 30
Main window3.2.1
................................................................................................. 31
Menu bar3.2.2
................................................................................................. 33
Toolbar3.2.3
.............................................................................................................. 34
3.3 First steps
................................................................................................. 34
Adding a sensor3.3.1
................................................................................................. 36
Installing USB-serial converter3.3.2
................................................................................................. 38
Balancing activation3.3.3
................................................................................................. 40
Register new detector3.3.4
.............................................................................................................. 42
3.4 Setting up configuration
................................................................................................. 42
Enter system tree3.4.1
................................................................................................. 43
Automatic assignment of RFID tags to measuring points3.4.2
................................................................................................. 45
Create a measuring point3.4.3
................................................................................................. 50
Setting characteristic values3.4.4
................................................................................................. 52
Editing / deleting sensors3.4.5
................................................................................................. 52
Managing measurement comments3.4.6
................................................................................................. 53
Add balancing configuration3.4.7
................................................................................................. 61
Setting up run up/coast down3.4.8

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Table of Contents
................................................................................................. 65Change alarm levels automatically3.4.9
................................................................................................. 67
Send configuration3.4.10
................................................................................................. 68
Deleting the Trendline database3.4.11
.............................................................................................................. 68
3.5 Bearing database
................................................................................................. 69
Search bearing3.5.1
................................................................................................. 71
Add bearing3.5.2
................................................................................................. 72
Edit / delete bearings3.5.3
................................................................................................. 74
Exporting / importing bearings3.5.4
................................................................................................. 75
Manage groups3.5.5
................................................................................................. 78
Add manufacturer3.5.6
................................................................................................. 78
Edit / delete manufacturer3.5.7
................................................................................................. 80
Select a different bearing database3.5.8
.............................................................................................................. 82
3.6 Create a route
................................................................................................. 82
Create a new route3.6.1
................................................................................................. 83
Create template3.6.2
................................................................................................. 84
Send route3.6.3
.............................................................................................................. 85
3.7 Download data from Detector
................................................................................................. 86
Sorting Wizard3.7.1
.............................................................................................................. 88
3.8 Viewing measuring data
................................................................................................. 88
Measured values3.8.1
................................................................................................. 91
Graphic3.8.2
.............................................................................................................. 92
3.9 Reset Alarm Status
.............................................................................................................. 93
3.10 Delete measured data
.............................................................................................................. 94
3.11 EService
................................................................................................. 94
Before starting3.11.1
................................................................................................. 94
Send data3.11.2
.............................................................................................................. 95
3.12 Create reports
................................................................................................. 96
Measurement report3.12.1
................................................................................................. 100
Alarm Report3.12.2
................................................................................................. 102
Route report3.12.3
................................................................................................. 102
Balancing report3.12.4
................................................................................................. 104
Creating a run up/coast down report3.12.5
.............................................................................................................. 105
3.13 Importing and exporting data
................................................................................................. 105
Importing data from a Trendline 3.x database3.13.1
................................................................................................. 105
Export wizard3.13.2
................................................................................................. 106
Export a measuring point3.13.3
................................................................................................. 110
Import and export between different workstations3.13.4
.............................................................................................................. 110
3.14 Program settings
................................................................................................. 110
General3.14.1
................................................................................................. 111
Database3.14.2

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................................................................................................. 111Report3.14.3
................................................................................................. 112
E-mail3.14.4
................................................................................................. 113
Data view3.14.5
................................................................................................. 113
Automatic export3.14.6
............................................................................ 114
4The FIS-Viewer
.............................................................................................................. 1144.1 The working interface
................................................................................................. 114
Interface areas4.1.1
................................................................................................. 115
Toolbar4.1.2
................................................................................................. 116
Tools4.1.3
................................................................................................. 122
Diagram display4.1.4
................................................................................................. 123
Cursor and measuring information4.1.5
................................................................................................. 125
The diagram information bar4.1.6
.............................................................................................................. 128
4.2 Working with the Viewer
................................................................................................. 128
Displaying several diagrams simultaneously4.2.1
................................................................................................. 128
Modifying the appearance of a diagram4.2.2
................................................................................................. 132
Using the mouse to control the cursor or zoom function4.2.3
................................................................................................. 132
Zoom tools4.2.4
................................................................................................. 137
Cursor tools4.2.5
................................................................................................. 144
Positioning of base cursor4.2.6
................................................................................................. 145
Modifying the cursor properties4.2.7
................................................................................................. 151
Other tools4.2.8
................................................................................................. 152
Using the diagram information bar4.2.9
................................................................................................. 160
Exporting data via the clipboard4.2.10
................................................................................................. 160
Viewer settings4.2.11
.............................................................................................................. 171
4.3 Keyboard shortcuts
............................................................................ 174
5Detector III
.............................................................................................................. 1745.1 Detector display
.............................................................................................................. 174
5.2 Keyboard
.............................................................................................................. 175
5.3 Explanation of the symbols
.............................................................................................................. 176
5.4 Connectors
.............................................................................................................. 176
5.5 Accumulator
.............................................................................................................. 178
5.6 Switching on and off
.............................................................................................................. 178
5.7 Main menu
.............................................................................................................. 181
5.8 Data transfer
.............................................................................................................. 182
5.9 Measuring procedure
.............................................................................................................. 182
5.10 CM-measurement
................................................................................................. 183
Selection of measuring point5.10.1
................................................................................................. 185
Measuring procedure5.10.2

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Table of Contents
................................................................................................. 185Display of values measured5.10.3
................................................................................................. 186
Viewing time signals on the Detector display5.10.4
................................................................................................. 187
Display of the FFT on the Detector display5.10.5
................................................................................................. 188
Repeated measurements5.10.6
................................................................................................. 188
Measuring with temperature sensor5.10.7
................................................................................................. 189
Using the headset5.10.8
.............................................................................................................. 189
5.11 Balancing measurement
................................................................................................. 194
Measuring rotational speed5.11.1
................................................................................................. 194
Reference run5.11.2
................................................................................................. 195
Trial run5.11.3
................................................................................................. 197
Display coefficients and apply balance weights5.11.4
................................................................................................. 198
Trim run5.11.5
.............................................................................................................. 199
5.12 Determining the resonance range of a machine
.............................................................................................................. 201
5.13 Free measurement
.............................................................................................................. 205
5.14 System messages and their meaning
.............................................................................................................. 208
5.15 Update firmware
............................................................................ 211
6Special information
.............................................................................................................. 2116.1 Time signals
.............................................................................................................. 212
6.2 Frequency selective characteristic values
.............................................................................................................. 213
6.3 Dynamic memory management
.............................................................................................................. 214
6.4 Analog branches in the Detector III
.............................................................................................................. 214
6.5 Establishing a data connection
............................................................................ 216
7Appendix
.............................................................................................................. 2167.1 General information on vibration monitoring
................................................................................................. 216
Introduction7.1.1
................................................................................................. 217
Frequency analysis7.1.2
................................................................................................. 218
Demodulation analysis7.1.3
................................................................................................. 227
Vibration characteristic values7.1.4
..................................................................................................... 228
Arithmetic mean value7.1.4.1
..................................................................................................... 228
Peak values (peak, peak to peak)7.1.4.2
..................................................................................................... 228
Root mean square (RMS)7.1.4.3
..................................................................................................... 229
Broad band RMS value7.1.4.4
..................................................................................................... 229
Selective RMS value7.1.4.5
................................................................................................. 230
Bibliography7.1.5
.............................................................................................................. 231
7.2 Principles of non-contact temperature measurement
................................................................................................. 231
Introduction7.2.1
................................................................................................. 231
Advantages of using IR thermometers7.2.2
................................................................................................. 232
Infrared measuring system7.2.3

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................................................................................................. 232Target7.2.4
................................................................................................. 236
Handling the pyrometer7.2.5
..................................................................................................... 236
Distance to spot size ratio7.2.5.1
..................................................................................................... 237
Emissivity7.2.5.2
..................................................................................................... 237
Measurement considerations7.2.5.3
................................................................................................. 237
Bibliography7.2.6
............................................................................ 239
8Technical data
Index ............................................................................239

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Welcome
1 Welcome
Overview
The FAG Detector III is a vibration measuring device, data collector and
operational balancing device in one. Together with the Trendline 3 software,
the device allows improved planning of maintenance and increased machine
availability.
Machine vibrations are a good indicator of a machine's condition. With the aid of
Detector III, you can monitor machine vibrations according to ISO 10816 and roller
bearing condition by means of the demodulation detection method. The base
curve and demodulation signals stored in the system can then be used to analyze
the signals in the time and frequency range. This permits detection of alignment
errors and imbalance as reliably as roller bearing damage or gearing problems.
Other process parameters that can be recorded are temperature and rotational
speed.
Applications
Measuring and analyzing machine condition
The FAG Detector III records vibration signals at pre-defined measuring points by
means of a sensor and then calculates the effective values for velocity,
acceleration and demodulation. These characteristic values describe the
condition of the machine and component.
You can define and monitor frequency bands of any frequency width in the range
from 0.1 Hz to 20 kHz. FAG Detector III can save up to 1600 measuring points and
up to 270 time signals. Once a measuring round has been finished, all data
recorded are transferred to the Trendline software, where they are evaluated,
analyzed and displayed.
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Balancing with the Detector III (available as accessory function)
There are many and diverse reasons for unscheduled machine standstills.
However, a considerable number of these is due, directly or indirectly, to
imbalance or alignment errors. During operation, imbalance may cause severe
vibrations, that can lead to consequential damage, for example premature bearing
wear or fatigue-induced breaks. The result is machine failure and thus
unscheduled production downtime.
The FAG Detector III is a tool with which you can not only detect but also remedy
such conditions easily and efficiently. The easy user interface provides good
support during the balancing process. Step by step, the device software guides the
user through the balancing process. The user can create a configuration for each
balancing process with the Trendline software. Furthermore, he can define
templates that can be adapted on site on the machine. The balancing results are
sent to the Trendline software. You can display them there in table form or as a
diagram.
Analyzing data with the Trendline bearing database
The integrated bearing database (approx. 20,000 bearings from various
manufacturers) simplifies and speeds up analysis of measured data in
combination with the FIS-Viewer . It allows you to detect any irregularities at
first glance and assign the appropriate components. You can save multiple
bearings per measuring point. This allows you to check multiple bearing ball-pass
frequencies at a measuring point. Every user can add new entries to the bearing
database to suit individual needs.
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General
2 General
2.1 About this documentation
This documentation describes the functionality of the Detector III and the Trendline
software. It explains:
·how to create configurations or measuring routes on a computer and
transfer these to the Detector;
·how to use the device to record measuring data;
·how to transfer data from the Detector to the computer and
·how data can be analyzed and stored.
The appendix also contains an introduction to the basic principles of vibration
monitoring and a brief description of the subject "Temperature measurement
with the Detector III ".
Safety information symbols
DANGER Safety symbol
This safety symbol warns you of material damage and dangers to
health, life-threatening injuries and death.
General information symbols
This symbol indicates
·helpful additional information and
·device settings or application tips that help you perform tasks
more efficiently.
Cross-reference symbol : This symbol indicates a page in the manual with more
detailed information. If you are reading the manual on screen in PDF format, you
can jump to this page by clicking the word to the left of the cross-reference symbol.
2.2 Mode of functioning
Detector III is a hand-held measuring instrument with data recording function for
offline monitoring of systems and machinery (condition monitoring). For this
purpose, the instrument senses vibrations at pre-determined measuring points
using a detector and works out the RMS values of vibration velocity, acceleration
in vibration and demodulation, the so-called characteristic values, for
characterizing machine or component condition. In addition, Detector can measure
42 82
216
216
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temperatures using an infra-red sensor.
·Once a measuring round is finished, the measured characteristic values and any
recorded time signals are transferred to a computer where they are evaluated,
analyzed and graphically depicted using the Trendline software .
·The exact location of the measuring point within the system to be monitored is
stored in the configuration . There, the sensor sensitivity for each measuring
point and the threshold values for main or preliminary alarm are stored as well.
The configuration is created using the Trendline software and transferred to
the Detector prior to measuring.
·For measuring, the vibration sensor is fixed to a pre-determined measuring point
with the help of a magnet footing. If this is not possible due to the housing
material (e.g. aluminum), attach an iron plate or a washer the size of the
magnetic at the measuring point. This is easiest done with the help of a fast-
curing superglue (e.g. cyan acrylate glue).
·The configuration of the measuring point is selected on the Detector and the
measuring started. Detector records the sensor signals broadband and works
out the characteristic values. These characteristic values are stored and
transferred to the computer once the measuring round is finished.
·For each measuring point, the newly measured characteristic values are
compared with the threshold values determined for this measuring point for a
main alarm and pre-alarm. The Detector (main alarms) and the Trendline
software (main and pre-alarms) display the threshold events. New characteristic
values are stored. You can depict them graphically in the Trendline software
depending on time of measuring.
In addition to the condition monitoring measurement (subsequently referred to as
CM measurement ) the Detector III also masters what is known as operation
balancing. During this process the Detector helps you find the optimum position of
balancing weights when carrying out the balancing measurement . These
weights serve to compensate for imbalances in rotating parts and therefore extend
their service life.
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182
189

11
General
Before you start
Ferrit modules will reduce electromagnetic fields from the device which could
otherwise affect other electronic devices in the vicinity.
You will receive three ferromagnetic modules with the RFID-Kit or the
RFID-Detector. The ferrit modules have to be fasten to the three sensor cables
(cable for the acceleration sensors as well as for the trigger sensor) of the
Detector.
Ferrit module
Proceed as follows:
1. Put the sensor cable into the groove of the ferrit.
2. Adjust the cable so that the rim of the ferrit modul is placed addording to the
picture. Please note that the ferrit module should be placed as close as possible
to the Detector.
3. Close the retractable ferrit module enclosing the cable firmly till it engages.
Ferrits fasten at the sensor cables

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2.3 Intended use
Disposal information
Neither the Detector not the associated components may be disposed of via
domestic waste as they contain electronic components and NiMH accumulators
that must be disposed of in the proper manner. Please return them to us so that
we can ensure disposal in keeping with legal and environmental requirements.
Returning used devices is an important contribution to environmental protection.
Information to the user
Changes or modifications not expressly approved by the party responsible for
compliance could void the user's authority to operate the equipment.
Note: This equipment has been tested and found to comply with the limits for a
Class A digital device, pursuant to part 15 of the FCC Rules. These limits are
designed to provide reasonable protection against harmful interference when the
equipment is operated in a commercial environment. This equipment generates,
uses, and can radiate radio frequency energy and, if not installed and used in
accordance with the instruction manual, may cause harmful interference to radio
communications. Operation of this equipment in a residential area is likely to
cause harmful interference in which case the user will be required to correct the
interference at his own expense.
Industry Canada
This Class A digital apparatus complies with Canadian ICES-003.

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General
2.4 Scope of delivery
DETECT3-KIT
·Base unit with accumulator
·Accelerometer with magnetic foot
·Infrared temperature sensor
·Battery charger with travel adapter
·PC data cable (serial/USB)
·Manual
·Protective bag with temperature sensor holder
·Trendline PC software
·Case

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DETECT3.BALANCE-KIT
·Acceleration sensor with magnetic foot and sensor cable
·Trigger sensor (optical and inductive)
·Scales
·Magnetic holder for trigger sensor
·Extension stick for magnetic holder
·Cable for trigger sensor (length 10 m)
·Reflex mark for optical trigger sensor
·Dongle for activating the balancing function
·Case

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General
RFID KIT
·Base unit with accumulator and RFID reader
·5 RFID tags
·Accelerometer with magnetic foot
·Infrared temperature sensor
·Battery charger with travel adapter
·PC data cable (serial/USB)
·Manual
·Protective bag with temperature sensor holder
·Trendline PC software
·Case
Accessories
Sensor extension cable (5m and 15m length), sensor bases and rail magnet
available on request.
2.5 Characteristic values
Detector III can store up to 4 different (or same just as well) characteristic values
per measuring point. The following characteristic values can be selected:
Charac-
teristic
value
Meaning
ISO 10816
RMS value of vibration velocity
Frequency range: 10 Hz to 1 kHz
Unit: mm/s
vsel
RMS value of vibration velocity with freely selectable upper and lower limiting frequency
Frequency range: 0.3 Hz to 20 kHz (depending on the lowpass frequency)
Unit: mm/s
aeff
RMS value of acceleration in vibration
Frequency range: 2 Hz to 20 kHz (depending on the lowpass frequency)
Unit: g
asel
RMS value of acceleration in vibration with freely selectable upper and lower limiting frequency
Frequency range: 0.1 Hz to 20 kHz (depending on the lowpass frequency)
Unit: g
deff
Demodulation signal of acceleration in vibration with switchable low-pass
Frequency range: 0.1 Hz to 20 kHz (depending on the lowpass frequency)
Unit: g
dsel
RMS value of demodulation in vibration with freely selectable upper and lower limiting frequency
Frequency range: 0.1 Hz to 20 kHz (depending on the lowpass frequency)

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Charac-
teristic
value
Meaning
Unit: g
T
Temperature
Range: -20°C to +550°C
Unit: °C
Crest factor
Ratio between peak value and RMS value (Crest factor = peak value / RMS value)
In addition to the aforementioned characteristic values, you can
also measure rotational speed.

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General
2.6 Statement of Conformance to electrical safety and EMI
requirements
Declaration of conformity as per the Radio and Telecommunication
Transmitter Devices Act (FTEG) and Directive 1999/5/EC (R&TTE)
The manufacturer: F'IS, FAG Industrial Services GmbH
Kaiserstraße 100
D-52134 Herzogenrath Germany
declares that the product: Detector III
Radio installation
Purpose: RFID application
Device category: Category 1
corresponds to the basic requirements of §3 and the other relevant provisions o
f
FTEG (article 3 of R&TTE) if used for the intended purpose.
Health and safety as per § 3 (1) 1. (article 3 (1) a))
Harmonised standards used: EN 60950-1: 2001, EN 50364: 2001
Protection requirements with regard to EMC § 3 (1) 2, article 3 (1) b))
Harmonised standards applied: ETSI EN 301 489-3 V1.4.1
Measures for efficient use of the radio frequency spectrum
Harmonised standards applied: ETSI EN 300 330-2 V1.3.1.
This statement of conformance is issued based on testing the EMC aspects of a
representative product sample of the above mentioned product in conformance
with the following standards:
ETSI EN 301 489 ETSI EN 300 330 EN 61000-6-2
EN 61000-6-4 EN 60950-1 FCC Part 15
Measuring device identifier: CE
Herzogenrath, 22.06.2007

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3 Trendline 3
The Trendline software is the server-based program for the Detector III. The
Detector itself is designed only for the recording of measured values. All data
organization and evaluation tasks are carried out by the Trendline software.
The monitoring of a system is configured using the software which also evaluates,
analyses, and stores the measuring data delivered by the Detector.
Further, Trendline 3 manages the exchange of data between the server on which
the software is running and the Detector.
3.1 Program installation
In addition to the application program, the Trendline software requires the MSDE
database server. It must be installed either on the local computer or on a network
server. If you are already using an MSDE database server, you can register the
databases with this.
Please note that you need Administrator permissions for your
computer to install the Trendline software completely. If you do not
have these permissions, ask your system administrator. For
example, you can install the software with Administrator
p
ermissions and then switch back to a normal user.
3.1.1 System requirements
In order to use the Trendline software in an optimum way, the following minimum
requirements must be met:
General system requirements
·Pentium III PC with 500 MHZ (recommended: 1 GHz)
·at least 512 MB RAM (recommended: 1 GB)
·Screen resolution: 1024x768 (pixels)
Operating systems
·with MSDE 2000: Windows 2000, Windows Server 2003, Windows XP
Please note that the Trendline software does not yet run on
Windows Vista.
Hard disk memory for installing the Trendline software
·Trendline software 3.2 (without database and database server): 62 MB

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Trendline 3
·Detector Flash Updater: 4 MB
·Demo database and bearing database: 20 MB
Hard disk memory for installing the database server
·MSDE 2000: 50 MB
Hard disk memory for the database
·MSDE 2000: at least 2 GB (recommended: 6 GB)
Other requirements
·Microsoft Internet Explorer 6.0 SP1 or later
3.1.2 Trendline software installation
Please insert the Installation CD. If you do not have a CD, you can download the
current version of Trendline from our website (www.fis-services.de).
If the installation program does not start automatically you can start it manually
using Windows Explorer:
1. Open My computer.
2. Under Equipment with removable media click the right-hand mouse button on
the CD-ROM drive then click Open.
3. Start the Trendline installation file (Trendline-Setup-3.2.exe) by doubleclicking
on it.
4. Please select the language to install the Trendline software. You can change the
language settings at any time after installing.
The Setup Wizard guides you through the rest of the installation:
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5. Select the directory where you want to install the software and click Next.
6. Select the Start menu directory to create the program link. Click on Continue.