FAG Detector III User manual

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Title page 1
by FAG Industrial Services
FAG Industrial Services GmbH
Kaiserstraße 100
52134 Herzogenrath
Germany
Telephone: [phone]
Telefax: [phone]
E-mail: [e-mail]
Internet: www .fis-services.com
All rights reserved.
No part of the documentation or software may be reproduced or processed, duplicated
or disseminated with electronic systems in any formwithout our written permission. The
names and trademarks of the individual companies used in the documentation are subject
to general trademark, copyright and patent protection.
Microsoft, Windows and Windows NT are trademarks or registered trademarks of
Microsoft Corporation in the USA and/or other countries.
© 2011-05-23 FAG Industrial Services
Imprint

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Table of Contents
Table of Contents
............................................................................................. 81 General
.............................................................................................................. 101.1 Safety information
.............................................................................................................. 111.2 Hazard symbols and signal words
.............................................................................................................. 121.3 About this documentation
............................................................................................. 132 Product description
.............................................................................................................. 142.1 Intended use
.............................................................................................................. 142.2 Modifications by the user
.............................................................................................................. 152.3 Technical data
.............................................................................................................. 182.4 Scope of delivery
............................................................................................. 213 Before you start
............................................................................................. 224 Trendline 3
.............................................................................................................. 224.1 Program installation
................................................................................................. 22Systemrequirements4.1.1 ................................................................................................. 24User rights and writing access4.1.2 ................................................................................................. 24Installation Trendline softw are4.1.3 .................................................................................................. 26Trendline Setup Wizard4.1.3.1 .................................................................................................. 28Detector Flash Updater Setup Wizard4.1.3.2 .................................................................................................. 28Database Setup Wizard4.1.3.3 ................................................................................................. 35Update4.1.4 ................................................................................................. 36Uninstalling4.1.5 .............................................................................................................. 364.2 Start program
................................................................................................. 36Automatic notification of updates4.2.1 ................................................................................................. 39User interface4.2.2 .................................................................................................. 39Main window4.2.2.1 .................................................................................................. 40Menu and toolbar4.2.2.2 .................................................................................................. 43Tree elements4.2.2.3
.............................................................................................................. 454.3 First steps
................................................................................................. 45Adding a sensor4.3.1 ................................................................................................. 48Installing USB-serial converter4.3.2 ................................................................................................. 50Balancing activation4.3.3 ................................................................................................. 52Register and configure new Detector4.3.4

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.............................................................................................................. 534.4 Setting up configuration
................................................................................................. 53Set up systemtree4.4.1 ................................................................................................. 54Automatic assignment of RFIDtags to measuring points4.4.2 ................................................................................................. 58Set up a measuring point4.4.3 ................................................................................................. 65Setting characteristic values4.4.4 ................................................................................................. 67Editing / deleting sensors4.4.5 ................................................................................................. 68Managing measurement comments4.4.6 ................................................................................................. 69Add balancing configuration4.4.7 ................................................................................................. 76Set up amplitude/phase configuration4.4.8 ................................................................................................. 82Set up run up/coast down4.4.9 ................................................................................................. 87Adjust alarmlimits automatically4.4.10 ................................................................................................. 90Send configuration4.4.11 .............................................................................................................. 904.5 Trendline database
................................................................................................. 91Users and passw ords4.5.1 ................................................................................................. 93Select database on server4.5.2 ................................................................................................. 95Database administration4.5.3 .................................................................................................. 96Attach database4.5.3.1 .................................................................................................. 98Detach database4.5.3.2 .................................................................................................. 98Update database4.5.3.3 ................................................................................................. 99Create database4.5.4 ................................................................................................. 100Open database4.5.5 ................................................................................................. 101Delete database4.5.6 ................................................................................................. 102Back up database4.5.7 .............................................................................................................. 1024.6 Bearing database
................................................................................................. 103Search bearing4.6.1 ................................................................................................. 104Add bearing4.6.2 ................................................................................................. 105Edit / delete bearings4.6.3 ................................................................................................. 106Export / import bearings4.6.4 ................................................................................................. 106Manage groups4.6.5 ................................................................................................. 108Add manufacturer4.6.6 ................................................................................................. 109Edit / delete manufacturers4.6.7 ................................................................................................. 109Select bearing database4.6.8 ................................................................................................. 109Close4.6.9 .............................................................................................................. 1094.7 Template and route planning
................................................................................................. 109Template planning4.7.1 ................................................................................................. 112Route planning4.7.2 ................................................................................................. 114Send templates and routes4.7.3 .............................................................................................................. 1154.8 Download data from Detector
................................................................................................. 115Sorting Wizard4.8.1

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Table of Contents
.............................................................................................................. 1174.9 Viewing measuring data
................................................................................................. 117Measured values4.9.1 ................................................................................................. 121Graphic4.9.2 .............................................................................................................. 1244.10 Reset alarm status
.............................................................................................................. 1244.11 Delete measured data
.............................................................................................................. 1254.12 Log file
.............................................................................................................. 1264.13 E-Service
.............................................................................................................. 1274.14 Create reports
................................................................................................. 127Measurement report4.14.1 ................................................................................................. 132Alarmreport4.14.2 ................................................................................................. 133Route report4.14.3 ................................................................................................. 133Balancing report4.14.4 ................................................................................................. 134Amplitude/phase report4.14.5 ................................................................................................. 135Run up/coast down report4.14.6 .............................................................................................................. 1364.15 Importing and exporting data
................................................................................................. 137Export wizard4.15.1 ................................................................................................. 138Export a single measuring point4.15.2 ................................................................................................. 142Importing data froma Trendline database4.15.3 ................................................................................................. 144Export and import templates4.15.4 .............................................................................................................. 1454.16 Program settings
................................................................................................. 146General4.16.1 ................................................................................................. 148Database4.16.2 ................................................................................................. 149Report4.16.3 ................................................................................................. 149E-mail4.16.4 ................................................................................................. 150Data view4.16.5 ................................................................................................. 150Automatic export4.16.6 ................................................................................................. 150Update4.16.7 ................................................................................................. 151Communication4.16.8 .............................................................................................................. 1514.17 Exit program
............................................................................................. 1525 FIS Viewer
.............................................................................................................. 1525.1 About the FIS Viewer
.............................................................................................................. 1525.2 The work interface
................................................................................................. 152Work interface areas5.2.1 ................................................................................................. 153Toolbar5.2.2 ................................................................................................. 154Tools5.2.3 ................................................................................................. 158Diagramdisplay5.2.4 ................................................................................................. 158Cursor and measuring information5.2.5

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................................................................................................. 159The diagraminformation bar5.2.6 .............................................................................................................. 1615.3 Working with the Viewer
................................................................................................. 161Displaying several diagrams simultaneously5.3.1 ................................................................................................. 161Modifying the appearance of a diagram5.3.2 ................................................................................................. 164Using the mouse to control the cursor or zoomfunction5.3.3 ................................................................................................. 165Zoomtools5.3.4 ................................................................................................. 169Cursor tools5.3.5 ................................................................................................. 178Positioning of base cursor5.3.6 ................................................................................................. 179Modify cursor properties5.3.7 ................................................................................................. 185Other tools5.3.8 ................................................................................................. 188Using the diagraminformation bar5.3.9 ................................................................................................. 197Export diagrams and information5.3.10 ................................................................................................. 198Waterfall charts5.3.11 ................................................................................................. 203Programsettings5.3.12 .............................................................................................................. 2095.4 Keyboard shortcuts
............................................................................................. 2126 Detector III
.............................................................................................................. 2126.1 Operation
................................................................................................. 212Keypad6.1.1 ................................................................................................. 214Sw itching on and off6.1.2 ................................................................................................. 214Display and icons6.1.3 .............................................................................................................. 2166.2 Connectors
.............................................................................................................. 2176.3 Accumulator
.............................................................................................................. 2186.4 Data transfer
.............................................................................................................. 2196.5 Device menu
.............................................................................................................. 2226.6 Measuring procedure
.............................................................................................................. 2236.7 CM measurement
................................................................................................. 224Selection of the measuring point6.7.1 ................................................................................................. 226Performing the measurement6.7.2 ................................................................................................. 226Display of values measured6.7.3 .................................................................................................. 229Display of time signals / trends6.7.3.1 .................................................................................................. 230FFTdisplay6.7.3.2 ................................................................................................. 231Multiple measurements6.7.4 ................................................................................................. 232Measuring with universal characteristic value6.7.5 ................................................................................................. 233Measuring with temperature sensor6.7.6 ................................................................................................. 233Using the headset6.7.7 .............................................................................................................. 2346.8 Balancing measurement
................................................................................................. 239Measuring rotational speed6.8.1

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Table of Contents
................................................................................................. 240Reference run6.8.2 ................................................................................................. 241Trial run6.8.3 ................................................................................................. 244Display coefficients and apply balance weights6.8.4 ................................................................................................. 245Trimrun6.8.5 .............................................................................................................. 2476.9 Run up/coast down (Determining the resonance range)
.............................................................................................................. 2496.10 Amplitude/phase measurement
.............................................................................................................. 2526.11 Free measurement
.............................................................................................................. 2586.12 Single measurements
.............................................................................................................. 2616.13 Delete measured data
.............................................................................................................. 2636.14 System messages and their meaning
.............................................................................................................. 2676.15 Update firmware
............................................................................................. 2697 Special information
.............................................................................................................. 2697.1 Characteristic values
.............................................................................................................. 2707.2 Frequency selective characteristic values
.............................................................................................................. 2717.3 Time signals
.............................................................................................................. 2727.4 Dynamic memory management
.............................................................................................................. 2737.5 Analog branches in the Detector III
.............................................................................................................. 2747.6 Connecting
............................................................................................. 2758 Maintenance and repairing
............................................................................................. 2769 Taking out of service and disposal
............................................................................................. 27710Manufacturer / Support
............................................................................................. 27811Appendix
.............................................................................................................. 27811.1 CE-Declaration of conformity
.............................................................................................................. 27911.2 CE-Declaration of conformity (RFID)
.............................................................................................................. 28011.3 Principles of non-contact temperature measurement
................................................................................................. 285Handling the pyrometer11.3.1
Index ............................................................................................289

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1 General
Overview
The FAG Detector III is a vibration measuring device, data collector and
operational balancing device in one. Together with the FIS 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 Hzto 20 kHz. FAG Detector IIIcan 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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General
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 cannot 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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1.1 Safety information
The Detector hardware is manufactured in accordance with the approved
standards and guidelines (see Declaration of Conformity in the PDF appendix)
and is safe for operation. Nevertheless, the device may pose certain
unpreventable residual risks to users and third parties or objects. Therefore, it is
essential that all safety information contained in this manual is complied with.
Moreover, the universal safety and accident prevention regulations must be
considered. Non-compliance can endanger the health and life of persons or
cause material damage. The safety information in this manual are valid in the
Federal Republic of Germany. In other countries are the relevant national rules
valid.
Please note the special security information, which can be found at the
beginning of the corresponding chapter or next to the individual steps.
Operating staff
Certain features of the Detector, e.g. balancing, may be performed only by
accordinglytrained staff.

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General
1.2 Hazard symbols and signal words
Hazard symbols used
Safety and hazard information is characterized by standardized, specific hazard
symbols. Ifno specific symbol applies, a general hazard symbol is used instead.
General hazard symbol
DANGER
Type and source of the danger are described here
Measures to prevent the danger are explained here.
Specific hazard symbols
DANGER
ELECTRICAL SHOCK HAZARD!
This symbol represents the electrical shock hazard which
can lead to personal injury including death or material
damage.
Signal words used
Signal words indicate the severity of danger given if the measures for reducing
damage are not observed.
Caution: Slight material damage can occur.
Warning: Slight personal injuryor severe material damage can occur.
Danger: Personal injurycan occur. In especiallyserious cases there is danger
to life.

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1.3 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 perform measurements;
how to transfer data from the Detector to the computer and
how data can be analyzed and stored.
The PDF appendix also contains a brief description of the subject Temperature
measurement with the Detector III. An introduction to the basic principles of
vibration monitoring as PDF is on the delivered CD-Rom (see "General
information on vibration monitoring").
Please read these instructions carefully prior to the start-up and keep them in a
safe place. Ensure that
these instructions are available to all the users,
these instructions are included when the product is transferred to other users,
any additions and changes provided by the manufacturer are always
included.
Symbols used
This symbol indicates
helpful additional information and
device settings or application tips that help you perform
tasks more efficiently.
Cross reference symbol : This symbol refers to a manual page containing
further information. When reading the manual in PDF-format on the computer
screen you can jump to that page by simply clicking on the word to the left of the
symbol.
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Product description
2 Product description
Detector IIIis 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 temperatures using an infra-red sensor.
Once a round of measurements is complete, the measured characteristic
values and anyrecorded time signals are transferred to a computer where they
are evaluated, analyzed and graphed 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 sensitivityfor each measuring
point and the threshold values for main or preliminaryalarm are stored as well.
The configuration is created using the Trendline software and transferred to
the Detector prior to measuring.
For the measurement, the vibration sensor is attached 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 (subsequentlyreferred to as
CMmeasurement ) 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 performing the balancing measurement . These
weights serve to compensate for imbalances in rotating parts and therefore
extend their service life.
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2.1 Intended use
The Detector as well as the associated components are not
admitted for the use in residential areas!
Detector devices must only be operated within the limits specified in the
Technical data to the extent provided, the limits of use of the individual
components mustalways be taken into consideration too.
Anyother use exceeding the above is deemed unintended and the user will bear
the full risk associated with it. The user is responsible for the intended use. This
includes the compliance with these instructions.
Information to the user
Changes or modifications not expressly approved by the party responsible for
compliance could void the user's authorityto 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 Adigital apparatus complies with Canadian ICES-003.
2.2 Modifications by the user
The user may not carry out any modifications to the hardware of the Detector
device. The user is merely allowed to make setting changes to the device by
means of the Trendline software. For modifications in exceeds to this the user
bears all responsibility! Should you encounter a defect in your Detector please
contact your customer adviser .
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Product description
2.3 Technical data
Device name
FAG DETECTOR III, DETECT3-KIT
Inputs
2 * BNC connectors (multiplexer)
ICP (4,7 mA), arbitrary configurable sensitivity
AC/DC ±5 V, impedance >100 kOhm
1 * AUX
Tachometer input 5 up to 24 V, 30-9999 RPM (rising or falling edge
selectable)
IR-temperature sensor ±5 V, impedance >100 kOhm (freely
configurable)
Battery charger
Vibration measurements
Outputs
Headset (envelope signal)
RS 232 for data transfer (38,4 kbps; 57,6 kbps)
AUX: supply trigger sensor (5 V max. 200 mA, 12 V max. 50 mA)
Measuring ranges
Acceleration / velocity 0,1 Hz to lowpass
0.1 Hz to 200 Hz; 0.1 Hz to 500 Hz; …
Demodulation 0 Hz until lowpass
Lowpasses 200 Hz, 500 Hz, 1 kHz, 2 kHz, 5 kHz, 10 kHz, 20 kHz
Highpass (demodulation branch) 750 Hz
Temperature -20 °C to +550 °C (temperature range depends on the
used sensor, freely configurable input)
Characteristic values
Aeff (2 kHz to lowpass), RMS value of the vibration acceleration
Asel RMS value of the vibration acceleration in a freely configurable
frequency range
ISO 10816 (10 Hz to 1000 Hz), RMS value of the vibration velocity
Vsel RMS value of the vibration velocity in a freely configurable
frequency range
Deff (frequency range depends on lowpass frequency), RMS
value of the demodulation signal
Dsel Effective demodulation signal in a freely configurable
frequency range
Crest factor, rotational speed, temperature, universal
Window type
Hanning
Averaging in frequency range
1–9 (FFT, characteristic value per channel)
Sampling rate
Linear
max. 51,2 kHz, depending on the configured lowpass frequency
(configured lowpass * 2,56)

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A/D converter
16-bit (auto ranging)
Dynamic range >90 db
Frequency resolution
1600, 3200 lines (0.0625 Hz up to 12.5 Hz depending on the
configured lowpass frequency)
Balancing
1 or 2 plane balancing
Weight positions: continuous (0 to 359°) or discrete (4 to 99
positions)
Remove trial weights: yes/no
Balancing measurement type
Acceleration, velocity, displacement
Measurement
Peak, Peak – Peak, RMS
Balancing units
g, mm/s, inch/s, µm, mil
Weights units
g, oz (up to 99 999,99 g / oz)
Automatic measuring point detection (RFID)
Radio frequency
13.65 MHz
RFID standard
ISO 15693
Product must only be operated
in
European Union (EU), Switzerland, USA, Canada, Australia
General
Separate measurements
Temperature, rotational speed, headset (envelope signal)
Keyboard
Membrane keyboard with 21 keys
Display
Backlit graphic display (LCD) 128x 64 pixels,
dimension 55 x 33 mm
Memory
1600 measuring points plus 270 time signals (maximal 300 time
signals)
Power supply
NiMh 2 000 mAh
Voltage 6V
Operation time approx. 6 to 8 hours (charging time for empty battery
approx. 4 h)
Size and weight
230 x 70 (53) x 45 (53) mm (L x W x H), approx. 500 g (including
battery)
Temperature range
0 to 50 °C (operating temperature)
0 to 40°C (to load the charger)
-20 to +70 °C (storage and transport temperature)
Operation time
approx. 6 to 8 hours continuous operation

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Product description
Housing
ABS, IP 40
Protective bag
Two compartments, black nylon material 2 windows with foil
cover, openings with Velcro strip fastener Velcro strip ties for cables
and sensor, carrying strap
EMC standards
EN60950-1, EN61000-4-2, EN61000-4-3, EN61000-4-6
Firmware
Free firmware updates on the Internet
Available languages: German, English, Finnish, French, Italian,
Dutch, Polish, Portuguese, Swedish, Slovenian, Spanish and
Turkish
Software
FIS Trendline (updates on the Internet)
Available in: German, English, French, Portuguese and Spanish
– Configuration of the FAG Detector IIIvia RS 232-interface
– Bearing database with ca. 20 000 bearings
– Graphical display of the measured values and trends
– Trend analysis
– View of time signals and FFTs
– Tabular and graphic view of the balancing data
– Configurable report tool
Subject to technical modifications!

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

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Product description
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)
Reflexmark for optical trigger sensor
Dongle for activating the balancing function
Case

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RFIDKIT
Base unit with accumulator and RFID reader
5 RFID tags:
2 units FIS.DETECTORIII.RFID.TAG.KEY
3 units FIS.DETECTORIII.RFID.TAG.DOME (speciallyfor metallic
foundations)
Accelerometer with magnetic foot
Infrared temperature sensor
Batterycharger with travel adapter
PC data cable (serial/USB)
Manual
Protective bag with temperature sensor holder
Trendline PC software
Case
Accessories
Sensor extension cable (5 m and 15 m length), sensor bases and rail magnets
are available on request.
Optional accessories
In connection with the Detector device, FAG Industrial Services offers a wide
range of optional accessories. Please contact your customer adviser .
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