Huatec Hg904 User manual

USER’S MANUAL

HG904

A Portable Dual-Channel

Microprocessor-Based

On-site Balancer

Spectrum Analyzer

Vibration Data Collector

E-mail:[email protected]

Fax: 8610 82916893

Tel : 8610 82921131

Address: Rm. 730, Chengyuan Building, the Mid. Road of Jiancaicheng

Haidian Dist. BeiJing, CHINA

www.huatecgroup.com

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The only difference between HG904 and HG907 is that HG904 can be used

together with Machinery Condition Monitoring software (WaveSoft) .In the following

contents of this manual we use the word ―HG904‖ in most case for both of HG904A

and HG907

The information contained in this document is proprietary. No part of this manual

may be reproduced or transmitted in any form or by any means without the

permission of HUATEC Group Corporation.

The information provided in this Manual is believed to be

reliable. However, HUATEC Group Corporation no responsibility

for inaccuracies or omissions. HUATEC Group Corporation

assumes no responsibilit y for the use of this information, and

all use of such information shall be entirel y at the user's own

risk. Specifications are subject to change without notice. No

patent rights or licences to any of the functions described are

implied or granted to any third party. HUATEC Group Corporation

does not authorise or warrant any HUATEC Group Corporation

product for use in life support devices or systems.

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CONTENTS

CHAPTER 1 GENERAL ……………………………………………………………………… 3

CHAPTER 2 BALANCE PRINCIPLES……………………………………………………… 4

CHAPTER 3 BALANCING PREPARATION …………………………………………….. .. 7

CHAPTER 4 BALANCING OPERATIONS………………………………………………… 8

1-plane balancing…………………………………………………………………………… 8

without influence coefficients…………………………………………………………. 8

with influence coefficients……………………………………………………………..13

2-planes balancing………………………………………………………………………… 15

without influence coefficients………………………………………………………….15

with influence coefficients……………………………………….. ………………… 21

CHAPTER 5 Vibration Analyzer / Data Collector…………………………………………….21

APPENDIX BALANCE GRADE OF RIGID ROTORS ……………………………….. 31

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1 GENERAL

Imbalance is one of the main causes of machine vibration. It is estimated that

about 50 percent of all the faults are caused by imbalance of rotors. The best mean for

getting rid of mechanical imbalance is on-site balancing. HG904 Machinery

Analyzer/Balancer is especially useful for this purpose. It can measure the intensity of

the vibration; diagnose vibration cause by analyzing the frequency spectrum. It can

also be used to measure the rotation speed and vibration phase, and to calculate the

imbalance weight and location.

Dual channel vibration analyzer Phase GDT-2 sensor

Features:

-Easy to use

-Vector illustration, the balancing process and result are shown clearly at a

glance

-Storage of 10 rotors balancing data

-Selectable of trial mass remove or remain

-Decompose of balancing result to two assigned location

-Trial weight range calculated according to the weight of rotor, rotation speed,

radius and required balance grade

-Trial mass validity judged automatically

-Measuring RPM, amplitude and phase

-On-site 400 lines FFT spectrum and diagnosis function

-Dual-channel simultaneous data collection

-Hardware envelop demodulation for bearing and gear diagnosis

-Transfer function for measuring natural frequency

-Waveform and spectrum display by large LCD

-Storage of vibration values and vibration waveform

Operation condition

-Temperature range: from 5C to 50C

-Relative humidity: < 85%, unsaturated

-Without caustic gases

-Without strong electric-magnetic field & strong impact

Safety

The HG904 are not permitted to contact with running part of machine.

Specifications

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Rotation speed range for dynamic balancing: 70-60,000 r/min

Auto-range and manual-range selectable

Measuring accuracy of vibration: 5 %

Sensors: Piezoelectric accelerometer, Magnetoelectricity velocity, Eddy

displacement and etc.

8th-order ellipse anti-aliasing filter, RPM band-pass filter

Input signal: Accelerometer, and voltage

Amplitude spectrum analysis: 100 lines to 400 lines (zoom), Hanning windowed

Frequency span of spectrum analysis: 100, 200, 500, 1K, 2K, 5K, 10KHz(only for

1-channel sampling)

Data storage: 400 waveforms of 1024-points and 400 data sets

Amplitude ranges & Frequency Response for overall vibration measurement:

Amplitude ranges

Frequency Response

Displacement

0.003 –5 mm peak-peak

10 –500 Hz

Velocity

0.2 –200mm/s true RMS

10 –1000 Hz

Acceleration

0.5 –250m/s2peak

20 –5000 Hz

Envelope

0.1 –20unit true RMS

5-1000Hz from 15-40 KHz

Voltage

0.1 –10V peak-peak

10 –10000 Hz

Notepad: 10 condition codes for visual inspection

Output: USB for communication with PC

Power: Ni-MH rechargeable battery for 8 hours continuous operation, low battery

warning

Operating Environment: 0~55 oC, 90% humidity non-condensing

Rotating speed measurement with photocell sensor

Dynamic Range: 60dB with 48dB adjustable gain range

Dimensions: 21×13×4 cm; Weight: 1.2 kg (Include batteries)

2 BALANCE PRINCIPLES

2.1 What is 1-plane rotor imbalance?

Rigid rotor works under the speed far less than its first-order critical rotate speed

and its deformation can be neglected. When the quality of the rigid rotor nearly

focuses on a disc, namely the ratio of its axial length and its diameter is less than 0.5;

we can do 1-plane balance on it and gain satisfactory result.

But for the flexible rotor, the deformation cannot be neglected. So its method of

balance differs from rigid rotor. However, the rotor with single imbalance plane can

also be balanced according to the method of 1-plane balance of rigid rotor. For above,

whether the rigid or flexible rotor, its quality of imbalance always focuses on one disc,

so both of them can be balanced according to the method of 1-plane rotor balance. In

the plant and manufactory, such rotating machines are ubiquitous, such as pump,

ventilator etc.

2.2 Principle of 1-Plane Balancing

HG904’s 1-plane balance adopts the method of influence coefficient, which is also

called balance method of 1-plane phase measuring. Just as its name implies, it’s

desirous to do the measurement with the phase of rotation-speed vibration when

measuring the vibration amplitude of rotor. The rotation-speed vibration can be

indicated as vector. The process of 1-plane balance is as follows:

(1) Measure and gain the initial rotation-speed vibration vector (A0) under the

normal operation condition.

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(2) Load the proper trial mass (M) on the rotor and then measure vibration vector

(A01) under the condition of the same rotate speed.

(3) Calculate the balance mass (Q) which should be load on the rotor according to the

following formula:

Q = - M xA0 / (A01 –A0)

During the balancing, all the vibration should be measured under the same rotate

speed because of the imbalance force of rotor relates with the rotate speed.

2.3 Principle of 2-planes balancing

Almost all the balance of single span rotor can be achieved through the method of

2-planes dynamic balance. As a matter of fact, 1-plane dynamic balance is only one

special example of 2-planes dynamic balance.

When doing 2-planes dynamic balance, two planes of adding mass and two points

of vibration measure are needed. HG904’s 2-planes dynamic balance also adopts the

method of influence coefficient. But the difference from 1-plane dynamic balance is

that the vibration of two measurement points should be measured when adding

trial-mass to one of the planes. That’s so-called interact effect. 2-planes dynamic

balance has four influence coefficients.

The steps to do 2-planes dynamic balance is as followings:

(1) Measure initial value of two measurement points.

(2) Load trial mass to first plane, then measure the vibration of two measurement

points respectively.

Load trial mass to second plane, and then measure the vibration of two

measurement points respectively.

(3) Get conclusion of the correction mass.

If the influence coefficient is known, it can be input directly and the above step (2)

can be omitted.

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1- Plane balancing

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2-Plane balancing

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3 BALANCING PREPARATION

Before using HG904 for balancing, the following must be done firstly:

<1> Confirm Dynamic Balance Needed

Affirm that machine has fault of imbalance and that it can be eliminated by the

method of balancing. Once the machine has heavy vibration, we should do frequency

analysis with the vibration signals firstly. Generally, the probability of imbalance is

higher. So, when the vibration includes a high rotation-frequency spectrum peak and

less harmonic frequency peak, meantime without evidence of other faults, very

possible it is the fault of imbalance.

<2> Mount Sensors

Vibration Sensors: It should be disposed in the horizontal direction (or vertical if

horizontal not possible) on the bearing base, or on the base frame. Because dynamic

balance is vector calculus, the position and direction of the sensor should keep

unchanged in the balancing process.

Photoelectric sensors: Paste a reflecting or unreflecting adhesive paper (according

to the condition of the rotor’s surface) to a visible place of the rotor or its axis.

Photoelectric sensor can give HG904 1 electric pulse per turn of the running rotor.

Not only the rotate speed can be measured but also the vibration signals can be

compared with pulse signals. So the phase of the rotation-frequency vibration can be

obtained. During the balancing process, the position of the reflecting adhesive paper,

the position and direction of the photoelectric sensor should keep unchanged.

<3> Connect Sensor Cables

The photoelectric sensor should be connected to the Tacho/Trigger socket of HG904.

For 1-plane balancing, 1 vibration sensor should be connected to the Accelerometer

Channel A or Voltage Channel A socket. For 2-plane balancing, a second

accelerometer should be connected to the Accelerometer Channel B or Voltage

Channel B socket.

<4> Start Machine

Start the machine and wait till it reaches its normal rotation speed (could be

measured with the RPM measurement function).

NOTICE:

1Because of the strong pull force of the magnetic mount, when remove the

sensor from the measurement surface, use your hand carefully. Do not

remove the sensor by dragging the cables.

2Before measurement, the sensitivity of the sensors must be inputted to

HG904 correctly.

3The internal/external trigger switch should be set to “external”.

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4. BALANCING OPERATIONS

4.1 1-Plane Balancing

4.1.1 WITHOUT INFLUENCE COEFFICIENT:

Step 1:Setting Parameters

Press 【On/Off】on the panel for a moment, the balancing page appears. Then

you can set the parameters.

Line 1 on the left: Change rotor number. The note displays ―Which Rotor to

Balance‖(It means which rotor you will choose to Balance,HG904/HG907 contains

200 arrays ,each arrays describe kinds of data during the balancing ). You can

press 〖〗or〖〗to change rotor number ,or you can input rotor number .The

method of input numbers is that you press 【In】at first, then input numbers

with number keys, press 【ENTER】or 【↓】at last to affirm it and the

cursor goes to the next position automatically. Press or key to move the

cursor between lines on the left (the following are the same).

Line 2 on the left: To set parameters, the note displays ―Enter Menu Key”,

press 【MENU】to right to set parameters.

Line 2 on the right: To choose the operation mode,the note displays ―How

Many Plane to Balance”. You press 〖〗or〖〗to choose 1 or 2(indicating

that 1-plane balancing or 2-plane balancing is to be performed).Here please

choose “1”.

Line 3 on the right: To choose the measuring mode, there are four modes such as

ACC(acceleration),VEL(velocity),DISP(displacement) and VOL(voltage).The note

displays ―Enter to Select”, press

〖〗or〖〗to choose the measuring mode,

The displayed is the selected.

Line 4 on the right: Input the weight of a trial unit. This is useful if some fixed

weight unit is used during the balancing. The method of input numbers is the same as

above.

Line 5 on the right: Tell whether the influence coefficients are known. The note

displays ―to S elect”, press 〖〗or 〖〗to choose YES or

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NO(indicating that the influence coefficients are known or unkown), Here please

choose NO.

The displayed is the selected.

Line 6 on the right: Input sensitivity of sensor A. The note displays ―Input

Sensitivity of Sensor A”.The sensitivity can be usually obtained from the sensor

certificate. The method of input numbers is the same as above.

Line 7 on the right: To Clear Data of the Rotor. The note displays‖Enter to

Clear”.Press 【ENTER】, fomat all is shown in the 7th line and only erase

this rotor is shown in the 8th line.Press 【↑】or【↓】to choose fomat all

or only erase this rotor ,then Press【ENTER】, the following warning is shown:

Are you sure

to format all？

YES NO

Press 〖〗or〖〗to choose YES or NO.

If you want to clear the rotor datas displayed,c hoose only erase this

rotor and press ENTER, then choose Y ES and press ENTER to erase the

rotor datas displayed , the measured data will be cleared, the balance grade and the

sensor sensitivities will change to default values at the same time ―successfully

eras e th is ro tor ”is showed.

If you want to clear all the rotor datas measured,c hoose f omat all

and press ENTER, t he n choose YES and press ENTER to clear all the rotor

datas measured, the measured data will be cleared, the balance grade and the sensor

sensitivities will change to default values at the same time ―successfully fomat”is

shown.

If you don’t want to clear any data,c hoose NO and then press ENTER to

return directly without clearing anyting.

Before a balancing operation is performed, each line of this page must be rightly

configured. You may skip a line by press or . Press to go to the next item.

Step 2: Estimate weight of trial, and then fix a trial mass on plane I

Line 3 on the left: Calculate the weight range of trial mass according to the

formula recommended by the ISO. The note displays ―Enter Menu Key”, press

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【MENU】to right.

Line 2 on the right: The note displays‖ Input How Heavy‖. The method of

input numbers is the same as above.

Line 3 on the right: The note displays‖ Maximal Rotation Speed ‖. The

method of input numbers is the same as above.

Line 4 on the right: The note displays‖ Input Radius of Trial Mass‖. The

method of input numbers is the same as above.

Line 5 on the right: The note displays‖ Enter to Select‖. Choose the

required balance grade according to ISO1940 with 〖〗or〖〗.4000→1600

→630→250 →100 →40→16 →6.3 →2.5 →1.0 →0.4→4000 are shown

circularly. The displayed is the selected.

Line 6 on the right: The note displays‖ Calculate Trial Range‖. Press

〖Enter 〗to calculate weight range of trial mass and the result is shown in the 7th line.

Stop the machine, fix a trial mass on plane I according to the calculation, and then

restart the machine.

Step 3: Initial measurement:

Line 5 on the left: The note displays‖ Enter Menu Key‖. Press〖MENU〗to

right.

Line 2 on the right:All the places showing values are vacant If you hope to see

some measurement, move the cursor to there, and then the value is displayed. You can

also input the value. The method of input numbers is the same as above. Rotation

Speed is shown in the 2nd line .When the cursor is in the 2nd line,the note

displays‖Enter to Measure‖. Press ENTER, to measure the rotation speed. The

RPM value on the right side of the 3rd line will update continually. And

Amplitude&Phase is shown in the 2nd line .When the rotation speed becomes

stable, press ENTER for a moment, the HG904 begins measuring vibration. The data

in the 3rd line (rotation speed) and in the 5th line (the left is amplitude while right is

phase) will update continually. When the rotation speed, amplitude and phase all

become stable, press ENTER for a moment to finish the measurement.

Step 4: Trial 1 measurement:

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Line 6 on the left: The note displays‖ Enter Menu Key‖. Press〖MENU〗

to right.

Line 2 on the right: The note displays‖ Input Angel‖. The method of input

numbers is the same as above.

Line 3 on the right: T he note displays‖ Input Trial Mass Weight‖. The

method of input numbers is the same as above.

Line 4 on the right: The note displays ―to Select”, press〖〗or 〖〗

to choose Remove or Remain The displayed is the selected.

Line 5 on the right: All the places showing values are vacant If you hope to see

some measurement, move the cursor to there, and then the value is displayed. You can

also input the value. The method of input numbers is the same as above. Rotation

Speed is shown in the 5th line .When the cursor is in the 5th line,the note

displays‖Enter to Measure‖. Press ENTER, to measure the rotation speed. The

RPM value on the right side of the 6th line will update continually. And

Amplitude&Phase is shown in the 5th line .When the rotation speed becomes

stable, press ENTER for a moment, the HG904 begins measuring vibration. The data

in the 6th line (rotation speed) and in the 8th line (the left is amplitude while right is

phase) will update continually. When the rotation speed, amplitude and phase all

become stable, press ENTER for a moment to finish the measurement.And the valid

of trial is shown in the 9th line,Valid means you can goto the next step, Remove ,add

indicating that you should add a new trial at another angle, Remove indicating that

you should add this trial at another angle.Stop the machine, adjust the trial mass

accordingly to the note. Repeat the trial I measurement.

//Line 10 on the right: The note displays ―Enter to See”.

Step 5: calculate influence coefficients and balancing mass

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Line 7 on the left: The note displays‖ Enter Menu Key‖. Press〖MENU〗to

right.

Line 2 on the right: The note displays‖ Enter to Calculate‖,all the places

showing values are vacant. If you hope to see some measurement, move the cursor to

there, and then the value is displayed. You can also input the value. The method of

input numbers is the same as above.Press 【ENTER 】, the balancing mass is

calculated and shown in the 5th line. The location of balancing mass is also shown

with vector chart. Press 【↑】or【↓】to move cursor on the right.

Line 3 on the right: The note displays‖ Enter to See

Coeffient‖.Press 【ENTER】to Coeffient page to see influence

coefficients .The cursor is in the 1st line, the note displays‖ Enter to

Return‖.Press 【ENTER】to the former page.

Step 6: discompose vector

Line 8 on the left: The note displays‖ Enter Menu Key‖. Press〖MENU〗to

right.

Firstly, the vector of balancing mass can be found in the vector graph just on the

circle.Then find two proper angles at each side of the vector of balancing mass .

Line 2 on the right: The note displays‖ Input Angle‖. Input the first angle PI1

(the first angle is at the anti-clockwise side of the balancing mass vector). The method

of input numbers is the same as above.

Line 3 on the right: The note displays‖ Input Angle‖. Input the first angle PI1

(the first angle is at the anti-clockwise side of the balancing mass vector). The method

of input numbers is the same as above.

Line 4 on the right: The note displays‖ Enter to Calculate‖. Press

【ENTER】then HG904 calculates. The weights of the balancing masses to fix on

the selected angles are shown on the right side of the 2nd and 3rd lines. Assure that the

sums of the two angles depart from the balancing mass should be less than 180

degree.

Stop the machine, fix balancing mass on the rotor according to the result

presented by HG904. The balancing mass is removed or remained should consist with

the settings. Restart the machine. When the rotation speed becomes steady, press

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【↓】to the next item.

Step 7: Verification

Line 9 on the left: The note displays‖ Enter Menu Key ‖. Press〖MENU〗to

right.

Line 2 on the right: All the places showing values are vacant If you hope to see