Monarch EXAMINER 1000 User manual

MONARCH INSTRUMENT
Instruction Manual
EXAMINER 1000
Vibration Meter
Electronic Stethoscope
15 Columbia Drive
Amherst, NH 03031 USA
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Website: www.monarchinstrument.com

Safeguards and Precautions
1. Read and follow all instructions in this manual carefully, and retain
this manual for future reference.
2. Do not use this instrument in any manner inconsistent with these
operating instructions or under any conditions that exceed the
environmental specifications stated.
3. This instrument is not user serviceable. For technical assistance,
contact the sales organization from which you purchased the
product or Monarch Instrument directly.
In order to comply with EU Directive 2002/96/EC on Waste Electrical and
Electronic Equipment (WEEE): This product may contain material which could
be hazardous to human health and the environment. DO NOT DISPOSE of this
product as unsorted municipal waste. This product needs to be RECYCLED
in accordance with local regulations, contact your local authorities for more
information. This product may be returnable to your distributor for recycling -
contact the distributor for details.
Monarch Instrument’s Limited Warranty applies. See www.monarchinstrument.com
for details.
Warranty Registration and Extended Warranty coverage available online at
www.monarchinstrument.com.
EXAMINER 1000 SPECIFICATIONS
Vibration Sensor: Piezoelectric accelerometer 100 mV/g with magnetic base, probe
and 5 foot cable to BNC
Display: LCD 3.5 digit , measurement, hold, low battery indicator
Measurement Acceleration 0.01-19.99 g (RMS)
Range: Velocity 0.01-19.99 in/sec., 0.1-199.9 mm/sec (RMS)
Envelope 0.01-19.99 ge (peak)
Frequency Range: Overall 10 Hz - 10 kHz
Envelope 0.5 kHz-10 kHz
Output: Sensor Excitation: 18 Vdc @ 2 mA (BNC)
Audio Out: 3.5 mm mini plug; 250 mW into 8 ohms, 150 mW into
32 ohms; Adjustable volume control with off position
Power: (2) “AA” cells
Operating Time: 20 hours continuous without headphones
Weight: Instrument: 7 oz. (0.19 kg); Complete Kit: 2.85 lb (1.30 kg)
Dimensions: 6.3 x 3.3 x 1.25” (152 x 83 x 32 mm)
Operating conditions: -14° to 122°F (-10° to 50°C)

OPERATING THE EXAMINER 1000
Overview ........................................................................... 1
Controls and Functions........................... ........................... 1
Rear Panel, Batteries and Connections ............................. 2
Parts of the System ........................................................... 3
Overview of Data Collection Procedure.............................. 3
APPLYING THE EXAMINER 1000
What is Predictive Maintenance? ....................................... 4
Benefits of Predictive Maintenance .................................... 4
Why Measure Vibration? .................................................... 5
Selecting Machinery & Measurements................................ 6
Selecting Measurement Types ........................................... 7
Getting Started in your Plant............................................... 8
Establishing a Data Collection Route.................................. 9
What are you Measuring? .................................................. 10
Measurement Techniques .................................................. 11
Evaluating overall Vibration Measurements ........................ 12
Evaluating Acceleration Envelope Measurements............... 13
GLOSSARY ........................................................................ 14
Vibration Severity Chart per ISO 10816-1 ........................... 16
TABLE OF CONTENTS
TABLE OF CONTENTS

OPERATING THE EXAMINER 1000
Overview
The EXAMINER 1000 is designed to be used with vibration limits established in
ISO Standard 10816 to help you detect signs of malfunction or changes in rotating
machinery during operation. This is accomplished with overall vibration (ISO
VIB) and envelope measurements. Problems with bearings occur when there is a
microscopic crack or flaw or when there is a breakdown in lubrication which leads
to metal-to-metal interaction. The EXAMINER 1000 is designed to detect flaws
or a lack of lubrication in bearings and gears at an early stage by measuring the
high-frequency impacts through acceleration envelope methods.
Vibration measurements are made by pressing the accelerometer sensor against
designated Measurement Points on your equipment with either the stringer probe
or with the magnetic base.
Controls and Functions
ON/SELECT Button - Press this button to turn power on. Power automatically
turns off after ten minutes of non-use.After turning the EXAMINER “on”,press the
ON/SELECT button again to select the measurement type. Pressing and holding the
ON/SELECT button while collecting data will HOLD the display value, indicated
by the word “HOLD” in the display. To release from HOLD mode, press the ON/
SELECT button again.
DISPLAY- The digital display shows the numerical value of the measurement.
An arrow indicates the measurement type selected. The units of vibration are
automatically displayed as the type of measurement is selected. The user may work
in either metric or imperial units in the V-velocity mode.
1
Type of
Measurement Value of Measurement
Units of
Measure
0.09 g
GE
in/s
mm/s
V
A
E
LoBat
HOLD
Low Battery
Indicator
Type of Measurement
Indicator
Hold Reading
Indicator

2
BATTERY
COMPARTMENT
Contains two “AA”
alkaline batteries.
REAR PANEL CONNECTIONS
AUDIO OUT SENSOR IN
CONNECTIONS
QUICK REFERENCE
INSTRUCTION
PANEL
PRODUCT SERIAL
NUMBER
AUDIO OUT
1/8” (3.5 mm)
stereo mini plug
SENSOR INPUT
BNC Connector
output 18 vdc @ 2 mA
VOLUME
CONTROL
TOP VIEW
E X A M I N E R
1 0 0 0
VIBRATION METER
ELECTRONIC STETHOSCOPE
REFER TO OPERATORS MANUAL
FOR INSTRUCTIONS
CONNECTIONS
SENSOR IN AUDIO OUT
Measurement Types Units
V velocity mm/s in/s
A acceleration g
E envelope ge
Monarch Instrument
15 Columbia Drive
Amherst, NH 03031 USA

Overview of Data Collection Procedure
1. Press the ON/SELECT button.
2. Press the ON/SELECT button again to select the desired measurement type.
Place the accelerometer sensor on the machinery Measurement Point (use proper
probe technique as discussed on the following pages).
3. Wait for the reading to stabilize, then press and hold the ON/SELECT button
to “HOLD” the measurement. Indicated by HOLD in the display.
4. Adjust headphones volume level and listen for any distinct patterns or noises.
5. Record the measurement value in your Machinery Data Worksheet.
6. To release the HOLD function, press ON/SELECT again.
7. Repeat the above steps for each Measurement Point.
Parts of the System
EXAMINER 1000 METER
ACCELEROMETER
WITH CABLE
HEAD PHONES
MAGNETIC BASE
STINGER PROBE
HOLSTER
ON-TIME SOFTWARE
(optional)
3

What Is Predictive Maintenance?
Predictive Maintenance can be defined as collecting information from machines
as they operate to aid in making decisions about their health, repair and possible
improvements in order to reach maximum runability, before any unplanned break-
down. Machinery maintenance has evolved because of the demands to become more
profitable through reduced maintenance costs. Below is the progression of these
maintenance philosophies:
• Break Down Maintenance
• Preventive Maintenance
• Predictive Maintenance
Break Down Maintenance occurs when repair action is not taken on a problem
until the problem results in the machines failure. Run to failure problems often cause
costly secondary damage along with expenses resulting from unplanned downtime
and unplanned maintenance.
Preventive Maintenance occurs when a machine, or parts of a machine, are
overhauled on a regular basis regardless of the condition of the parts. While better
than run to failure, preventive maintenance results in excessive downtime due to
unnecessary overhauls and the excessive costs of replacing good parts along with
worn parts.
Predictive Maintenance is the process of determining the condition of machinery as
it operates, to predict and schedule the most efficient repair of problem components
prior to failure. Predictive Maintenance not only helps plant personnel eliminate
unplanned downtime and the possibility of catastrophic failure, but allows them
effectively order parts, schedule manpower, and plan multiple repairs during
scheduled downtime.
Benefits of Predictive Maintenance
Documented experience proves that plants which establish a predictive maintenance
program are able to:
• Improve Machinery Reliability-reduced “unplanned failures”
• Reduce Maintenance Costs-knowing the exact problem to fix
• Increase Production-optimize machinery capabilities
• Lower Energy Consumption- less vibration usually means less friction
• Extend Bearing Service Life- reduce vibration and lubrication failures
• Improve Product Quality- where less vibration improves finish
The benefits are numerous and will vary depending upon the implementation of
your Predictive Maintenance Program.4

5
Why Measure Vibration?
Vibration is considered the best operating parameter to judge dynamic conditions
such as balance (overall vibration), bearing defects (enveloping) and stress applied
to components. Many machinery problems show themselves as excessive vibration.
Rotor imbalance, misalignment, mechanical looseness, structural resonance, soft
foundation, and gearmesh defects are some of the defects that can be measured by
vibration. Measuring the “overall” vibration of a machine, a rotor in relation to a
machine or the structure of a machine, and comparing the measurement to its normal
value (norm) indicates the current health of the machine.
The EXAMINER 1000 measures the vibration of a machine while it is operating.
Trending these measurements shows how a machine’s condition changes over a
period of time. Analyzing these, along with other measurements, provide insight into
the condition of the machine and which components may be wearing or failing. How
to best monitor a machine’s condition requires one to know which measurements
to take and where and how to take them. Sensors are placed at strategic Points on
the machinery to monitor the machine’s condition.
The EXAMINER 1000 processes the accelerometer’s mechanical vibration
energy into an electrical signal and displays the measurement value in numerical
form for evaluation. Commonly measured physical characteristics in Predictive
Maintenance are:
• Vibration (as explained above)
• Temperature
• Oil Analysis
Temperature
As a bearing fails, friction causes its temperature (or its lubricant’s temperature)
to rise. While trending a bearing if the temperature rises followed by a vibration
increase, then it is safe to conclude their was a loss of lubrication which induced the
mechanical failure. If vibration increased first, followed by increased temperature
readings then a mechanical defect caused the lubrication failure.
Lube Oil Analysis (Ferrography)
Monitoring oil condition warns of an increase in foreign substances, such as water,
which can degrade the lubricating properties of the oil and cause bearing failures.
It also detects the presence of metallic particles carried into the oil stream. These
metallic particles are analyzed to determine which part of the machine is wearing
and how fast. Lubrication analysis is the earliest warning of a developing problem.
Lube oil testing results can be trended with On-Time software.

6
Selecting Machinery and Measurements
Maintenance personnel have always made visual and hands-on inspections of their
machinery on a periodic basis. Systematic data collection and trending allows
for recall and comparison of events over time but is not a replacement for good
maintenance practices. Collecting machinery data is an aid to the maintenance
professional, which is used in addition to good maintenance practices.
Selecting and Classifying Machinery
Setting up an effective Predictive Maintenance Program requires a careful study
of the needs of the plant. It is necessary to know each machine and its response to
change. The following is an example of machinery classification:
Critical Machines expensive premium equipment, generally >500 HP. Usually
less than 5% of all plant equipment. Maintenance dollars per horsepower per year
average $11.00. This category of equipment is very well maintained and monitored.
Continuous monitoring systems are better suited for this type of equipment.
Essential Machines medium size equipment, 100-500 HP. This group may be 30-
40% of all the equipment in the plant. Maintenance costs can average $22.00 per
horsepower per year. Less attention is paid to these machines even though their
repair costs can be as high as critical machines. Select some of these machines for
your Predictive Maintenance Program.
Redundant Machines small redundant equipment usually < 100 HP. This group
can be as much as 50% of all machines in a plant and yet they are usually neglected.
By far the most expensive to maintain at $49.00/HP/year, this group will benefit
the most from Predictive Maintenance practices. At many facilities, this group
consumes 80% of the annual maintenance budget. If you want to have an immediate
impact begin with these machines. Also include machines with known problems
or a history of problems.Personnel Safety is always the first priority in selecting
machinery to monitor.
CRITICAL
ESSENTIAL
REDUNDANT

Selecting Measurements
Establish measurement types that most accurately reflect the condition of the
equipment. Different causes or “mechanisms” are acting on the machine; various
types of measurements have been developed to measure each type of mechanism.
Those mechanisms are:
Stress
Aforce on the machine or components which deflects the part. Best measured
in Displacement. The Examiner 1000 does not measure Displacement as
it is a very low vibration frequency, below 10 Hz (600 RPM).
Fatigue Repeated cycles of stress on a component. If you bend a part back and
forth enough times it will fatigue. As a general rule, fatigue failures result
from vibration frequencies 10 -2000 Hz and Velocity measurements are
used. Velocity will be the primary measurement taken.
Force Mass x acceleration. Measured in Acceleration. Acceleration is the rate
of change of velocity. Acceleration is used for high frequencies above
2000 Hz (120,000 RPM). Bearing defects and gearmesh frequencies are
usually found in this range.
Impact forces The result of fatigue. Impact forces are cyclical events which
can be detected with Acceleration Enveloping. These are high
frequency-low amplitude events and a filter in the EXAMINER
1000 is set at 10-30 kHz to measure them.
Types of Measurements in the EXAMINER 1000
Velocity- Good for frequency ranges 10-2000 Hz (600-120,000 RPM).
Acceleration-used for higher frequencies or speeds above 2000 Hz (120,000 CPM).
Acceleration Enveloping-uses a high pass filter to measure high-frequency,
repetitive bearing and gearmesh vibration signals. Used for early detection of
developing bearing or lubrication problems. Use this type in combination with the
other types to detect changes in machinery.
Select Measurement Intervals
Based on the classification of the machine, its repair history and the amount of data
required for a detailed trend analysis. At the beginning of a Predictive Maintenance
Program, collect data frequently to build a rapid history of each machine. Adjust
your program as you go. If measurement results are indicating signs of change,
measurements should be performed more frequently.
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