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DLI Watchman ST-101TM Vibration Screening Tool

The ST-101 in a PdM Program
The DLI Watchman ST-101 is designed as a simple vibration screening and diagnostic tool. Where a complete predictive maintenance program is operating using advanced data collectors, it might seem like the ST-101 would be of no value, but this is far from the case. There are many applications where the ST-101 can enhance and extend a conventional predictive maintenance program, and in some cases even do a better job than conventional data collectors and analyzers.

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The ST-101 as a Screening Tool
Using conventional vibration data collectors, a certain amount of overhead is involved in preparing the machine for measurements, determining the mechanical features of the machine, setting up the measurement locations in the database, creating the setup files in the expert system, and so forth. Once all the setup work is done, the actual data collection usually involves members of the maintenance staff, who often have more work than they can handle. This effort of course is well justified for critical machines, but becomes less justified on non-critical machinery in the plant. The ST-101 can help make more effective use of the maintenance staff members’ time. Screening machinery to determine what to include in the program When a predictive maintenance program is started, the machines to be included in the program must be selected. Machines critical to the operation, machines with a history of maintenance problems, and machines requiring a lot of calendar-based maintenance are usually the first choices to include in a program. Beyond this, there may be many machines that are basically unknowns, but they are too numerous to include every one in the predictive maintenance program. The ST-101 can be used to quickly screen these unknown machines to determine which ones have potential problems which could lead to failure. The only information required to provide a good reading with the ST-101 is the machine speed, and the magnetically mounted accelerometer can take rapid measurements without the need to attach accelerometer mounting disks. In this way, the machines most likely to fail can be identified and included in the full scale predictive maintenance program. This increases the effectiveness of the program by concentrating monitoring on machines most likely to fail, and reduces the chances of failure of the machines that aren’t routinely monitored. Screening machinery periodically that is not included in the program Some plants have so many machines that they cannot all be included in a conventional monitoring program. The ST-101 can extend the effectiveness of the monitoring program by allowing machinery operators or plant mechanics to periodically test the machines in their area, and notify the predictive maintenance program staff of any increases in vibration levels which would

Literature Number PM-AN104

APPLICATION NOTE

The results are increased product quality and reduced costs from the tool crib. These spindles may be directly driven from a motor. Monitoring problem machines The conventional predictive maintenance measurements may show problems with a machine. The ST-101 can be used on a more frequent basis to detect additional deterioration that would call for immediate repairs. or the bearings fail. It is important to monitor these spindles Motor frequently to detect problems before product quality suffers. a spindle can be measured in just a couple minutes. with the results instantly available. Monitoring Machine Tool Spindles Many machine tools have a simple spindle arrangement driving some kind of cutter or grind stone. Axial or may be belt driven. or time to call maintenance personnel to replace the bearings or install a new belt. and reduces the chance of unexpected failures. Applications Where the ST-101 Can Be the First Choice For some applications. so the machine operator will know it’s time to change the tool. Bearing Machine Tool Spindle deterioration. but because of production demands or other requirements. repair action can be taken immediately if warranted. This increases the effectiveness and coverage of the predictive maintenance program. Vertical Vertical . When a machine has been flagged. Spindles of this type basically fail because the machine tool wears and becomes out of balance.indicate the possibility of failure. and can easily be interpreted on the spot. Using the ST-101. Either of these Rolling Element Cutting Tool Bearings failures can result in poor product quality and rejected materials. Some machines have a limited number of faults that can occur and these faults have a clear characteristic pattern on the ST-101. tool imbalance and belt problems all have distinct patterns on the ST-101. that machine can’t be removed from service for repair. readings can be taken on every shift or even more often as conditions warrant. Since measurements with the ST-101 require only a few minutes. the ST-101 will actually out perform conventional predictive maintenance monitoring methods. or the machine monitored using conventional technology. a machine can be monitored on a daily or even hourly basis to squeeze the maximum operating life from a critical machine before shutting it down. Machinery operators and mechanics can be trained to use the ST101 in a short period of time. Since the measurements take just a minute or two.

and to have this information in the hands of the person taking the measurements. where there are so many moving components located close together that the no sense can be made of the vibration data. so this important maintenance item is easily identified. and none is clearly worse than the others based on repair history and performance. It is important to document the test conditions for each machine. The Pocket Guide and the Operator’s Manual are available on the web site. The ST101 requires only a few seconds for a reading to stabilize. the machine with the higher levels is probably the one needing overhaul the most. and extend coverage to machines that would otherwise be overlooked. The patterns on the ST-101 bargraphs provide good information about the cause of high vibration levels. This includes machines like textile weaving machines. . and the pattern on the bargraphs represents the problem causing high vibration levels. A diagram of the ST-101 controls is shown on the next page. Where funds are available to overhaul one out of several machines. the broad band readings of the ST-101 can prove useful. Train the personnel using the ST-101 Operation of the ST-101 is simple. and the results read out after a few seconds of stabilizing. The pattern can be compared to a pocket reference guide to determine what type of fault the machine has. deterioration can be detected. even when interrupt processing is used (see 8603 ap note). A log sheet can be used to identify measurement locations and test conditions. and by trending the levels. the operating speed selected.Monitoring machines with short operating cycles Some machines operate with very short operating cycles that preclude conventional measurements. Measurements will be taken in the same location every time if a magnetic transducer attachment pad is installed at each test location. Some familiarity with machinery is helpful when using the ST-101. A sample log sheet is available on the web site. A variety of application notes are also available on the web site to aid in using the ST-101. Ranking Complex Machines Some machines are so complex that conventional vibration signatures are impossible to interpret. Use magnetic disks to mark the test locations As with any vibration monitoring program. so measurements are possible with almost any operating cycle time. the ST-101 may be the only tool that can be used to make measurements. Deteriorating bearings which may not be otherwise noticeable have a distinct pattern on the ST-101. it is essential that test measurements be taken in the same location each time to allow trending of the test results. and can be learned with a short training session. The magnetically mounted accelerometer is placed on the test location. In some cases. Machinery operators and plant mechanics will have no trouble effectively using the ST-101. A Monitoring Program for Machinery Operators and Mechanics Periodic measurements made by plant mechanics and machinery operators can greatly enhance the scope of a predictive maintenance program. Readings can be made under the same operating conditions and at the same locations. Establish repeatable test conditions Measurements must be made under consistent test conditions to allowing meaningful trending of results. A few guidelines can help ensure that proper measurements are taken by personnel with little background or training. and to record vibration levels for each survey. Red and green LED bargraghs indicate acceptable vibration levels.

Press the button to display desired units in the 4 digit display above. 900 750 Power 1200 1000 1800 1500 3600 3000 Disp Velocity Accel Display US Unit ISO Units Displacement mils rms mm rms Velocity IPS rms mm/s rms Acceleration g rms m/s2 rms The ST-101 is simple to use. US or metric units are selected as shown above. Turn it on. or the vibration units selected by the bottom row of switches. Bainbridge Island. A simple pocket guide quickly allows untrained personnel to determine the machinery condition resulting in unacceptable vibration levels. Red LED bargraphs indicate high vibration levels that should be investigated. 50 Hz operating speeds are in white. and make the measurements.Basic Operation LOW 128 122 116 110 104 98 92 86 MID 148 142 136 130 124 118 112 106 HIGH 60 Hz 50 Hz Englis h Metric VdB re 10-8m / VdB res10-9m / s Select 50 or 60 Hz operation by pressing and holding 900 and 1800 RPM buttons until power frequency is toggled. It will turn itself off after a few minutes. RPM Select the nominal operating speed of the machine here. 60 Hz operating speeds are in yellow. select the machine speed. For example. Satisfactory vibration levels are shown by green LED bargraphs. Select the local power line frequency as discussed above. DLI Engineering 253 Winslow Way W. DLI WATCHMAN ST-101 Vibration Screening Tool Read the Quick-Trend number here. The pattern on the ST101 bargraphs indicates the most likely cause of the unacceptable vibration levels so that repairs can be planned. WA 98110 800-654-2844 206-842-7656 Literature Number PM-AN104 . an out of balance pump will require different tools and personnel to correct than a deteriorated motor bearing. Press the POWER switch to turn the unit on. Select US or metric units by pressing and holding 1200 and 1800 RPM buttons until units are toggled between “US CAL” (English) and “ISO CAL” (metric). Determining that a problem exists is only part of the problem.