Manual SPM & Ir30

Diagnostics Training Manual
SPM, Vibration Measurement and

Data Logging using IR30
SPM and IR30
IR30 and SPM Introduction.............................................. 1-5
SPM Data Acquisition General Rules .............................. 6
dBm/dBc Interpretation General Rules ............................ 7-8
Vibration Severity Monitoring (VSM)................................ 9
IR30 Trending .................................................................. 10-11
Condmaster Pro Software................................................ 12
IR30 Success Stories....................................................... 13
Short Test ........................................................................ 14
Procedures
Keypad Functions ............................................................ 1
Taking SPM Measurements............................................. 2
SPM Instrument Set Up ................................................... 3-5
SPM Data Acquisition ...................................................... 6
Vibration Severity—Instrument Set Up ............................ 7-9
Condmaster Pro Rounds—Data Acquisition.................... 10-11
IR30—Other Menus Instrument Set Up........................... 12-14
Service Instruments & Accessories (CCN Part #) ........... 15
Rotary Compressors
SPM Measuring Point ...................................................... 1-10
dBi and dBm Values ........................................................ 11-20
SPM Logs ........................................................................ 21-23
Sierra Compressors
SPM Measuring Point ...................................................... 1-8
dBi Values........................................................................ 9-11
SPM Logs ........................................................................ 12-14
Nirvana Compressors
Contact Cooled SPM Measuring Points & dBi Values..... 1
Oil Free SPM Measuring Points & dBi Values................. 2
SPM Logs ........................................................................ 3
Reference Materials
Websites .......................................................................... 1
Slide Presentation
Bearing Damage, Causes and Failure Prevention
Condmaster Pro
Diagnostics Training Manual
Ingersoll Rand Global Service Education Team
Issue: 06/Davidson, March, 2006. ©Ingersoll Rand Proprietary Information
IR30 and Condmaster Pro
IR30 - Introduction
The IR30 Sentinel

In this section, you will learn CCN 54636535
• The type of monitoring IR30 is capable of. This unit works in the same way as the
• Two models of IR30 and their differences. data logger instrument, with the
• SPM and how is it applied in industry exception that all data has to be
manually loaded prior to taking each
• Decibel Initial (dBi). reading and it has no PC loading/
• How you can take vibration readings using downloading capabilities. This unit has
the IR30. only SPM monitoring capabilities. The
• Which indicator is used for Bearing condition. IR30 Sentinel can be upgraded to IR
• Which indicator is used for lubrication 30 Logger at an extra cost
condition.
The IR30 Compact
• Condmaster Pro software. The IR30 Compact uses the same
technology as logger and Sentinel to
take SPM readings. Can store ten
What is the IR30? readings. Has infrared temperature
IR30 is an Ingersoll Rand hand held instrument reading. Electronic stethoscope
that can be used to: capability with standard set of
• analyse bearing condition headphones
• measure vibration CCNS:
• log other parameters from the running IR30 Compact (A): 38444105 - without quick
compressor. connect cable
IR30 Compact (B): 38444113 - with quick
The IR30 is primarily connect cable
used for Ingersoll Rand
rotary compressors; Kit includes: IR30 Compact instrument,
however, it is capable of accessory bag, protective cover, AA batteries,
analyzing any roller quick start guide, evaluation guide, technical
element, or anti-friction documentation CD, and Ingersoll Rand packaging
bearings and vibration box.
severity on any other Vibration Accessory Kit
rotating machinery. CCN 38034872
The Vibration Accessory Kit consists of Vibration
There are 2 current Cable (VIC 19), Vibration Transducer (TRV 13),
models of the IR30 available. Vibration Transducer Probe (TRX 28) and can be
used with the IR 30 Sentinel to take vibration
The IR30 Data Logger Kit readings (mm/sec). The vibration severity
CCN 39263009 measurement provides valuable information
includes: about the general condition of the unit and can be
• IR30 Instrument used on any rotating machinery
• CondMaster Pro Software
• Instruction manual IR30 Accessories in AP
20 x studs CPN 89218721
• PC cables and hardware key
50 x studs CPN 89218739
• SPM & Vibration probes
Stud Mounting Kits
• Batteries Drill and 90o Countersink CPN 39262992
• Carrying case
IR30 Accessories in DSA
50 Adapters and Caps CCN
42464602
In addition to SPM and vibration Chamfer Drill CCN 39262993
readings, rounds can be uploaded from a PC and
technicians can log other parameters such as
temperatures and pressures. This data can be
downloaded later to a PC for further evaluation
and trend monitoring.
Diagnostics Training Manual Page 1 SPM and IR30

IR30 - Introduction
Benefits to the Customer • Verifies the qualify of service and repair work,
Customers benefit because they can: such as bearing replacements
• Minimize loss of production • Improves planning for the replacement of
• Avoid costs resulting from secondary damage bearings and air ends
• Utilize the entire lifetime of the compressor air The IR30 can also:
ends • Expand the number and size of service
• Schedule major overhauls contracts
• Avoid the costs of renting replacement • Allow Ingersoll Rand to do bearing monitoring
compressors and vibration analysis on other compressors,
Benefits to Ingersoll Rand pumps, fans, etc.
• One of the key Airend business drivers • Build Ingersoll Rand’s database and increases
• An objective method of verifying the operating our expertise in vibration
condition of rotary machinery • Enhance the professional image of Ingersoll
IR30 - Description and Function Buttons

Menu Screen
Communication for COM

MUN
IR30 Logger only ICAT
Clock
Date 00.07.29
Displays 4 lines with up to Time 14.31
Condition Scale
Contrast
Light auto
Sensitivity 5
Instrument
Light Sensor
Measuring Key
Set Key Enter Key

Time mm
o
Display C
English
Up Arrow Key Right Arrow Key
Left Arrow Key Down Arrow Key
Input Connector SPM Input Connector Vibration
Input Connector Software

SPM - Introduction
What is SPM (Shock Pulse Monitoring)?

The Shock Pulse Method was developed about 20 A shock pulse pattern consists of a rapid sequence
years ago as a method for measuring the true of strong and weak pulses. It is defined by two
operating conditions of rolling element bearings. measured values, Decibel Carpet (dBc) for the
large number of relatively weak shock pulses and
As a result of extensive research and development, Decibel Max (dBm) for the few strong pulses in the
it is now virtually the only method readily available pattern.
for that purpose. Not only can damage be detected
and quantified at an early stage, but the vital oil film Decibel Carpet (dBc)
thickness can be assessed. Imagine that you are waiting at a railway crossing
for a freight train to pass. You hear the normal
The basis of the technique is that it measures the ‘clickety-clack’ sound of the wheels crossing the
mechanical impacts generated by any rolling rail joints, but the sound is not always the same; it
element bearing, which is a function of the ball or is louder as the heavier cars go past and less
roller velocity surface roughness. intense for the empty cars. This sound is usual for
a freight train and, in SPM terms, it is called the
These Decibel Carpet.
mechanical
impacts What IR30 does Decibel Max (dBm)
generate However, if one of the wheels has a ‘flat spot’, it
pressure Transducer will make a repetitive banging sound as the flat
waves spot hits the rail. This banging sound can be heard
through the well above the Decibel Carpet and, in SPM terms,
bearing it is called the Decibel Max.
housing, Shock dBm
which can be waves dBc
Decibel Initial (dBi)
detected by This factor can be likened to calibrating your ear as
piezo- the train passes. This ‘calibration’ regulates the
electric transducers (approximately 32kHz intensity with which the ear perceives Decibel Max
frequency range). This frequency is convenient as it and Decibel Carpet.
amplifies the shock signal and filters out machine
vibration. Applying the technology
Applying SPM technology to steel roller bearings
It is important to appreciate that the Shock Pulse requires only reasonable access to the outside
Method detects pressure waves, not physical diameter of the monitored bearing, through an
movement of material as in the case of vibration uninterrupted metal path. Permanently attached
measurement. Consequently the rules of SPM are metal studs are best for this purpose.
that the measuring point must be selected to provide
the shortest possible straight line to the bearing; no A mechanical “clip-on” accelerometer is used to
additional interfaces other than the bearing housing anchor to and read the acoustical signature from
and the outer race of the bearing must be present; the bearing, through the housing to the studs. A
and it must be in the loaded zone of the bearing. hand held, contact probe can also be used with
good results.
Over the years, the Shock Pulse Method has been
developed to an exceptionally high level of accuracy The IR30 reads the shock pulse dBm/dBc values
and reliability, with sophisticated equipment being and displays them as two numerical values. Any type
developed which is user-friendly, yet produces of steel roller bearing can be monitored; however,
results that enable the engineer to confidently plan the Shock Pulse Method has no application to sleeve
his production and maintenance schedules. With the bearings.
aid of CondMaster Pro software, it is now possible to
download directly to a PC and all the analysis and
results, with the action required, can be displayed or
printed.
There are 3 terms used in SPM. These are

• Decibel Carpet (dBc)
• Decibel Max (maximum) (dBm), and
• Decibel Initial (dBi)

SPM - Introduction
This is a short and simplified summary of some Carpet Value dBc
important facts needed to understand the Shock Shock pulses are generated in the rolling interface
Pulse Method (SPM) for bearing condition between the loaded rolling element and the raceway
monitoring: of the bearing. Bearing surfaces are rough. This
causes pressure variations in the oil film which
• Shock pulses are caused by impacts. An separates the moving surfaces, as well as collisions
impact is a single event caused by one body between peaks in the surfaces.
hitting another. In a
bearing, the impacts Results of an impact:
Both result in pressure
typically occur at random
waves - shock pulses -
(and extremely short)
which spread through
intervals.
the material of the
• The impact sends a shock
bearing, the bearing
wave through the material
housing, and adjacent
of both bodies. Vibration
machine parts.
follows impact as a
secondary event. In the 1. A shock wave spreads
shock pulse transducer, through the material
vibration is filtered out.
• The shock pulse
transducer reacts to the
amplitude of the wave
front at its own resonance
frequency. This magnifies
the low energy signal. The IR 30 samples the pattern and displays two
Only the wave front is 2. The body vibrates. measured values to quantify it, dBm and dBc
measured, causing one • Carpet value (dBc) is the measured value for
shock pulse from the transducer. the large number of weaker pulses in the
• The amplitude of the wave front is a function of pattern. It is directly related to the thickness of
impact velocity. This means, the higher the the lubricant film in the rolling interface.
rpm, the higher the shock level. Because the • The carpet value is low when the surfaces of
rotational speed of the bearing depends on its rolling elements and raceway are completely, or
size and the rpm, both are needed as input almost completely, separated by a lubricant film.
data. • The carpet value rises when lubricant film
• Shock pulses are transient signals. They lose thickness decreases and there is more metal to
their energy on the way through the material of metal contact between the bearings.
the machine. Also, they are reflected from
surfaces and severely dampened by interfaces
in the material. That is why we need defined Low Carpet Value High Carpet Value
measuring points.
• All impacts cause Shock pulse measurement
shock pulses. You
must make sure
that you are A A = f (v)
measuring a signal
from the bearing. 1. Shock waves converted to
electrical pulses
2. Pulse magnitude is measured,

vibration is filtered out.

SPM - Introduction
Maximum value dBm • When you set the dBi to “- -” (below -9), the
Maximum value (dBm) is the measured value of the IR30 will take an unnormalized reading, in
strongest pulses detected during the measuring dBsv (absolute shock values). The condition
interval. zones do not apply. This method is used for
comparative reading on different bearings and/
While the bearing surfaces are undamaged, the or other shock pulse sources.
difference between dBm and dBc is small.
A high dBm and a

large difference
between dBm and
dBc is caused by
surface damage or
foreign particles
between rolling
element and
raceway.
The IR30 indicates “bad

operating
condition” (arrow
pointing at the red zone Different shock pulse patterns
of the condition scale). The signal from a bearing should be highest on the
bearing housing. If you get a higher signal outside of
the bearing housing (across an interface in the
material), you are most likely measuring shock
Initial value dBi pulses from another bearing or some other source.
Normalized and Unnormalized readings
The absolute shock pulse level of a bearing, a) For good bearings, the dBm is within the green
measured in dBsv (decibel shock value), is both a zone. dBm and dBc are not close together.
function of rolling velocity and of bearing condition. b) The shock pulse pattern from a damaged
To neutralise the effect of rolling velocity on the bearing contains strong pulses in the red zone, a
measured value, the IR30 has to be programmed random sequence, and a large difference
with shaft diameter (mm or in) and rotational speed between dBm and dBc. When you grease
(rpm). lubricate the bearing, the values should drop but
rise again.
The IR30 will then calculate the initial value dBi, the
c) A dry running bearing has a high carpet value
starting point of the condition scale for a particular
very close to the dBm. When you grease
bearing. You can also input the dBi directly. The
lubricate the bearing, the values should drop and
condition scale is graded in normalised shock
stay low. A similar pattern is caused by pump
values, dBn.
cavitation, in which case readings on the pump
housing are stronger than those taken on the
The IR30 takes a sample count of the shock pulses
bearing housing, and are not influenced by
occurring over a period of time and displays:
lubricating the bearing.
• the maximum value dBm for the small number d) A regular pattern, containing bursts of strong
of strong shock pulses. pulses in a rhythmic sequence, is likely caused
by scraping parts.
• The carpet value dBc for the large number of
weaker shock pulses. e) Individual pulses in a regular sequence are
• An arrow against a field on the condition scale: caused by clicking valves, knocking parts,
green, yellow and red. regular load shocks.
• The maximum value dBm defines the bearing’s f) A sudden drop in the shock pulse level is
position on the condition scale. The difference suspicious. Check your measuring equipment.
between dBm and dBc is used for a finer If the reading is correct, you may have a slipping
analysis of the causes for reduced or bad bearing ring.
condition.
SPM– Data Acquisition Rules
Shock Pulse Bearing Monitoring using a hand held probe
Data acquisition is a simple process
You will find dBi (Decibel Initial) values for various
Ingersoll Rand compressor models and the locations
of bearing probe points in the Specifications & Parts
Lists section of the Diagnostics Reference Manual,
so you can enter dBi into the IR30 without having to
determine the dBi value for the particular bearing(s).
dBi is calculated using the inside diameter of the

bearing (d) in mm and rotative speed (n) in rpm.
Where two different diameter bearings are used on a Hand held
shaft with near equal instrument should be
loads on both ends, an positioned radially to
average of both the bearing housing
diameters is used. The with +/- 5o angle
IR30 calculates Decibel
Initial (dBi once the
diameter of the bearing
and rotative speed are
keyed into the
instrument. Arrow indicates good SPM measuring points
We try to use bearing

housing flange edge
Bearing Data surfaces, since these
TLT on areas have ample depth,
3000 rpm
are free of air or oil
90 dmm dBI 26
passages, and provide a
direct (if somewhat curved)
solid metal path to the
outer race of the subject bearing. More accurate and consistent results are achieved by
installing permanent studs on the unit.
Refer to the following pictures for more information.
Studs are fitted by drilling
and tapping sites with M8
or 5/16” - 18P threads,
1/2” deep, with a 90
No direct Degree entering chamfer.
path It is important to check if
studs are installed
correctly and tightly to the
casing, as the IR30 could Good Bad
provide incorrect readings.
IR30 - SPM measurement using stud clip on probe.

Correct
Position
Air
Pocket

dBm/dBc Interpretation for Rotary
General Rules SPM in summary
dBm/dBc values are indicators of bearing condition

and lubrication deterioration.
Rule 1
dBm values, on new flooded/oil free compressors,
will run in the 20 to 40 range. dBc is about half the
dBm.
Rule 2
dBm values which rise in the 45 range and above,
particularly when unit is loaded, are to be noted.
dBc will also rise, coming close to dBm.
Rule 3
Two consecutive dBm readings at or above 55 in • Shock pulses are pressure waves, generated
700 hours, signal a need to consider bearing in the contact zone between the loaded rolling
overhaul. elements and the raceway.
• Shock pulses are measured using specially
Rule 4 tuned transducer which amplifies the shock
Sudden changes are to be especially noted and signal and filters out machine vibration.
monitoring frequency "doubled up". A cracked or • A shock pulse pattern consists of a rapid
loosened inner race will result in such drastic sequence of strong and weak pulses.
changes, and must receive immediate attention.
• dBc (Decibel Carpet) is the large number of
Rule 5 relatively weak shock pulses.
Oil Free Compressors will display consistent dBm • dBm (Decibel Max) are the few strong pulses
of 10, 15 points higher than dBc in normal running in the pattern.
condition, loaded or unloaded.
Rule 6 Ingersoll Rand units have a number of bearings

Flooded (Contact Cooled) single stage units seem per casing, the shock pulse emissions radiate
to display closer dBm/dBc points than oil free, and and overlap as they are read from the casing
when running unloaded dBm/dBc will be equal to flanges; therefore, we use the following guide.
or higher than loaded. When gas load is relieved,
rotors seem to become more unstable and "rattle Bad Condition - dBm is above 55
around" in the bearing clearances.
Caution zone - dBm is between 45 - 55
Rule 7 Good condition - dBm is between 20 - 45
Flooded two stage units display dBm/dBc loaded
points consistent with single stage and oil free • If dBm is above 55 another reading needs to be
machines. However, unloaded dBm/dBc seem to taken in 700 hours.
run at, or considerably higher than, loaded figures. • If the dBm stays above 55, the unit qualifies for
Therefore, on flooded units, loaded dBm/dBc a bearing overhaul.
figures are to be considered dominant decision
points. Drive motor bearings behave in a similar Do not give the verdict “bearing damage” before
manner. making a further investigation.
Rule 8 As a first measure,
Two stage units have four bearing points per
• see if the peak indicator is
casing. The shock pulse emission from the four
blinking.
points radiates and overlaps as it is read from the
• use the probe transducer to
casing flanges. However, trending, and observing
measure on and outside of the bearing housing
loaded dBm/dBc using these guidelines should
to identify the shock pulse source.
yield accurate indications of repair requirements.
• Make sure that TLT is above 15.

dBm/dBc Interpretation for Rotary
For specific maximum dBm values of newly started The effect of different lubricants, their quality,
units for different size Airends, refer to dBMax values viscosity, supply to the rolling interface, etc., on an
for Rotary compressors. individual bearing can be immediately studied by
comparing the resulting dBc numbers.
If you lack specifics for any particular model,
use: The high dBc number reveals poor lubrication films
• 25 dBi for contact cooled rotary units,and which are due to mechanical faults, such as
• 35 dBi for oil free units. misaligned shafts, unround bearing housings or
installation faults.
This applies to competitive machines as well as
Ingersoll Rand units.
SPM Reading Indications
Early damage detection
The main purpose of bearing condition monitoring is
High dBm Bearing Damage
the early detection of bearing damage. This method
is less expensive and more reliable than periodic
replacements, because a bearing that has not failed
before its scheduled replacement is likely to be
serviceable for a long time. High dBc Poor Oil Film Film
Thus, bad bearing condition can be shown by a

single reading. Systematic measurements over a
period of time will then provide a reliable trend and
basis for selecting suitable replacement dates.
Low dBc Adequate Oil Film
Readings of the following patterns can provide
indications of bearing damage, lubrication and
bearing installation problems.
The fact that the service life of bearings is mainly

dependent on lubrication is well known.
Bearing Damage Lubrication Bearing Installation
Very large sums can be saved if bearing life can be

extended by improving lubrication. There is a
relationship between the measured shock pulse
pattern and the lubrication condition of the bearing.
The IR30 displays a value called dBc (decibel

carpet) which decreases in proportion with the
thickness of the lubricant film between the rolling
elements and the raceway in the loaded part of the
bearing.

Vibration Severity Monitoring (VSM)
Vibration Severity Measurement

General machine vibration
increases when something is
loose, broken or out of balance.
Vibration severity readings
supply valuable information
about the general condition of
the unit.
VIB
ISO 10816
Class 3 2/76
mm/s
VIB V
• Vibration severity is defined as RMS (Root

Mean Square) value of vibration velocity (mm/
s, inch/s) in the frequency range of 3 to
1000Hz.
• The evaluation consists of a comparison of the
measured value with vibration limits to
specification ISO 10816, which classifies VIB A
vibration severity into six grades, Class 1 to 6. H
• Ingersoll Rand has chosen Class 3 for its full VIB
range of machines. Class 3 applies to large
machines on rigid foundations.
• Indications: up to 4.5mm/s acceptable; 4.5 -
11mm/s caution; above 11mm/s - warning.
• Vibration velocity is a measure for general
machine condition.
• By measuring in three directions you can get
indication of the causes for increased vibration:
VIB H: most
representative for
balance condition
VIB V:
most representative for
structural weakness
VIB A:
most representative for
faulty alignment and
bend shafts.

IR30 - Trending
Decision making is based on the data acquired. This

consists of operating the machine in loaded and
unloaded condition, while measuring dBM/dBC
values with the IR30.
Each measuring point can be pre-determined and

the route stored in the IR30 Logger for later
acquisition, downloading to a PC and printing.
Electronic recording requires use of “Condmaster
Pro” software which comes with the IR30 Logger Kit.
Data is taken:
1 From the Condmaster 2 to the IR30 3 and data is acquired from

Pro software Logger the machine.
then downloaded from

the IR30 Logger
for 1). Trend Analysis 5
2). Database to the Condmaster Pro 4
3). Report writing software
Manual recording of data can also be done on

paper logs, designed by the user to suit the
purpose.
Normally, data is taken monthly for the first three

months of operation of a new machine, then
quarterly.

IR30 - Trending
Upload/Download
Acquisition process process
Decision Making Process

Condmaster Pro Software
Data Management with Condmaster Pro

Software
Condmaster Pro software provides an effective
means of reducing the administrative work
connected with large scale condition monitoring. It
supplies data entry forms, graphic displays of
measurements and alarm lists for bearings in bad
condition.
Work schedules for any desired time span can be

printed, including measuring point numbers,
instrument settings, last readings and space to
enter current results.
The user can store bearing data, measuring

schedules and readings.
Database
Decibel Trending
Alarm Indication

IR30 - Success Stories
IR30 success stories from China Guangzhou Air Center recommended an airend
exchange program. The customer accepted the
recommendation and the airend was changed
Case Study 1 during a weekend.
Shanghai Air Center, ASG China During overhaul it was found that bearings were
worn and the rotor scratched. The air end would
In September 2003, an Ingersoll Rand Service have been damaged in a short period of time.
Engineer visited a Steel Mill in Shanghai, which
had 5 ML250 units .
Using the IR 30, he established that the vibration

on one air end was abnormally high. After
consultation with the customer the airend was
overhauled and new bearings were installed.
This air end would have

been damaged within 2
months, and would have
cost the customer over
US$15,000 in parts and over
US$50,000 per day of lost
production.
The IR30 helped the Air Center to bring in

revenue of US$4,000, built customer confidence
and satisfaction and secured further business.
Case Study 2
Guangzhou Air Center, ASG China
Over a 6 month period, Guangzhou Air Center,

used IR 30 for 35 customers and on over 130
units of rotary compressors.
IR 30 is playing a key role in closing deals for

overhaul, air end rebearing & rebuilding.
For example, one customer

had 4 units of EP100, all of
them had run over 35,000
hours (since November,
1990) and they had no
intention of overhauling the
air ends.
SPM checks established that the dBM was at it’s

limit. If one unit stopped the customer would have
lost over US$25,000 per day.

Short Test
Short Test
Answer each question as fully as you can, or tick the best option.
When you finish, check your answers by reading through the section again.
1 The basic principle of Shock Pulse Method is:
2 What does the abbreviated term dBi stand for?
3 What does the abbreviated term dBm stand for?
4 What does the abbreviated term dBc stand for?
5 If the dBi of a particular shaft is not known, describe briefly what two facts are
needed and then how dBi can be determined.
6 What two types of machinery condition monitoring can be performed by IR30?

a)
b)
7 Decribe briefly the conditions required for a clean, solid shock pulse signal to
be transmitted from the outside diameter of the bearing to the stud location.
8 Why do sudden changes in dBC/dBM values need to be especially noted?
9 What kinds of machinery faults can be identified by using the vibration severity
capability function of the IR 30 Logger and sentinel.
10 Why are dBm/dBc values are higher during compressor unloaded operation?

IR30 Procedures
Keypad Functions
The functions of the keypad vary, depending on the active menu, as the instruments now contain too many
functions to limit each key to a single action. Holding down any key for one second switches on the instrument.
Condition Scale Display Screen

The green-yellow-red marking Shows the current active menu
beside the display is the or the last function used when
condition scale. the instrument is first turned
An arrow points to one of the on. Information is on 4 lines of
colours during normalized SPM 16 characters each.
readings and Vibration
measurements.
Light Sensor
Instrument Type Logo Detects light levels and
1 Basic IR30,
automatically switches on
2 Logger IR30 &
the LED backlight of the
IR30 Sentinel
display if the light option is
set to automatic.
Peak Indicator
Blinks each time it registers
a pulse stronger than the
displayed dBm value Measuring Key
during SPM readings. Used exclusively to start
taking measurements.
Set
Moves the cursor to a new
row on the screen, or ENT (Select) Key
Transducer sensitivity if Confirms selections
vibration screen is selected. Saves values and settings.
Up Arrow
Increases number values.
Down Arrow
Decreases number values
Toggles the TLT on & off.
and toggles the TLT on & off.
Selects measuring points
(if loaded in logger mode).
Left Arrow
Right Arrow
Moves the cursor to the
Moves the cursor to the
left to individual numbers
right to individual numbers
along a row.
along a row. Moves to the
Moves to previous screen.
next screen.
Connection point for A modular jack for PC connection. Connection point for the
an SPM transducer. vibration transducer TRV-12 .
Diagnostics Training Manual Page 1 IR30 Procedures—Keypad

IR30 Procedures
Taking SPM Measurements
Using the SPM Adaptor Using a hand held probe

The installation of shock pulse adapters is Measuring points for the hand-held probe should be
recommended for systematic shock pulse clearly marked. Always measure in the same spot.
monitoring.
CAUTION: When using the hand held probe Do
Adapters are not take measurements on the shock pulse
solid metal bolts adapters. This may give readings as much as 10
tuned for correct to 15 dB over normal readings leading to
signal incorrect diagnosis of machine troubles.
90o
transmission.
Countersink
They are The probe can also be
installed in used to measure
threaded, elsewhere on the
2-4 mm
countersunk 15mm deep machine, in case it is
mounting holes M8 thread
necessary to search for
on the bearing other shock pulse
housings. Preparation for Fixed Adaptor sources such as pump
cavitation or rubbing
parts.
Correct position. Probe is 90o,
pressure is steady and the center
The probe tip is spring of the tip is touching the surface
loaded and moves of the unit.
within a
sleeve of hard rubber. To maintain a
steady pressure on the tip, press the
probe tip against the measuring point
To attach the until the rubber sleeve is in contact
transducer with with the surface.
quick connector,
press it against
Incorrect
the adapter and position.
twist clockwise. Probe must
be held at
Hold the probe
2
90o to the
steady to avoid unit.
rubbing between
probe tip and
surface.
Twist counter-
clockwise to remove it. The probe is directionally sensitive.
It must be pointed straight at the bearing.
The centre of the probe tip should

touch the surface. Avoid
pressing the probe tip against
Check that installed transducers and adapters are cavities and fillets which are
properly mounted and in good condition. You will not smaller than the probe tip.
get a useful signal by attaching the quick connect
transducer to a rusty or loose adaptor. The only part likely to wear out is
the rubber sleeve for the probe
If TLT (Transducer Line Test) is less than 15 during tip. It is made of chloroprene Incorrect position.
SPM readings, it is an indication of a bad connection. rubber (neoprene) and tolerates Cavity is too small.
110ºC (230ºF).
When you finish taking measurements, use an
plastic cap to protect the adaptor.
Diagnostics Training Manual Page 2 IR30 Procedures—Taking SPM Measurements

IR30 Procedures
SPM - Instrument Set Up
To Display dBm/dBc To Change the Settings

Step Action Step Action
1 Use the Left & Right Arrows to display 1 When SET is pressed, the cursor will
the SPM menu SET blink and you can move from one Row
to another.
2 Moves the cursor to the LEFT to
individual numbers along a row
SPM
TLT 20 3 Moves the cursor to the RIGHT to
dBm 16 individual numbers along a row
dBc 9 dBi 26
4 Change the value of shaft speed, di-
ameter and decibel initial values by
scrolling them UP or DOWN with
2 Press SET to display bearing data. these keys.
SET
Toggle TLT on and off.
5 Save and returns the display to the
ENT SPM Menu
Bearing Data
TLT On
3000 rpm
90 dmm dBi 26
3 Pressing SET moves the Cursor

SET to another line.
4 Use the Up & Down Arrows

to change data values
Diagnostics Training Manual Page 3 IR30 Procedures—SPM Instrument Set up

IR30 Procedures
Normalized Reading Unnormalized Reading

1 For a normalized reading of bearing condition 1 For a unnormalised reading, scroll the dBi
with the IR30 you need to set initial value dBi. down past -9 to “—”.
The IR30 will calculate and display the dBi You will then measure in dBsv (absolute
when you input the rotational speed (rpm) and shock values). There will not be any condition
the shaft diameter (shown in mm). indication, that is, no arrow pointing to the
green/yellow/red condition scale.
Bearing Data
TLT On
3000 rpm Bearing Data
90 dmm dBi 26 TLT On
—— rpm
— dmm dBi —
However, this information is not always readily
available, so you can change the dBi directly,
which is faster.
dBi values for 50Hz and 60Hz compressors

can be founds in the Specifications Section of
this Manual.
2 Press SET to move the cursor to the
SET dBi line. You will find the dBi values
for all Ingersoll Rand units in the
following Specification section of this
manual. Transducer Line Test
3 When setting dBi, the screen will look as Step Action
follows
1 When TLT test is on, the instrument will
display the result of a transducer line test on
the display for data input, so you can check
Bearing Data
the quality of signal transmission between
TLT On transducer and instrument. Values below 15
—— rpm are not acceptable and you have to check
— dmm dBi 26 cables and connectors for bad connections
and moisture.
4 Use the Up & Down Arrows

to change the dBi values
SPM
TLT 20
dBm 16
dBc 9 dBi 26

IR30 Procedures
Taking a Measurement
Step Action
1 SPM Connect the transducers to the
measuring point
2 Press M to start taking a
M measurement.
3 It takes approx. 2-10 seconds to take each

reading, during which time the connected
transducer type is displayed as:
SPM
TLT
dBm 16
dBc 9 dBi 26
When M is pressed, TLT changes to a rotating

symbol and PROBE or TRA is displayed
during the measurement.
4 The two measuring results are the maximum

value dBm and the carpet value dBc.
SPM
PROBE
dBm 16
dBc 9 dBi 26
5 An arrow indicating the dBm level will point to

either the green, yellow or red zone on the
condition scale.
Bad > 35
Caution 21—34
Good < 20
This is a general guide only, used for all
individually installed anti-friction bearings
and is not applicable to Ingersoll Rand
Rotary products.

IR30 Procedures
SPM - Data Acquisition
Quick Check Routine

Step Action
1 Remove Instrument from the carrying case
2 Check the battery. Go to the Battery Test on

page 12 of this section and replace batteries if
necessary.
3 Check connections and transducer condition.
SPM reading—Setting up the IR30 SPM reading—Taking Readings

Step Action 8 At each measuring point,
press the wand against the
1 Attach the hand held probe or clip on housing, depress the spring
SPM
the transducer to the IR30 in the cable loaded plunger fully and hold;
socket marked SPM.
2 Press right or left arrow until or install a clip on
the SPM screen appears the unit
3 Prepare the log sheets.

9 While holding the probe, press M.
4 Set the M Keep pressing that key for 5 to 10
“dBi” value. seconds or until the display and Peak
red light stop blinking.
To do this, SPM
10 Release “M”; continue to hold wand and
determine the TLT 17
dBm 18 observe the display. The final number will
Compressor appear in a second or two.
Model from dBc 9 dBi 21
the machine 11 Release the wand and note the dBm and dBc
nameplate. on the log sheet.
For example: for a Sierra Model HH125, you would
consult the “Sierra Compressor Module” dBi
tabulation, choose “CD-14, HH125” and read
across to the “LPMR dBi” column which lists the
value as “32”. SPM
5 Press Set to go to the “dBi” position dBm 18

SET on the instrument display. dBc 9 dBi 21
6 Use the Up or Down arrow to

raise or lower the dBi value.
12 Go to the next measuring point and change
the dBi, is required.
7 Press ENT to save the new dBi value.
ENT
Repeat Steps 8 to 13
Diagnostics Training Manual Page 6 IR30 Procedures—SPM Data Acquisition

IR30 Procedures
Vibration Severity - Instrument Set Up
Vibration reading Measuring points and transducers for

VIB
A VIB measurement reads the RMS value of vibration
velocity in mm/s (or inch/s).
Vibration severity is defined as the RMS (root mean
Step Action square) value of vibration velocity measured in the
frequency range of 3 to 1000 Hz. It is the best
1 Use the Left and Right Ar-
indicator of the energy content of machine
rows to display the Vibration
vibration.
Screen.
2 Use the Up and Down Arrows to set Vibration velocity is primarily a measure of general
the ISO machine class as 3. machine condition. Vibration at the measuring point
should be representative for the overall vibration of
the machine.
Typical measuring points are bearing housings.

VIB By measuring in three directions, you can get an
ISO 10816 indication of the causes of increased vibration:
Class 3 2.76
mm/s Measurements taken on the Non-Drive End :
Vertical in the plane

3 of rotation, most
M Press M to start a reading. representative of
structural weakness.
The evaluation consists of a comparison of the
measured value with the ISO limit values VIB V
recommended for the different classes.
An arrow points at the condition scale. If no class is

input, the arrow is not shown. The majority of Axial along the line of
industrial machinery belongs to the vibration the shaft, most
classes: representative of
Class 2: Medium size machines without bent shafts.
special foundations
Class 3: Large machines on rigid foundations VIB A
Class 4: Large machines on soft foundations
H
For example, most smaller process pumps in a VIB Horizontal in the plane
chemical plant would be Class 2. of rotation, most
representative of
Ingersoll Rand has chosen class 3 for its balance condition.
full range of compressors.
The ISO values shown on he condition scale are:
Red = above 11mm/s = danger (needs urgent
attention)
Yellow = 4.5-11mm/s = caution
Green = up to 2.8-4.5mm/s = acceptable
General machine vibration increases when

something is loose, broken or out of balance. ISO
recommended vibration severity readings supply
valuable maintenance information.
Diagnostics Training Manual Page 7 IR30 Procedures—Vibration Severity

IR30 Procedures
Measurements taken on the Drive End :
Vertical in the plane

of rotation, most
representative of
structural weakness.
VIB V
Axial along the line of

the shaft, most
representative of
bent shafts.
VIB A
H
VIB
Horizontal in the plane
of rotation, most
representative of
balance condition.
Attaching the transducer.
Push the cap on and twist the adaptor into place.
Magnetic probe Vibration Pen

IR30 Procedures
Vibration reading
Step Action
1 VIB Connect the magnetic pickup to the
IR30 in the cable socket marked VIB
and check the connections.
2 Press the right or left arrows
until the VIB screen appears
3 Select class 3 by pressing the

up & down arrows.
4 Take three measurements on each air end, in

both loaded and unloaded operation.
“V” = Vertical;
“H” = Horizontal;
“A” = Axial.
5 Choose the best available flat surfaces and
wipe them free of dirt and debris.
6 When magnet is attached to surface,
M press and hold M for 3 seconds, then
release the key.
7 Record mm/sec number in the correct box on
the log sheet.
VIB
ISO 10816
Class 3 2.75
mm/s

IR30 Procedures
Condmaster Pro Rounds - Acquire Data
Rounds
These are lists of machines and measuring positions When you get to SPM Reading, the screen will look
loaded into the IR30 from a PC. like this:
Using rounds is the easiest method of taking

readings on site and recording data for use in the
software program. The first screen looks similar to: ROW
1 ML75=123456
2 MR1 LOADED
3 SPM 014
ROW
4
1 ML75=123456
2 pkg disch pres/p
3 kg disch temp Row Explanation
4 * ALT 1 001
1 Shows model, serial number and location
number as created in CondMaster Pro.
Row Explanation
2 Indicates measuring point and Male rotor inlet
1 Shows model, serial number and location during loaded operation.
number as created in CondMaster Pro.
3 The type of technique to be used (either SPM
2 Package discharge pressure per kilogram or VIB) and the number in the round.
3 Package discharge temperature
4 The Asterisk (*) indicates that the data has

already been recorded.
ALT1 refers to package discharge pressure.
001 is the number of the machine measuring
point.
Use the following keys to access and change

values
Step Action
1 Takes you into the pre-downloaded

round.
2 Scroll up and down to find the

serial number, model of
machine and measuring point.
Diagnostics Training Manual Page 10 IR30 Procedures—Condmaster Pro Rounds

IR30 Procedures
Condmaster Pro Rounds - Acquire Data
When an SPM measuring position When a VIB measuring position

to be recorded is found to be recorded is found
Press this key to open a new window.If there Press this key to open a new window.If there
ENT has been a measurement previously, the last ENT has been a measurement previously, the last
results will be displayed as: results will be displayed as:
ROW
ROW
ML75.123456 1 ML75.123456
1
TLT 17 2 VIB
2
3 dBm18 3 Class 3 2.75
4 dBc 9 dBi 21 4 mm/s
Row Explanation Row Explanation

1 Model, serial and location number 1 Model, serial and location number
2 TLT (Transducer Line Test) value and date of 2 Type of reading and date of reading as
reading as mmddyy. mmddyy.
3 The recorded maximum (dBm) decibel value. 3 Class (Ingersoll Rand always uses Class 3) and
reading value.
4 The Carpet (dBc) and initial (dBi) decibel
values. 4 Value type (shown as millimeters per second in
the example).
Take an SPM reading Take a VIB reading
1 SPM Ensure that the correct probe is 1 VIB Ensure that the correct probe is
connected connected
2 2
Press M to take a measurement. Press M to take a measurement.
M M
3 If the result looks correct press ENT 3 If the result looks correct press ENT
ENT to log ENT to log
4 If you need to take the reading again 4 If you need to take the reading again
M press M again to take a second M press M again to take a second
reading. reading.
5 When you are happy with the result 5 When you are happy with the result
ENT press ENT to record it into the meter. ENT press ENT to record it into the meter.
6 Repeat this process at the next location. 6 Repeat this process at the next location.
Diagnostics Training Manual Page 11 IR30 Procedures—Condmaster Pro Rounds

IR30 Procedures
IR30 - Other Menus Instrument Set Up
Setup Menu The current battery voltage is shown. A low battery

warning is given at 5.1 V. At this stage, only ongoing
General instrument functions are available under the data transmission works, while the display shows
Setup menu, “Battery low”.
Use the Up and Down arrows to se-
lect the Setup Menu. Memory and the clock are protected for
approximately 24 hours by a capacitor. If you
replace the batteries within that time, you will not
lose any data.
ROW
1 Communication The battery life depends on how the instrument is
2 used. Full power is only consumed while a reading
Battery test
is in progress: from pressing the M key until a
3 Version measured value is displayed. The instrument uses
4 Current setup much less power when it is idle and only the display
is on, and virtually no power when it is off.
However, for long-time storage, the batteries should
Row Explanation be removed.
1 Open for data transfer to and from a PC Battery life (with high effect cells like Duracell
2 Shows present battery voltage, there are no PROCELL, backlight off) is about 1 year with power
adjustments to be made off, otherwise it is as specified below:
3 Shows EPROM version, date, check sum. • Typical readings:
There are no adjustments to be made 5000 measuring points, using several
techniques and points.
4 Go to the Current Setup Menu. This is based on an average measuring time of
Press ENT to close and save any changes 1 min./point, without backlight. A single
ENT made to the functions. measurement takes approx. 2-10 sec, here the
calculation is based on 10 sec. per
measurement.
• Continuous read: At least 50 hours.
Battery test
Step Action
1 The instruments are powered by 6 batteries
type MN 1500 LR6, 1.5 V. The battery
compartment is located
at the back and is
fastened by two screws.
Remove the protective
cover to reach the
screws.
2 Use SET to position the cursor

SET beside Battery test on the second
row
3 Press ENT to display the battery test
ENT screen
Battery test
(Min 5.2 V)
8.6V
Diagnostics Training Manual Page 12 IR30 Procedures—Other Menus

IR30 Procedures
Current Setup Menu Clock Menu

A number of displays are permanently stored in the Step Action
Instrument and these can be accessed and changed
from this menu. 1 Press SET to position the cursor
SET beside Time on the first row
2 Press ENT to display the Clock Menu

ROW ENT
1 Time mm
o
2 Display C
3 English Clock
4 Off 5 min 00 sec
Date 97.11.02
Time 14.36
Row Explanation
1 Time goes to the Clock menu which allows
changes to the date and time. The data format is YY.MM.DD, i.e., the last two digits
and of the year followed by the month and the day. The
mm - Bearing diameters and vibration velocity format is fixed and cannot be adjusted to the format
can be displayed in mm/s or inch/s. used in Condmaster Pro.
2 Display goes to the Contrast menu which
allows changes to light, sensitivity and The time display used the 24 hour clock, i.e., from
brightness. 00.00 to 23.59.
and
ºC - Toggle between the temperature units ºC For data loggers, the time of the instrument must be
and ºF. adjusted within 5 minutes of the PC’s time.
3 Scroll through the list to select the language
you want. • date
• time
4 Off shows how much time has elapsed
1 Press SET to position the cursor at
between pressing any key and the automatic SET the appropriate row
power off.
Use the following keys to access and change 2 Use the Right and Left Arrows to
• mm move the cursor along the line. For
• ºC example, if you only want to change
the month, use these keys to get to
• English the correct position.
• Length Measuring Unit
(this function is past the Off line, use SET to get 3 Use the Up and Down Arrows to
there). scroll the values up or down to
1 Press SET to position the cursor at change the setting.
SET the appropriate row
2 Use the Up and Down Arrows to

changes the settings 4 Press ENT to save the changes, exit
ENT the Clock Menu and return to the
• toggle between mm/s and inch/s Current Setup Menu.
• toggle between ºC and ºF
• change the time in 10 second
intervals
• change the length measuring unit

IR30 Procedures
Display Menu
Step Action
1 Press SET to position the cursor
SET beside Display on the second row
2 Press ENT to show the Display Menu

ENT
Contrast
Light AUT
Sensitivity 5
Brightness 5
The menu controls the appearance of the normal

instrument display, with and without backlighting.
Please note: that with the backlight on, the

instrument draws approx. 30% more power. Do not
cover the sensor when measuring; if on automatic,
that will switch on the backlight.
• contrast
• light
• sensitivity
• brightness
1 Press SET to position the cursor at
SET the appropriate row
2 Changes the settings

• contrast - adjust setting in
normal light
• light - toggle between AUT
(automatic) and OFF. On
automatic, the backlight is
switched on by the action of the
light sensor above the keypad.
• sensitivity - a scale of 1 to 9
and refers to the sensor
brightness - a scale of 1 to 9 and
refers to the backlight.
For fine adjustments, make the
settings in bad light.
3 Press ENT to save the changes, exit
ENT the Clock Menu and return to the
Current Setup Menu.

IR30 Procedures
Service Instruments and Accessories
CCN
IR30 Data Logging Kit 39263009
consisting of:
IR30 Instrument 39262829
TRA 22 Probe 39262837
TRA 31 Quick Connector 39262845
13603 Communication Module 39262852
CAB 31 Computer Cable 39262860
EMD 13 Carying Strap 39262878
TRV 12 Vibration Transducer 39262886
TRX 16 Magnetic Foot 39262894
VIC 19 Vibration Cable 39262902
CAS 22 Carrying Case 39262910
6, 9022 Batteries 39262928
PRO46-1 Condmaster Pro Software, Level 1 39262936
91263 Hardware Key 39262951
Instruction Manual Package 39262969
IR 30 Basic 54504774
The IR 30 Basic works in the same way as the Data Logging instrument with
the exception that all data has to be manually loaded prior to taking each
reading. It has no PC loading/downloading capability. The IR30 Basic can
be upgraded to the logger format
IR30 Sentinel 54636535

The IR30 Sentinel only has SPM monitoring capability and cannot be
upgraded to Logger format.
IR30 Compact
IR30 Compact (A): 38444105 - without quick connect cable
IR30 Compact (B): 38444113 - with quick connect cable
The IR30 Compact uses the same technology as logger and Sentinel to take SPM
readings. Can store ten readings. Has infrared temperature reading. Electronic
stethoscope capability with standard set of headphones
Kit includes: IR30 Compact instrument, accessory bag, protective cover, AA
batteries, quick start guide, evaluation guide, technical documentation CD, and
Ingersoll Rand packaging box.
Items required for field installation:

Standard Shock Pulse Adapters (50 per set):
5/16x18 Thread, 24 mm long with caps
42464602
Drill & 90 Degree Countersink:

Adapter Installation Tool
39262993
Diagnostics Training Manual Page 15 IR30 Procedures—Service Instruments

SPM Measuring Points for Rotary Compressors
General
Oil Flooded Rotary Measuring Points

On oil flooded (contact cooled) compressors, we take the
following readings when the unit is fully loaded.
Single Stage Compressor
MR2 Male Rotor Inlet Bearing (roller bearing)

MR1 Male rotor Discharge Bearing (tapered bearing)
MBRG Motor Bearing
Two Stage Compressor
LPMR2 Low Pressure Male Rotor Inlet Bearing

LPMR1 Low Pressure Male Rotor Discharge Bearing
HPMR2 High Pressure Male Rotor Inlet Bearing
HPMR1 High Pressure Male Rotor Discharge Bearing
MBRG Motor Bearing
We also recommend taking SPM readings on motor non-drive

end bearings.
Monitoring
Stud MR2
Single Stage
Two Stage
MBRG
MR2 MR2
LPMR2
LPMR1
HPMR1 HPMR2
Diagnostics Training Manual Page 1 SPM Measuring Points for Rotary Compressors
Single Stage Flooded - General Guide
VIB V
MR1
VIB A
H
VIB
VIB V
MR2
MTB
VIB A
H
VIB
CF90 Air End
MR2 DE
Male Rotor
MR1 NDE (thrust)

Male Rotor
178.5mm Air End
MR2 DE
Male Rotor
MR1 NDE (thrust)

Male Rotor
226mm (World Wide) Air End
MR2 DE
Male Rotor
MR1 NDE (thrust)

Male Rotor
226mm Extended Air End
MR2 DE
Male Rotor
Two Stage - General Guide
VIB V
VIB V
LPMR2
VIB A
H MTB
VIB LPM1
VIB A
H
VIB
HPM1
HPM2
297mm/250mm Air End
1 MR2 DE Male
Rotor 1st Stage
1 MR1 NDE (thrust)

Male Rotor 1st Stage
297mm/250mm Air End
2 MR2 DE
2nd Stage
2 MR1 NDE
2nd Stage
dBi Values for Rotary Compressors
50Hz Single Stage Units
Legend:
GD = Gear Driven
SSR M11-50kw GD & BD HG Built BD = Belt Driven
HG = Hindley Green
Male Female Motor D = Davidson
Unit Airend dBi dBi DE dBi NDE dBi
SSR ML11 100 20 16 17 21
SSR MM11 100 19 15 17 21
SSR MH11 100 18 14 17 21
SSR ML15 100 22 18 23 21
SSR MM15 100 21 18 23 21
SSR MH15 100 21 17 23 21
SSR ML18.5 100 23 20 23 21
SSR MM18.5 100 23 19 23 21

SSR MH18.5 100 22 18 23 21
SSR ML22 100 25 24 23 21
SSR MM22 100 25 21 23 21
SSR MH22 100 24 20 23 21
SSR ML30 100 26 23 24 22
SSR MM30 100 26 23 24 22
SSR MH30 100 26 22 24 22
SSR ML37 100 29 25 23 24
SSR MM37 100 28 25 23 24
SSR MH37 100 28 24 23 24
SSR ML45 127.5 28 23 23 23
SSR MM45 127.5 27 23 23 23
SSR MH45 127.5 26 22 23 23
SSR ML50 127.5 28 24 25 24
SSR MM50 127.5 27 23 25 24
SSR MH50 127.5 27 23 25 24
M37 LATE 23 24
M45 LATE 23 23
SSR M15-18.5kw BD HG Built

Male Female Motor
SSR ML15 100 22 18 23 21
SSR MM15 100 21 17 23 21
SSR MH15 100 20 17 23 21
SSR MU15 100 18 15 23 21
SSR ML18.5 100 23 20 23 22
SSR MM18.5 100 23 19 23 22
SSR MH18.5 100 22 19 23 22
SSR MU18.5 100 20 16 23 22
SSR M22-30 BD HG Built

Male Female Motor
SSR ML22 100 24 21 24 22
SSR MM22 100 24 21 23 21
SSR MH22 100 23 20 23 21
SSR MU22 100 22 18 23 21
SSR ML30 100 26 23 23 21
SSR MM30 100 26 22 23 21
SSR MH30 100 25 22 23 21
SSR MU30 100 23 20 23 21
Diagnostics Training Manual Page 10 dBi Values for Rotary Compressors

Legend:
GD = Gear Driven
SSR M90-150SS BD = Belt Driven
HG = Hindley Green
Male Female Motor D = Davidson
SSR ML90 226 20 15 20 19
SSR MM90 226 19 14 20 19
SSR MH90 226 18 14 20 19
SSR MU90 226 16 11 20 19
SSR ML110 226 21 17 20 19
SSR MM110 226 21 16 20 19
SSR MH110 226 20 16 20 19
SSR MU110 226 19 14 20 19
SSR ML132 226 23 18 21 20
SSR MM132 226 22 18 21 20
SSR MH132 226 21 17 21 20
SSR MU132 226 19 15 21 20
SSR ML150 226 24 19 21 20
SSR ML150 226 23 19 21 20
SSR ML150 226 22 18 21 20
SSR MU150 226 21 17 21 20
BCP TECV M90 20 20
BCP TECV M110 20 20
BCP TECV M132 20 20
BCP TECV M150 20 20
SSR M90-150SS-ER
Male Female Motor
SSR ML90 226ER 20 16 20 19
SSR MM90 226ER 19 15 20 19
SSR MH90 226ER 18 14 20 19
SSR MU90 226ER 16 12 20 19
SSR ML110 226ER 21 18 20 19
SSR MM110 226ER 21 17 20 19
SSR MH110 226ER 20 17 20 19
SSR MU110 226ER 19 15 20 19
SSR ML132 226ER 23 19 21 20
SSR MM132 226ER 22 18 21 20
SSR MH132 226ER 21 18 21 20
SSR MU132 226ER 19 15 21 20
SSR ML150 226ER 24 20 21 20
SSR ML150 226ER 23 19 21 20
SSR ML150 226ER 23 19 21 20
SSR MU150 226ER 21 17 21 20
BCP TECV M90 20 20
BCP TECV M110 20 20
BCP TECV M132 20 20
BCP TECV M150 20 20

Legend:
GD = Gear Driven
BD = Belt Driven
SSR M90-150SS-ER2 HG = Hindley Green
D = Davidson
Male Female Motor
SSR ML90 226ER2 20 16 20 19
SSR MM90 226ER2 19 15 20 19
SSR MH90 226ER2 19 14 20 19
SSR MU90 226ER2 16 12 20 19
SSR ML110 226ER2 22 18 20 19
SSR MM110 226ER2 21 17 20 19
SSR MH110 226ER2 21 17 20 19
SSR MU110 226ER2 19 15 20 19
SSR ML132 226ER2 23 19 21 20
SSR MM132 226ER2 23 18 21 20
SSR MH132 226ER2 22 18 21 20
SSR MU132 226ER2 20 15 21 20
SSR ML150 226ER2 24 20 21 20
SSR ML150 226ER2 24 19 21 20
SSR ML150 226ER2 23 19 21 20
SSR MU150 226ER2 22 17 21 20
BCP TECV M90 20 20
BCP TECV M110 20 20
BCP TECV M132 20 20
BCP TECV M150 20 20
SSR M200-250SS-ER
Male Female Motor
SSR ML200 226ER 26 22 26 26
SSR MM200 226ER 26 22 26 26
SSR MH200 226ER 25 21 26 26
SSR ML250 226ER 28 24 26 26
SSR MM250 226ER 27 24 26 26
SSR MH250 226ER 26 23 26 26
BCP TEFV M200 26 26
BCP TEFV M250 26 26
SSR M200-250SS-ER2
Male Female Motor
SSR ML200 226ER2 27 22 21 21
SSR MM200 226ER2 26 22 21 21
SSR MH200 226ER2 26 21 21 21
SSR ML250 226ER2 28 24 21 21
SSR MM250 226ER2 28 24 21 21
SSR MH250 226ER2 27 23 21 21
LS TEFV M200 21 21
LS TEFV M250 21 20
BCP ODP M200 20 20
BCP ODP M250 20 20
BCP TEFV M200 22 20
BCP TEFV M250 22 20

Legend:
GD = Gear Driven
BD = Belt Driven
SSR M300-350FATBOY HG = Hindley Green
D = Davidson
Male Female Motor
SSR ML300 304FB 28 25 20 20
SSR ML300 304FB 28 25 20 20
SSR MH300 304FB 27 24 20 20
SSR ML350 304FB 30 27 20 20
SSR MM350 304FB 30 26 20 20
SSR MH350 304FB 29 26 20 20
BCP TEFV M300 22 20
BCP TEFV M350 22 20
LS ODP M300 21 21
LS ODP M350 21 21
LS TEFV M300 21 21
LS TEFV M350 21 21
SSR M300-350CI
Male Female Motor
SSR ML300 304CI 0 0 20 20
SSR M300 304CI 0 0 20 20
SSR MH300 304CI 0 0 20 20
SSR ML350 304CI 0 0 20 20
SSR MM350 304CI 0 0 20 20
SSR MH350 304CI 0 0 20 20
BCP TEFV M300 22 20
BCP TEFV M350 22 20
LS ODP M300 21 21
LS ODP M350 21 21
LS TEFV M300 21 21
LS TEFV M350 21 21

50Hz Two Stage Units
SSR M75-150-2S
1st Stage 2nd Stage
Male Female Male Female Motor
Unit Airend dBi dBi dBi dBi DE dBi NDE dBi
SSR ML75 226/182 18 14 17 15 20 19
SSR MM75 226/182 17 14 17 15 20 19
SSR MH75 226/182 17 13 16 14 20 19
SSR MXU75 226/182 15 11 15 13 20 19
SSR ML90 226/182 20 16 19 17 20 19
SSR MM90 226/182 19 15 18 16 20 19
SSR MH90 226/182 18 15 18 16 20 19
SSR MXU90 226/182 17 13 16 14 20 19
SSR ML110 226/182 21 17 20 18 20 19
SSR MM110 226/182 21 17 20 18 20 19
SSR MH110 226/182 20 16 19 17 20 19
SSR MXU110 226/182 19 15 18 16 20 19
SSR ML132 226/182 22 19 22 20 21 20
SSR MM132 226/182 22 18 21 19 21 20
SSR MH132 226/182 21 18 21 19 21 20
SSR MXU132 226/182 20 16 19 17 21 20
SSR ML150 226/182 24 20 23 21 21 20
SSR MM150 226/182 23 20 23 20 21 20
SSR MH150 226/182 22 19 22 20 21 20
SSR MXU150 226/182 21 18 21 19 21 20
LS TEFV M75 19 19
LS TEFV M90 19 19
LS TEFV M110 20 20
LS TEFV M132 21 20
LS TEFV M150 21 20
SSR M200-350-2S
1st Stage 2nd Stage
Male Female Male Female Motor
Unit Airend dBi dBi dBi dBi DE dBi NDE dBi
SSR ML200 297/250 21 16 18 15 21 21
SSR MM200 297/250 21 16 18 15 21 21
SSR MH200 297/250 20 15 17 14 21 21
SSR MXU200 297/250 18 13 15 13 21 21
SSR ML250 297/250 23 18 20 17 21 21
SSR MM250 297/250 22 17 19 16 21 21
SSR MH250 297/250 21 17 19 16 21 21
SSR MXU250 297/250 20 15 17 14 21 21
SSR ML300 297/250 24 19 21 18 21 21
SSR MM300 297/250 24 19 21 18 21 21
SSR MH300 297/250 23 18 20 17 21 21
SSR MXU300 297/250 21 17 19 16 21 21
SSR ML350 297/250 25 20 22 19 21 21
SSR MM350 297/250 25 20 22 19 21 21
SSR MH350 297/250 24 19 21 18 21 21
SSR MXU350 297/250 23 18 20 17 21 21
LS TEFV M200 21 21
LS TEFV M250 21 21
LS TEFV M300 21 21
LS TEFV M350 21 21

Single Stage, SSR Compressors dBi Data

MR1 MR2 MBGR Max dBm
60 Hz Models A/E Size dBi dBi dBi
HP, EP, XF, 50 hp 26 26 24 50
127.5 mm
HP, EP, XF, 60 hp 27 27 25 50
HP, EP, XF, 75 hp 22 22 20 50
178.5 mm
HP, EP, XF, 100 hp 24 24 20 50
HP, EP, XF, 125 hp 20 20 21 50-54
HP, EP, XF, 150 hp 21 21 21 50-54
HP, EP, XF, 200 hp 226 mm 23 23 23 50-54
HP, EP, XF, 250 hp 24 24 23 50-54
HP, EP, XF, 300 hp 26 26 23 50-54
HP, EP, XF, 250 hp 304 mm 21 21 23 50-54
HP, EP, XF, 250 hp 25 25 23 50-54
255 mm
HP, EP, XF, 300 hp 26 26 23 50-54
HPE, EPE, XFE, 300 hp 23 20 23 50-54
HP, EP, XF, 350 hp 304 mm 24 24 23 50-54
HP, EP, XF, 400 hp 25 25 23 50-54
HP, EP, XF, 450 hp 26 26 23 50-54
All other single stage oil flooded 25 25 25
Models

60Hz Two Stage Units
2 Stage, SSR Compressors dBi Data

LP M1 LP M2 HP M1 HP M2 MBRG
60 Hz Models dBi dBi dBi dBi dBi
XFE100-2S 18 18 18 18 21
EPE100-2S 18 18 17 17 21
HPE100-2S 18 18 16 16 21
XFE125-2S 21 21 19 19 21
EPE125-2S 20 20 19 19 21
HX/HPE125-2S 19 19 18 18 21
XFE150-2S 22 22 21 21 21
EPE150-2S 21 21 20 20 21
HX/HPE150-2S 21 21 20 20 21
XFE200-2S 25 25 23 23 23
EPE200-2S 24 24 22 22 23
HX/HPE200-2S 24 24 22 22 23
XFE250-2S 19 19 18 18 23
EPE250-2S 19 19 17 17 23
HPE250-2S 18 18 17 17 23
HXPE250-2S 16 16 15 15 23
XFE300-2S 21 21 20 20 23
EPE300-2S 20 20 18 18 23
HPE300-2S 20 20 18 18 23
HXPE300-2S 18 18 17 17 23
XFE350-2S 22 22 21 21 23
EPE350-2S 21 21 20 20 23
HPE350-2S 21 21 19 19 23
HXPE350-2S 21 21 20 20 23
XFE400-2S 23 23 21 21 23
EPE400-2S 23 23 21 21 23
HPE400-2S 22 22 20 20 23
HXPE400-2S 20 20 18 18 23
XFE450-2S 24 24 22 22 23
EPE450-2S 24 24 22 22 23
HPE450-2S 23 23 21 21 23
HXPE450-2S 21 21 20 20 23
XFE500-2S 25 25 23 23 23
EPE500-2S 24 24 22 22 23
HPE500-2S 24 24 22 22 23
HXPE500-2S 22 22 21 21 23

60Hz Single Stage Belt Driven Units
Single Stage Belt Driven, SSR Compressors dBi Data

MR1 MR2 MR Max dBm
HP 60 Hz Models A/E Size dBi dBi RPM Drive
ESP 20 20 3055 38 Belt
7.5-10 CE55R2
ESP/SE/"Lynx" Belt 25 25 40 Belt
CE55R3
ESP 20 20 38 Belt
15 CE55R2
ESP/SE/"Lynx" Belt 25 25 40 Belt
CE55R3
3 ESP 14 14 1850 35 Belt
5 ESP 19 19 3400 38 Belt
SE EP 7.5 66 mm 19 19 3376 40 Belt
7.5
SE HP 7.5 18 18 2981 40 Belt
SE XP 7.5 17 17 2565 38 Belt
SE EP 10 21 21 4157 44 Belt
10
SE XP 10 19 19 3520 44 Belt
SE EP 30 25 25 4365 45 Belt
30-40
SE HP 30 24 24 4075 45 Belt
SE HXP 30 CF75D5 22 22 3225 45 Belt
SE EP 40 27 27 5655 50 Belt
SE HP 40 26 26 5310 50 Belt
SE HXP 40 25 25 4316 45 Belt
EP15U 26 26 45 Belt
15-25
HP15U 25 25 4718 45 Belt
XP15U U85 mm 24 24 4314 45 Belt
EP25U 30 30 48
HP 25U 29 29 7168 50 Belt
XP25U 28 28 6616 50 Belt
20-30 XF thru HXP "Jaguar" 85 mm 26 26 45 Belt
15-25 SE Model 27 27 45 Belt
90 mm
20-25 ESP 27 27 45 Belt
EPE 25 25 45 Belt
25-40
HPE U100 28 28 45
XPE 35 35 45 Belt
30-50 30 ESP 23 23 45 Belt
25 100 mm 21 21 40 Belt
30 SE Models 23 23 45 Belt
40 25 25 45 Belt
50 28 28 50 Belt

Acceptable Values-Different Airend Sizes
The following lists are for recent and current NOTE:

Production Air Ends used in Oil Flooded Screw Maximum dBm Values are subject to change
Compressors and give Decibel Initial Values, and
projected maximum dBm values indicating repair
requirement.
Maximum
Airend CCN HP Used in Model(s) Drive M.R. RPM dBi Value
(Ave.) dBm
CE55R2 42437491 7.5-10 ESP Belt 3055 20 38
42437483 15 ESP
CE55R3 39248117 7.5-10 ESP/SE/”Lynx” Belt 25 40
15
66MM 39230131 3 ESP Belt 1850 14 35
5 ESP Belt 3400 19 38
7.5 SE EP 7.5 Belt 3376 19 40
7.5 SE HP 7.5 Belt 2981 18 40
7.5 SE XP 7.5 Belt 2565 17 38
10 SE EP 10 Belt 4157 21 44
10 SE XP 10 Belt 3520 19 44
CF75D5 39225297 30-40 SE EP 30 Belt 4365 25 45
30-40 SE HP 30 Belt 4075 24 45
30-40 SE HXP 30 Belt 3225 22 45
30-40 SE EP 40 Belt 5655 27 50
30-40 SE HP 40 Belt 5310 26 50
30-40 SE HXP 40 Belt 4316 25 45
U85MM 39694708 15-25 EP15U Belt 26 45
15-25 HP15U Belt 4718 25 45
15-25 XP15U Belt 4314 24 45
15-25 EP25U Belt 30 48
15-25 HP 25U Belt 7168 29 50
15-25 XP25U Belt 6616 28 50
85 MM 39895230 20-30 XF thru Belt 26 45
HXPJaguar”
90 MM 39845052 15-25 SE Model Belt 27 45
20-25 ESP Belt 27 45

Acceptable Values-Different Airend Sizes
Maximum
Airend CCN HP Used in Model(s) Drive M.R. RPM dBi Value
(Ave.) dBm
CF 90 42455501 60 HP60ESP Gear 25 50
42448654 60 XF60ESP Gear 25 50
42448662 75 XF75ESP Gear 25 50
42427716 60 EP60ESP Gear 25 50
42427724 76 EP75ESP Gear 25 50
U100 39694716 25-40 EPE25,30,40U Belt 25 45
HPE25,30,40U Belt 28 45
XPE25,30,40U Belt 35 45
100 MM 42377028 30-50 30 ESP Belt 23 45
25 SE Models Belt 21 40
100 MM 39036967 15-40 Gear 25 45
39675814 50 ESP & SSR Gear 28 48
127.5MM 39014469 50-60 XFE, EPE, HPE Gear 27 50
178.5MM 39632146 75-100 XF, EP, HP Gear 27 50
39605449 “Cougar” 25 50-54
226MM 39014600 150-300 XF, EP, HP Gear 25 50-54
255MM 39656194 250-300 XF, EP, HP Gear 25 50-54
304MM 39632237 300-450 XF, EP, HP Gear 26 50-54
(“Fat Man”)
304MM 42379362 300-450 XF, EP, HP Gear 26 50-54
350MM 39014634 Gear 25 50-54
255/204MM 39072343 900 60 HZ Gear See Book 52-55
39072350 1200 60 HZ Gear See Book 52-55
42362715 1350 60 HZ Gear See Book 52-55
226/182MM 39871082 100,200SSR 2 Stage Gear See Book 52-55
297/250MM 42389429 250-450SSR 2 Stage Gear See Book 52-55
45 KW “Nirvana” Shock Pulse Data Is Acquired At “Fixed Speed” 29 50
75 KW “Nirvana” Shock Pulse Data Is Acquired At “Fixed Speed” 26 50
Notes: Decibel Maximum values are acquired with the compressor at full load and pressure. Unloaded values,
while useful, are not the dominant values used to make decisions regarding bearing replacement.
Two stage oil flooded units will always have unloaded dBm values significantly higher than loaded values.
Therefore, unloaded dBm / dBc values must be noted, but discarded.

SPM Logs for Rotary Compressors
Single Stage Units

Two Stage Units

Two Stage Units

SPM Measuring Points for Sierra Compressors
General Guide
Sierra Measuring Points

On Sierra Compressors, we take readings on male
and female rotor bearings on drive and non-drive ends
and bullgear bearings, when the unit is loaded and
unloaded.
We also recommend taking SPM readings on the

motor drive and non-drive end.
r
lg ea
HPF1 l
Bu
HPM1
HPM2
HPF2 LPM1
LPF1
LPM2
LPF2
LPM
Monitoring
Studs
LPF1
Diagnostics Training Manual Page 1 SPM Measuring Points for Sierra Compressors
CD8 Air End
LPM2
LPF2
CD8 Air End
LPM1
LPF1
CD8 Air End
HPF2
HPM2
CD14 Air End
BG1
LPM1
LPF1
CD14 Air End
LPM2
LPF2
CD14 Air End
HPM2
HPF2
CD14 Air End
HPF1
HPM1
dBi Values for Sierra Compressors
CD8 Air End
Sierra Compressor Module CD8

GHH IR Drive BG LPMR LPFR HPMR HPFR
Model Model RPM dBi dBi dBi dBi dBi
60 Hz Units
CD - 8 L 50 3570 26 33 29 37 33
CD - 8 H 50 3570 26 32 28 33 29
CD - 8 L 60 3570 26 35 30 35 31
CD - 8 H 60 3570 26 34 29 35 31
CD - 8 L 75 3570 26 36 32 37 33
CD - 8 H 75 3570 26 35 31 36 32
CD - 8 HH 75 3570 26 35 30 34 30
CD - 8 L 100 3570 26 38 34 39 35
CD - 8 H 100 3570 26 38 34 38 34
CD - 8 HH 3570 26 37 33 37 33
50 Hz Units
CD - 8 SL 37 2975 25 33 29 34 30
CD - 8 SM 37 2975 25 32 28 33 29
CD - 8 SL 45 2975 25 35 30 35 31
CD - 8 SM 45 2975 25 34 29 34 30
CD - 8 SL 55 2975 25 36 32 37 33
CD - 8 SM 55 2975 25 36 31 36 32
CD - 8 SH 55 2975 25 35 31 35 31
CD - 8 SL 75 2975 25 38 34 38 34
CD - 8 SM 75 2975 25 38 34 38 34
CD - 8 SH 75 2975 25 37 33 37 33
Diagnostics Training Manual Page 9 dBi Values for Sierra Compressors

CD14 Air End

60 Hz Units
CD - 14 L 200 3570 26 37 32 40 34
CD - 14 H 200 3570 26 36 32 39 33
CD - 14 HH 200 3570 26 35 31 38 32
CD - 14 L 150 3570 26 34 30 37 32
CD - 14 H 150 3570 26 34 30 37 32
CD - 14 HH 150 1780 20 33 29 36 30
CD - 14 L 125 1780 20 33 29 36 30
CD - 14 H 125 1780 20 32 28 36 30
CD - 14 HH 125 1780 20 32 28 34 29
50 Hz Units
CD - 14 SH 150 2975 24 36 31 39 33
CD - 14 SM 150 2975 24 36 32 40 34
CD - 14 SL 150 2975 24 37 32 39 34
CD - 14 SH 132 2975 24 34 30 37 32
CD - 14 SM 132 2975 24 35 31 38 32
CD - 14 SL 132 2975 24 36 31 39 33
CD - 14 SH 110 2975 24 33 28 36 30
CD - 14 SM 110 2975 24 34 30 37 31
CD - 14 SL 110 2975 24 34 30 37 32
CD - 14 SH 90 1480 18 32 27 34 28
CD - 14 SM 90 1480 18 32 27 35 29
CD - 14 SL 90 2975 24 33 28 36 30

CD26 Air End

60Hz Units
CD - 26 L 250 1780 22 33 29 36 31
CD - 26 L 300 1780 22 34 31 38 33
CD - 26 L350 1780 22 36 32 39 34
CD - 26 H 250 1780 22 32 29 36 30
CD - 26 H 300 1780 22 34 30 37 32
CD - 26 H 350 1780 22 35 31 38 33
CD - 26 HH 250 1780 22 32 28 35 30
CD - 26 HH 300 1780 22 33 29 36 31
CD - 26 HH 350 1780 22 34 31 38 33
CD - 26 HH 400 1780 22 36 32 39 34
50 Hz Units
CD - 26 SL 200 1480 20 33 30 37 31
CD - 26 SL 250 1480 20 36 32 39 33
CD - 26 SM 200 1480 20 33 29 36 31
CD - 26 SM 250 1480 20 35 31 38 33
CD - 26 SH 200 1480 20 32 28 35 30
CD - 26 SH 250 1480 20 32 28 35 30
CD - 26 SH 300 1480 20 36 32 39 33

SPM Logs for Sierra Compressors
CD8, CD14 & CD26 Air End



SPM for Nirvana Compressors
Nirvana Air End—Contact Cooled
SPM Measuring Points
M
R2
M
R1
dBi Values
Nirvana Compressors dBi Data
Unit Size Kw/Hp A/E Size MR1 MR2 Max dBm
Single Stage
37/50 29 29 50
CF 90
45/60 29 29 50
55/75 26 26 50
CD 128
75/100 26 26 50
90/125 22 22 50
110/150 22 22 50
226 WW
150/200 22 22 50
Two Stage
75/100 25 25 50
90/125 226/182 25 25 50
110/150 25 25 50
150/200 25 25 50
Diagnostics Training Manual Page 1 SPM for Nirvana Compressors

SPM for Nirvana Compressors
Nirvana Air End—Oil Free
90KW/125HP - 160KW/200HP Units
Shock Pulse data acquisition procedure is the same
for either model of Nirvana.
Five points will be measured:
dBi Values
LPM1 LPM2 HPM1 HPM2 BG
IRN90KW / 125HP-OF 33 33 36 36 20
IRN110KW/150HP-OF 34 34 37 37 26
IRN132KWHP-OF(ESA) Only 34 34 37 37 26
IRN160KW/200HP-OF 36 36 39 39 26
Procedure:
The Compressor should be running at or near
maximum speed and pressure.
Set dBi in the instrument, and acquire data in the

normal manual manner outlined in APDD 741 or
APDD 766.

SPM Log for Nirvana Compressors
Nirvana Air End

IR30
Reference Material
The following is a list of websites that contain

helpful information.
About the site Website address

SPM Site http://www.spminstrument.com/
Reliability Magazine http://www.reliability-magazine.com
SKF Bearing Monitoring http://www.skfcm.com/
Diagnostics Training Manual Page 1 SPM and IR30—Reference Material

IR30
Bearing Damage and Causes
Introduction
This group of photographs was assembled to
illustrate the appearance of various types of damage
and failure occurring to spherical roller bearings in
service. The listing is by no means complete but
does represent some of the more common types of
damage. Many failures are a combination of two or
more contributing causes and the resolution of the
primary cause may be difficult.
• Staining in storage
• Corrosion
• Corrosion and failure
• Corrosion in storage
• Installation damage
• Brinelled raceway
• Damage in transit
• Installation damage Figure 1—Staining in Storage
• Cross section thru scuff mark Improper storage conditions often result in damage
• Poor seating on tapered shaft to bearings. Figure 1 shows staining that occurred
on a bearing stored with inadequate protection in a
• Fretting corrosion
humid atmosphere. Special types of packaging are
• Heat checks available for storage of bearings in high humidity
• False brinelling atmosphere.
• Lubrication failure – Outer
Figure 2—Corrosion
• Lubrication failure – Inner and rollers This outer ring was a
• Lubrication failure – Rollers component of a
• Lubrication failure – Outer race bearing operation in
a high humidity at-
• Lubrication failure – Retainer
mosphere. Corrosion
• Lubrication failure – Thrust is general. See Fig-
• contact surfaces ure 3.
• Abrasive wear- Rings and rollers
• Abrasive wear – Outer ring cross-section
• Abrasive wear – Inner and outer rings
• Abrasive wear – Roller ends
• Fatigue
• Thrust loading
• Single spall
!
Caution
To insure that bearings are in factory fresh condition
when installed, they should be kept in the original
package and stored in a dry warm place until needed
for mounting.
Figure 3—Corrosion
An enlargement of Figure 2 shows the innumerable
pits in the surface. Each can be a nucleus for com-
plete failure.
Diagnostics Training Manual Page 1 IR30—Bearing Damage & Causes

IR30
Figure 4—Corrosion and Failure

Spalling frequently occurs from corrosion. This
photograph shows an inner ring where failure has
occurred at roller spaced intervals and
had its inception in corroded areas. See Figure 5.
Figure 7—Installation Damage
Bearings are frequently damaged when improperly
handled, particularly during installation. Here are the
inner ring and a roller of a bearing forcibly realigned
after a roller had been radially displaced. Both
flanges are broken and the roller is marked. Refer to
Figure 8.
Figure 5—Corrosion and Failure

The opposite side of the same race shown in Figure
4 is illustrated. The original corrosion pattern which
resulted in the failure is apparent. The corrosion
was due to entrapped moisture while the bearing
was stationary. Figure 8—Installation Damage
Figure 9—Brinelled Raceway

Brinelling of the raceway illustrated was caused by
Figure 6—Corrosion in Storage roller impact. The damage occurred during mounting
This is another example of the corrosion which of the bearing. There is a displacement rather than a
results from storing bearings in a moist atmosphere. loss of metal in brinelling. Raceway This is the
The corrosion takes place underneath the rollers companion outer ring (and a roller) of the inner ring
where moisture is trapped. If this bearing had been of Figure 7. Severe mishandling is necessary to
put in service, it probably would have failed in a cause this damage. Surface brinelling results in a
manner similar to that shown in Figure 4. noisy bearing and such a mark can be the nucleus
for premature failure.
IR30
Figure 10—Damage in Transit

Vibration during shipping can be detrimental to a
bearing and for that reason a new bearing is always
wrapped and placed in a container in such a manner
as to offer the maximum protection against such oc-
currence. This photograph shows scuffed rollers
from a bearing which was installed on a piece of Figure 12—Damage in Transit
equipment and shipped without any provisions made See Figure 10. Shown in this photograph is the
to protect the bearing. The vibration in transit caused damaged raceway surface of the outer ring.
the scuffing. A bearing in this condition is noisy in
operation and early failure can be expected. Figure
12 is of the companion outer ring.
Figure 13—Cross Section Through a Scuff Mark

This photomicrograph (at 250 magnification) shows
the effect of a typical scuff mark on a bearing
surface. Scuffing results when axial sliding motion
is permitted between rings and rollers. Mishandling,
prior to and during installation, is the chief cause.
protective lubricant is usually absent or inadequate
and the pressures and frictional heat, although
instantaneous, are high enough to heat this area
above the hardening temperature. The result is
rehardening (the white areas) which yields a
mixture of austenite and untempered brittle
martensite.
The darker underlying zone is softened, tempered

structure. None of these are desirable for
sustaining load or shock. Thus they serve as nuclei
for early failure of the bearing in service. Many
early failures, often attributed to steel defects, have
their origins in scuff marks.
The black upper part of the photograph is the

bakelite mount which held the specimen.
Figure 11—Installation Damage

This photograph shows a bearing on which the face
of an inner ring was chipped by a blow during instal-
lation. It should be noted that the outer raceway and
rollers were scuffed by the same impact. Such scuffs
are nuclei for failure.
See photo Figure 13.

IR30
Figure 16—Heat Checks

Heat checks occur on the boundary surfaces of a
bearing as a result of relative motion between the
bearing and a contacting part. This usually occurs
when they are either loose-fitted or mounted with
insufficient interference fit. When a bearing ring
creeps, sufficient heat may be generated to develop
cracks on the rubbing surface. These cracks are
Figure 14—Poor Seating on Tapered Shaft normal to the direction of rotation. This photograph
Serious damage can occur to a tapered bore bearing shows heat checks on the O.D. of an outer ring.
which is not seated properly on the shah. An
example of such damage is illustrated. If the shaft
taper is not correct, the inner ring will be improperly
supported and failure can be expected.

See description of Figure 16. These are heat checks
on the bore of an inner ring. If the inner ring
becomes heat checked. it should not be
subsequently mounted with an interference fit, since
heat checks can cause the inner ring to fracture.
Figure 15—Fretting Corrosion

Insufficient interference fit of an inner ring on a shaft
will permit the ring to creep and result in fretting
corrosion. The resulting oxides, being abrasive,
accelerate wear of the shaft and the inner ring bore.
The lapping action of the abrasive also causes wear
in the bearing itself and increases the internal
clearance. This is an example of fretting corrosion in
the bore of an inner ring. Outer ring O.D.’s can be
similarly affected.

See Figure 16. This is an illustration of heat checks
on the face of an inner.

IR30
Figure 19—False Brinelling

While true brinelling is a flow of material due to Figure 21—Lubrication Failure-Inner and Outer
excessive pressure that caused indentation in a part, Rollers
false brinelling, on the other hand, involves an actual These are the companion parts for the outer of
removal of material and is a wear condition. The Figure 21. The roller paths are deeply grooved and
exact cause of false brinelling is not agreed upon by the rollers severely worn to an inverted hour glass
authorities. It is known that relative motion, load and shape. Raceways and rollers usually have a dark
oxygen are prerequisites. Other names for this brown discoloration in this type of failure.
phenomenon are fretting corrosion and friction
oxidation.
Figure 20—False Brinelling

This is another example of false brinelling resulting
from rollers vibrating in the bearing raceways.
Figure 21—Lubrication Failure-Raceway

Here is an example showing an advanced stage of
failure in a spherical roller bearing outer ring
resulting from
inadequate Figure 23—Lubrication Failure-Rollers
lubrication. The This is an example of a less advanced stage of
roller paths are spherical roller bearing failure due to inadequate
deeply grooved. lubrication. The rollers have started to spall on the
The spall pattern is ends in a comparatively fine grained pattern. Note
fine grained that the ends of the rollers start to spall first while the
contrasted to that centers are relatively intact.
of normal fatigue.
(See Figures 33 &
34.)

IR30
Figure 27—Lubrication Failure-Retainer

Bronze retainers are sensitive to inadequate
lubrication and can wear quite rapidly. In this case
Figure 24—Lubrication Failure-Rollers the web portion of the cage which rides on the
This is a close-up view of some of the rollers of center flange of the inner ring has worn to about half
Figure 23 and more clearly shows the spall pattern. its thickness.
Figure 25—Lubrication Failure-Rollers Figure 28—Lubrication Failure-Thrust Contact

This is another example of roller damage due to Surfaces
inadequate lubrication. Note the fine grained spall The cycloidal smear marks on the thrust flange and
pattern. The failure feathers out from the large roller ends are due to the breaking of the oil film at
spalls to the original surface. In the lesser this point. This is the result of inadequate lubrication
distressed areas, the surface has the pulpy and/or overload.
appearance of a peeled apple.
Figure 26—Lubrication Failure-Outer Ring

This photograph shows an outer ring with a
lubrication failure in
an early stage. The
failure is very
shallow and has the
appearance of a thin
surface layer peeled
from the raceway
leaving a roughened
area.

IR30
Figure 30—Abrasive Wear-Outer Ring Cross-

Section
This photograph shows a cross-section of the outer
ring of a self aligning spherical surface, but the
abrasives have worn the paths down to the shape
shown, which is that of the roller contour.
Figure 29—Abrasive Wear-Rings and Rollers

Abrasive wear can be identified by the frosty gray or
lapped appearance of the affected surfaces. Actual
wear is usually most obvious on the O.D. of the inner
ring center flange and on the thrust contact surfaces Figure 31—Abrasive Wear-Inner and Outer Ring
of the rollers. Wear on both of these areas can be The bearing pictured had been in service in a shaker
seen in this illustration. The roller path pattern in the screen. Wear was due to abrasive contamination.
outer raceway is interesting. Each path has the The wavy pattern of the inner raceways resulted
characteristic frosty lapped appearance. The narrow from vibration and is not uncommon in screen
dark band in each path is the original surface of the applications.
raceway.
The retainers of the bearing became charged with

the abrasive contaminant which in turn caused the
rollers to wear at their largest diameter. The rollers
did not contact the outer ring at these zones, leaving
the band of original surface. Continued operation
would of course wear away these zones also. The
same phenomenon occurs on the inner raceways
also but usually is not as pronounced as on the outer
raceways. Figure 32—Abrasive Wear-Roller End
This photograph shows the pattern on roller ends
where abrasive wear had occurred. Two sizes of
rollers are shown. Roller ends are worn to the
contour of the retainer pocket bottom. For
comparison, two new rollers era also pictured.
loading conditions are evident, the load zone arcs
on both roller paths being of equal length.

IR30
Figure 36—Thrust Loading

This illustration is the same type of failure, thrust
loading, as that of Figure 35. However, the thrust
loading was more severe and the roller path has
been displaced to the extent that it has run to the
Figure 33—Fatigue edge of the outer and fractured pieces from the
The normal failure of a bearing is fatigue. Pictured is edge. Failure in both cases resulted from fatigue.
a typical failure on an inner ring. The coarse grained
pattern should be noted in contrast to the pattern of
a lubrication or abrasion failure. Good loading
conditions are evident, the load zone arcs on both
roller paths being of equal length.
Figure 37—Single Spall

The single spall on this inner ring was caused by
Figure 34—Fatigue mechanical damage to the bearing, either in
Note comments on Figure 33. This is a typical handling or in operation; the material, being
fatigue of an outer ring. Again, loading options were overstressed at this point, failed prematurely.
good.
Figure 35—Thrust Loading

This photograph shows the load pattern of an outer
ring loaded in thrust. The spalling on one of the
paths covers a much longer arc than on the other. In
addition, there is an axial displacement of roller
paths in the direction of the thrust load.

IR30
Bearing Failure
Life Expectancy Safety Recommendations

Bearing life expectancy based on material fatigue • Store product in a dry and clean area.
can be calculated if the operating loads and speeds
• Do no open package until ready to use.
are known. These calculations must assume that
the bearing is correctly mounted, lubricated and • Proper installation and maintenance must be
otherwise properly handled. It cannot take into adhered to for ultimate performance.
consideration the effect of adverse operating • Failure to adhere to recommendations may result
conditions. in premature product failure, and/or in extreme
cases, personal injury.
Bearing failures not attributed to material fatigue are
generally classified as premature. The majority of
premature bearing failures are caused by:
• Faulty mounting
• Improper lubrication
• Contamination
• Improper handling
• Improper maintenance
Great savings in time, effort and expense can be

effected if the bearing user can establish the reason
for premature failure and undertake corrective
action to prevent further failure.
With this in mind, this guide has been published to

help maintenance and quality control personnel
identify and correct some of the more commonly
encountered failures. It is beyond the scope of this
guide to discuss the complexities of metallurgical
failure. But the mechanical diagnosis of failure can
be outlined and this publication should serve as a
guide for the determination and correction of such
failures.
There are many reasons for bearing failure, and

usually each failure is due to a combination of
causes, not just a single cause. In the following
pages the major categories of failure will be
covered, photographic examples will be shown,
similar names for each cause will be listed, and
identification, cause and preventive measures for
each category will be discussed. Diagrams and line
drawings are also included to support the written
material. This guide should aid you in cutting
needless expenditures of time and funds in the
maintenance of machinery's most important single
component – the bearing.
Diagnostics Training Manual Page 9 IR30—Bearing Failure

IR30
Fatigue Failure
Fatigue Failure • If a bearing with insufficient internal clearance

Identification (space between rolling elements and races) is
Flaking or Spalling of the normally smooth mounted on a shaft with an excessively heavy
raceway press fit, the bearing will operate with increased
Spalling is caused by a friction and torque — because with the outer ring
granular weakening of the held firmly, the inner ring has been expanded,
bearing steel. The failure pinching” the rolling elements between the two
begins as a small fracture rings.
of the steel’s internal • If the bearing housing is out-of-round, the outer
structure. This fracture ring will tend to conform to the shape of the
progresses (propagates) to housing. This will exert a localized pressure on
the surface of the bearing the rolling element contact area, in addition to
where particles of metal the normal pressure imposed by the operating
flake away. Flaking or Spalling work load.
of Raceway
• When a roller bearing is end loaded (due to
Noisy Running of the Bearing misalignment, shaft slope, etc.) the load on the
Because of the rough surface and the loosened bearing is no longer uniformly distributed over
metal chips there will be an increase in bearing the bearing’s full width. This overloads a portion
vibration and noise. of the races and rolling elements resulting in
localized fatigue.
Cause
Normal Duty Non-Bearing Quality Steel
A bearing has a life expectancy Roller bearings often operate on raceways supplied
which depends upon load and by the customer. Occasionally a raceway is made
speed imposed on the bearing. from a non-bearing quality steel. The raceway will
Calculations, based upon then fatigue spall sooner than another raceway
laboratory testing and field made from a “cleaner” bearing quality steel.
experience, have been
established to determine, as Normal Bearing Preventive Measures
accurately as possible, the life span Operation Normal Duty
of a group of bearings of a given The bearing has lasted its normal life expectancy;
size. Fatigue failure is the result of a bearing living simply replace the bearing.
out its normal life span.
Overload Failure
The flaking of the races is the result of the combined Where overload is the cause of a premature fatigue
effect of load and speed. In any rotating or failure, several alternatives are open:
oscillating bearing there is a constant flexing or
deflection of the ring and the rolling element material • Redesign to permit incorporating a bearing with
under load. Speed determines how often the greater capacity. Many types of standard
deflection occurs while load determines the actual bearings such as needle roller bearings,
amount of stress under which the bearing steel cylindrical roller bearings, spherical bearings,
operates. Assuming good machine design, extra light, light, medium and double row series
satisfactory lubrication and sound maintenance are available to fit the same shaft size. The
practices, it is load and speed that will, over a period heavier series have thicker ring sections and
of time, cause eventual failure. larger rolling elements for greater capacity. Also
available for higher radial capacity is the
Overload on the bearing maximum capacity type of ball bearing,
Premature failure of the bearings cylindrical roller bearing and spherical roller
may result from the bearing being bearing. These bearings have certain similar
either radially or axially loaded bore dimensions, but all can accept more radial
beyond its normal capacity. load — either because there are more rolling
Excessive operating load is not, elements, larger roller elements or larger
however, the only reason for envelope dimensions (certain restrictions will
bearing overload. apply).
Overload may also occur due to • The load may be decreased to prolong the life of
Outer Ring
abusive operating conditions. For Squeezed by the bearing.
example: Housing • Housings should be gaged for out-of-roundness
Diagnostics Training Manual Page 10 IR30—Fatigue Failure

IR30
Fatigue Failure
and machined for proper symmetry and size. This

insures that the outer ring will not be “pinched” or
“squeezed”, resulting in an overload situation.
• If the failure is caused by an overload imposed by
inner ring expansion, either the shaft fit may be
made looser by regrinding it to the proper size or,
in the event of thermal expansion, a bearing with
a looser internal fit (more clearance between
rolling elements and rings) may be
recommended.
• If the failure is caused by end loading, the cause
of the end loading must be corrected.
Non-Bearing Quality Steel

Use steel that is listed as bearing quality for this
particular application. Particularly avoid leaded and
high sulphur content steels.
Manufacturing tolerance
Shaft diameter
for bearing 0.018mm
tolerance 0.011mm
reference:
Housing bore
FJ-1516 bearing Min. initial radial
tolerance 0.021mm
clearance 0.016mm
Min. initial radial

Housing bore
clearance .0005 in.
reference:
J-1616 bearing
Manufacturing tolerance Shaft diameter

for bearing .0009 in.
Manufacturing Tolerances and Built-In Clearances
INTERNAL
CLEARANCE
Bearing with a Looser Internal

Fit May Be Recommended
Diagnostics Training Manual Page 11 IR30—Fatigue Failure

IR30
Contamination
Contamination steel making etc., there will be an abrasive waste or

Identification by-product which infringes on the effective operation
of bearings. This would also apply where coolants,
Debris - Scoring, washing solutions, acids or other liquids are used
Pitting, Scratching around a bearing application.
A failure caused by the
entrance of foreign Moisture, Water
objects into the When water enters a bearing it can react with the
bearing may show a
lubricant or its additives (particularly EP additives)
number of identifying
marks. Where large Examples of Scoring, Pitting and form acids and other corrosive chemical
particles of dirt or dust and Scratching compounds which attack the bearing surfaces. The
are present there will most significant moisture damage occurs when the
be scratches and pits around the periphery of the race bearing is stationary because of the minimal lube
with corresponding scoring of the rolling elements. Where film in the roller element’s contact zones which leads
the contamination is in the form of very fine abrasives to etching at point of contact. The water which
such as glass powder, graphite or dust impregnated entered the bearing could come from direct
lubricants, the impurities will act as a lapping agent, compromise of bearing or housing seals or from
altering the appearance of rolling elements and raceway.
condensation due to environmental conditions.
This type of failure may be characterized by intermittent
noise
in the bearing. The actual presence of dirt in the bearing Preventative Measures
is the indication of this type of failure. Avoid Damage from Abrasive Waste Product
Where a manufacturing process involves an
Rust
abrasive by-product, it is essential that the bearing
Where rust forms on the O.D. of the outer ring, it will not
usually interfere with the bearing’s performance in be properly sealed. Where failures of this kind
standard application, but rust in the bore is more serious prevail, a more efficient seal is required. In
because of the importance of inner ring-to-shaft fit. Rust in applications where extreme contamination exists, a
the raceways or on the roller elements precludes any sealed housing or shroud may be incorporated into
further use of the bearings. the design to protect the bearing.
Moisture - Etching, Staining Clean Work Surroundings

If moisture is allowed to enter a bearing it can damage the Careful control of your area, tools, and clean dry
bearing in several different ways. The internal surfaces
hands are extremely important to prevent bearing
may become corroded or etched. A stationary bearing
exposed to moisture will probably show individual staining failure. The following is a list of procedures outlined
on the race in locations of contact between rolling by the American Bearing Manufacturers Association
elements and raceway; or random spots of corrosion on (ABMA) for the control of cleanliness in handling
exposed surfaces. Either pattern of corrosion deters bearings:
proper bearing performance and results in excessive • Work with clean tools in clean surroundings.
noise, clearance, or the corroded zones may fatigue
prematurely. • Remove all outside dirt from housing before
exposing bearings.
Cause • Handle with clean, dry hands.
Debris or Dirty Surroundings • Treat a used bearing as carefully as a new one.
Most bearing failures may be traced to some sort of • Use clean solvents and flushing oils.
contamination. Dirty working conditions are one of • Lay bearing out on clean paper and cover.
the bearing user’s greatest problems. Thousands of
dollars each year may be saved simply by taking • Protect disassembled bearings from dirt and
certain precautions against the entrance of moisture.
impurities into the bearings. Internal clearance in • Use clean, lint-free rags if wiping bearings.
precision bearings is measured in the ten- • Keep bearings wrapped in oil-proof paper when
thousandths (.0001) of an inch. Most dirt and not in use.
particles are larger than one-thousandth (.001) of an
• Clean inside of housing before replacing
inch, so hard particles will indent the race and the
bearings.
roller element surfaces when the bearing rotates.
• Install new bearings as removed from packages.
Abrasive Waste Materials • Keep bearing lubricants clean when applying and
In most applications such as; paper making, metal cover containers when not in use.
working, food processing,
Diagnostics Training Manual Page 12 IR30—Contamination

IR30
Contamination
Moisture Entry
Consult a Sales Engineer for the optimum seal
configuration for your application. External seals
may be required on a specific case basis. When the
entry of moisture cannot be prevented, regular
Re-lubrication is necessary to purge the
contaminated grease from the bearing and replace it
with fresh grease.
PLYA Seal
“R” Seal
Tri-Ply Seal
Needle Bearing Seal
Sealed Pillow Block Housed Roller Bearing
Diagnostics Training Manual Page 13 IR30—Contamination

IR30
Brinelling
Brinelling Cause
Identification Force incorrectly exerted - Ball Bearings
Indentations high on the race shoulder are caused in
Mounting indentations (thrust force) - Ball mounting (or dismounting) where force is applied against
Bearings the unmounted ring. When mounting a bearing on a shaft
This failure will appear with a very close fit, pushing of the outer ring will exert an
as tiny indentations excessive thrust load bringing the rolling elements into
(sometimes barely sharp contact with the race shoulder, causing brinell.
discernable to the
naked eye) high on the Radial shock load - Ball and Roller Bearings
shoulder of the race. Radial indentations are caused by a shock load or static
overload imposed radially on a non-rotating bearing. This
The dents will be may be imposed by hitting the bearing with a hammer or
angularly spaced in by an operating shock load exerted on a static shaft.
correspondence to the
rolling element spacing.
There will be a
corresponding
indentation of lesser
magnitude on each
rolling element. When
the bearing is radially Example of Mounting
loaded the brinells on the Indentation
race shoulder may not
interfere with the roller tracks. In this event, the dent
on the rolling
element will cause the failure. In the later stages of
failure, spalling or chipping may result. The race
shoulders can be inspected (with a microscope
if available) to see if a spalling pattern may have Incorrect Arbor Press Dismounting
resulted from initial brinelling. The term brinell
comes from the mark on the bearing looking like the
mark left from a brinell hardness testing machine. Preventative Measures
Proper Mounting Procedure
Radial Indentations (radial force) - Ball Bearings In mounting a bearing, force should always be exerted
The indentations have the same general against the ring being mounted. In other words, when
appearance as mounting indentations except that mounting the bearing on a shaft, the pressure should be
they appear in the center of the race instead of on applied against the inner ring. When mounting in a
the shoulder. This type of brinell is less common housing, press against the outer ring. The ring having the
than the mounting brinell because, under the sharp tighter fit (usually the ring which will rotate in application)
should be pressed.
impact of radial shock load, the rings may fracture
beneath the force. Be sure when mounting a bearing to apply the mounting
pressure slowly and
Radial Indentations (radial force) - Roller evenly.
Bearings
In a uniformly loaded (no shaft slope or end load) Operation
roller bearing indentations appear as even, full Identify source of
contact lines the length and shape of roller. When overload on bearings
an end load is present the marks will deepen at the and eliminate. It must
be determined first if it is
end and the mark may not extend for the full length
shock loading (dynamic
of the roller. As with all true brinell marks the loading) or static
surface manufacturing marks are visible in the overload.
indentations.
Proper Mounting Procedure
Diagnostics Training Manual Page 14 IR30—Brinelling

IR30
False Brinelling
False Brinelling Small Angular Oscillation

When a bearing does not rotate
Identification through a large enough angle,
Axial Indentations – so one rolling element can
Ball Bearings reach the previous resting point
This type of brinelling of the adjacent rolling element.
will appear as elliptical Over time, this results in a
impressions which run depletion of lubricant from the
axially across the contact zone, and failure
races. There will be a proceeds as outlined above in:
build-up of reddish “Vibration in a Static Bearing.”
Oscillatory Vibration
lubricant around each Causes of False Brinelling
brinell. Also, the
brinells will be spaced Examples of Axial Indentations Preventative Measures
with the corresponding roller element. Vibration:
Correct the Source of Vibration
Circumferential Indentations – Ball Bearings The source of agitation-loose parts, non-precision
This will appear exactly as the brinelling above, except machinery, rough transportation, should be corrected so
that the impression will be wider in a circumferential that vibration is avoided.
direction.
Locking the Bearing
Roller Indentations – Roller Bearings When transporting bearings, apply a light thrust load
In a roller bearing, false brinell impressions look similar to (imposed by springs or rubber pads) to bring all of the
the ‘true’ brinells produced by overload or shock load. rolling elements into contact with the races.
They appear as roller shaped indentations in the raceway.
However, careful examination will reveal the original All Surfaces Adequately Lubricated
surface manufacturing marks have been worn away in the Where bearings are oil lubricated and employed in units
false brinell indentation. This indicates the impression that may not be in service for extended periods of time,
was formed through attrition. the equipment should be set in motion periodically to
spread the lubricant over all bearing surfaces. Intervals of
Cause one to three months should suffice.
Vibration in a Static Bearing Tighten Internal Fits
False Brinelling is caused by the Sometimes a bearing with line-to-line contact between
vibration of the rolling elements rings and roller elements will alleviate a false brinell
between the races (or themselves failure. Great care should be taken, however, that a tight
in a full complement bearing) in a internal fit is satisfactory from an operations point of view.
stationary bearing. This vibration
may be axial or circumferential. Low Viscosity Lubricant
The appearance of the brinells will False brinelling is more common when stiffer lubricants
tell you which. As the roller are used. This failure is less apt to occur where oil or a
element light viscosity grease is used, because the liquid
vibrates between the races, the characteristics make it difficult for the lubrication to be
lubricant is forced out of the Axial Vibration forced out of the control area.
contact area between roller and
race. The failure is the result of a breakdown of the
lubricant causing metal-to-metal contact and localized
Oscillation:
wear of rollers and races. The wearing action causes the Increase the Angle of Rotation
formation of a fine reddish-brown powder (iron oxide). The When possible, the application should be altered to
oxide impregnates the increase the angle of bearing rotation, thus redirecting
lubricant and provides an abrasive compound that will forces causing oscillation.
polish (lap) the rollers and races if the bearing is put into
operation. The indentations themselves will result in a All Surfaces Adequately Lubricated
rough and noisy operating bearing. Vibrations in a bearing Bearings which are oil lubricated need a sufficient flow of
may be caused by a number of factors which result in oil to force wear debris away from the roller contact zone.
false brinelling. Two common causes of this failure occur: When grease is used - regular relubrication is required to
purge contaminated grease from bearing.
• n when mounted, but unlocked bearings are
transported. Select Different Bearing Type
• n when the bearings in a non-operating machine Depending on application, machinery, and environment, a
are subjected to the static vibration by other different type bearing may be less susceptible to false
brinelling.
machinery operating in the area.
Diagnostics Training Manual Page 15 IR30—False Brinelling

IR30
Thrust Failure
Thrust Failure Preventative Measures

Identification Maximum Capacity Failure
Maximum Capacity A more suitable Conrad or angular contact type
Bearings with filling slots are not bearing must be selected if high or predominate
recommended for heavy thrust thrust capacity is required. Obviously, the maximum
loading because, as the balls pass capacity failure was caused by using a bearing
over the inner ring and outer ring using a bearing designed for heavy radial, or
notches, they may become nicked combined radial thrust loads; not for pure thrust
or dented. This in turn may loading. It is recommended that no more than 60
cause spalling of the races percent of the accompanying radial load on the
(probably in the vicinity of bearing be applied in thrust.
the loading slot).
Counterbore Failure
Counterbored Bearing The remedy here is to mount the bearing correctly
There will be a breakdown of so that the balls have full shoulder support on both
the counterbored shoulder of the inner and outer rings. Remember that the outer
the bearing which may result Examples of Thrust Failure ring counterbore bearing will take thrust against the
in the fracture of the ring. inner ring on the counterbored side of the bearing,
The balls will be banded from riding up against the and the outer ring on the side opposite the
shallow shoulder. Also the bearing may become counterbore. The word THRUST will be stamped on
disassembled during service. the outer ring face showing the proper thrust
surface.
Cause
Improper Mounting or Misapplication as
Indicated
Maximum Capacity Failure
This failure results from excessive thrust loads on a
bearing not primarily intended for heavy thrust The Word “Thrust” Stamped Here
loads. The arrows in the diagram indicate that too
much thrust load from either direction will cause
interference between the rolling elements, and one
of the loading slots which are ground in both the
inner and outer rings.
Counterbore Failure
A thrust failure is caused either by mounting the
bearing backwards (so that the load is carried
against the shallow shoulder) or by putting a
counterbored bring into a
bi-directional thrust
application.
Proper Thrust Direction
Incorrect Thrust Direction
Diagnostics Training Manual Page 16 IR30—Thrust Failure

IR30
Misalignment
Misalignment Shaft Bowing

Shaft bowing may be caused by the following:
Identification • As a result of improper handling
Ball or Roller Path
• Overhung load exceeding shaft capacity.
In a bearing with one
side misaligned in • Initial shaft bowing due to
relation to the other, the grinding inaccuracies.
ball or roller path will run • Shaft shoulders ground out-of-
from one side of the race square with the shaft centerline
to the other around one- which will, by cocking the inner
half of the circumference ring, force a bowing of the shaft.
on the non-rotating ring.
The rotating Shaft Misalignment
ring will have a wide
roller path. Because of Examples of Bearings with
the extra pressure Misaligned Rings
imposed on the bearing
due to misaligned conditions, an excessively high
temperature may develop which will discolor the
raceways and the rolling elements while destroying
the lubricant.
Shaft Bowing
Retainer Housing
The purpose of the retainer is to space the rolling Misalignment
elements and to guide them in a true path around
the raceway. Where a ring is misaligned, the rollers Preventative Measures
are driven up against the race shoulder and a Housing
stress point is established between the roller and its The remedy is to dimensionally check and insure
retainer pocket. The pocket will flex, increasing the that both the housing bores are true to each other.
possibility of retainer fracture in the advanced
stages of stress. Shaft
The shaft should be gauged to make sure that is
Cause concentric and straight. Heavy overhang loads
Shaft Misalignment should be lightened or moved closer to the bearing.
Misalignment of the shaft in relationship If the shoulders are out-of-
to the housing causes an overload of the square; they should be
balls or rollers which will result in the reground and gauged so
failure described. that they are perpendicular
Roller Path to both the bearing seat
Housing Misalignment and the shaft centerline.
Housing misalignment may be caused
either by the housing being cocked in relation to the
plane of the shaft or the housing shoulder being
ground out-of-square so that it forces the outer ring
to cock in relation to the inner. It may also Squaring-Up Shaft
be caused by the settling of housing frames Shoulders
or foundations.
Examples of Ball Path Running Both Housing Bores Must Be

from One Side of the Race to the True to Each Other
Other Side
Diagnostics Training Manual Page 17 IR30—Misalignment

IR30
Electric Arcing
Electric Arcing Electric Leakage

Faulty wiring, inadequate or defective insulation, or
Identification loose rotor windings on an electric motor are all
Electric Arc possible sources of
Erosion current leakage.
Arcing, which Either AC or DC
produces high currents will damage
temperatures at bearings.
localized points,
results when an Short Circuit
electric current Wires which are
passing through a Electro-etching on Both Inner and crossed or contacted
bearing is broken Outer Ring by a common
at the contact conductor will cause a
surfaces between races and rolling elements. Each short circuit and may result in a The Current Path
time the current is broken in its passage between passage of current through the bearing.
the ball or roller and race, a pit is produced on both
parts. Eventually the phenomenon known as fluting
develops, (see photograph). As it becomes deeper, Preventative Measures
noise and vibration result. Shunts and Slip Rings
Where there is a passage of current through a
Granular Race Surfaces bearing and the source of the current cannot be
If the current is of higher amperage intensity such as corrected, a shunt in the form of a slip ring
a partial short circuit, the next phase of the failure assembly may be incorporated to by-pass the
will show up as a rough granular appearance in the current around the bearing.
ball track.
Corrective Maintenance
Pitting or Cratering Be sure wiring, insulation, or rotor windings are
Heavy jolts of high amperage charges will cause a sound and all connections are properly made. In arc
more severe failure resulting in the welding of metal welding, great care should be taken that the welding
from the race to the ball or roller. These protrusions apparatus is not grounded on something that will
of metal on the roller will, in turn, cause a cratering circulate the current through the bearings.
effect in the race. This phenomenon will result in
noise and vibration in the bearing. Grounding Belts
To eliminate static charges, ground the belt, or
change the belting to a less generative material.
Insulating Bearings
Sleeves of nonconductive material may be used
either between the outer ring and housing or
between inner ring and shaft, depending upon the
source of current.
Magnification of Magnification of Conductive Grease

Electric Pitting Granular Race Surface Utilizing an electrically conductive grease will
provide a path for the current to minimize or cease
damage to your bearings. Consult your lubricant
supplier for availability.
Cause
Static Electricity
Static electricity usually emanates from charged
belts or from manufacturing processes using
calendar rolls (leather, rubber, cloth, paper). The
current is carried from the belt to the pulley or
sheave — from the sheave to the shaft — through
the shaft to the bearing — and from the bearing to
the ground.
Diagnostics Training Manual Page 18 IR30—Electric Arcing

IR30
Electric Arcing
COPPER
SLEEVE
CARBON
STICK
HOUSING SHAFT
GROUND GROUND
Use Sleeves of Non-Conductive Material

Either Between the Outer Ring and Housing,
or Inner Ring and Shaft
STATIC ELIMINATOR
Ground Belts to Eliminate Static Charges
Diagnostics Training Manual Page 19 IR30—Electric Arcing

IR30
Lubrication Failure
Lubrication Failure the friction heat developed within the lubricant will
cause its own rapid deterioration.
Identification
Grease Appearance Inadequate Lubrication
If the grease is stiff or caked and changed in color, it Heat will result from under-lubrication, also. Where
indicates lubrication failure. The original color will there is inadequate lubricant to cover all metal
usually turn to a dark shade or jet black. The grease surfaces, friction will result in heat-up of the bearing.
will have an odor of burnt petroleum oil. Lubricity will
be lost as a result of lack of oil. In cases of Lithium Wrong Kind of Lubricant
base greases, the residue appears like a glossy, Selection of the correct lubricant is very important in
brittle varnish which will shatter when probed with a achieving maximum efficiency and endurance from
sharp instrument. the bearing application. After experimentation with
many types of lubricants, the equipment
Abnormal Temperature Rise manufacturer recommends those which he feels
Probably the first indication of lubricant failure is a will provide ideal lubrication life under given
rapid rise from the normal operating temperature. operation conditions. Insofar as availability allows,
Test by hand is not necessarily conclusive since you should use the same lubricant or its equal. Thus
normal operating temperature may exceed the you are assured of using the correct lubricant, in
bearable limit of roughly 120°F. addition to avoiding the problems associated with
mixing two types of grease.
Noise
Lack of lubrication is soon accompanied by a Many greases are incompatible and, although
whistling noise coupled with the rise in temperature. completely adequate when used individually,
If not corrected, the bearing temperature will may prove unsatisfactory when mixed.
continue to rise and the intense heating will reduce
the bearing hardness. Other Failure Modes
The primary cause of lubricant failure is from the
Bearing Discoloration high temperatures developed when excessive loads
A brownish or bluish discoloration of the races and overpower the lubricant film. In many instances
rolling elements indicates that the bearing operating lubricant failure will accompany the bearing failures
temperature was excessively high to the extent that described in this manual. Lubricant changes might
the bearing lost its physical properties and was no reduce the failure rate but the proper cause of action
longer operable. The bearing part that first indicates is to eliminate the primary cause for the lubricant
distress in lubrication failures is usually the retainer breakdown.
where the greatest amount of rubbing action takes
place. Inadequate Viscosity of Lubricant
The viscosity of the lubricant was inadequate to
Inadequate Viscosity of Lubricant properly separate the bearing surfaces.
The surface of the bearing has lost its as-
manufactured appearance and now has a frosted
appearance. When examined under a microscope
you will see that the surface has roughened and
appears granular. Under some conditions the
granular appearance is visible even without using a
microscope. Occasionally some areas of the bearing
will be highly polished.
Cause
Dirty Lubricants
Contaminants found in lubricants often act as an
abrasive compound which will lap or polish roller
and race surfaces, increasing the probability of early
failure.
Too Much Lubricant

A very common error in the maintenance of
machinery is the tendency to over-lubricate. If the
bearing reservoir is kept constantly full of grease,
Diagnostics Training Manual Page 20 IR30—Lubricating Failure

IR30
Lubrication Failure
Preventative Measures
Avoiding Dirty Lubricant
Always keep grease containers covered. Dust
particles in the air can contaminate the lubricant.
Use a clean, rust-resistant spatula for relubricating
open bearings. When relubricating bearings through
a grease fitting, always wipe off both the fitting and
nozzle of the grease gun. Any steps which you can
take to keep lubricants clean will pay off in longer
bearing life.
Amount of Lubricant
In standard applications, it is generally
recommended that the bearing should be greased
one-third to
one half full.
Inadequate Viscosity of Lubricant

Select a lubricant with sufficient viscosity to properly
separate the rolling contact surfaces. Typically, we
recommend a lubricant with a viscosity of at least
100 SUS (20 cSt) at the bearing operating
temperature. If an application’s lubricant does not
meet the bearing’s viscosity requirements and a
lubricant with a greater viscosity cannot be
substituted, improved cooling of the current lubricant
may lower its operating temperature (and thus
increase its viscosity) enough to obtain acceptable
bearing life. Similarly, improving the surface finish on
customer supplied races may allow the current
lubricant to separate the rolling contact surfaces.
Lubrication Failures in Ball

Bearings Are Usually Accompanied
by a Thermal Expansion of the
Components
Diagnostics Training Manual Page 21 IR30—Lubricating Failure

IR30
Miscellaneous Failures
Miscellaneous Failures Roll Out (Sub Case Yielding, Case Crushing)

Cam Failure – Wide Inner Ring Ball Drawn Cup Bearings, or other case hardened
races
Bearings
Identification: Identification:
Broken cam, misaligned travel path, bearing will wobble. Circumferential cracks in the load zone.
Cause:
Cause:
Undersize shaft, outer ring unable to align due to housing.
Overload
Preventive Measures:
When a bearing is grossly overloaded, the stress is driven
Correct the shaft size, use the Fafnir self-aligning feature
deep into the race. If it is a case hardened race, the stress
– a spherical outer ring to compensate for initial
may then exceed the strength of the relatively soft core.
misalignment and correctly mount bearings. The proper
When this happens the race’s core will plastically deform
mounting procedure is to:
in the axial direction. (It is constrained in the radial
• Align the bearing in its housing and slide unit into direction by the housing.) As the core expands axially, it
position on the shaft carries the case with it causing the case to fracture
• Bolt the housing tightly to its mounting support circumferentially.
• Engage and tighten locking collar and setscrew. Attrition

It a case hardened race is subjected to severe wear, the
case can wear away. The stress from a normally loaded
bearing then will reach the core, and cause roll out as
described above.
Overload
Eliminate the source of the overload or change to a
bearing with greater capacity.
Attrition
Correct the cause of the wear.
Shaft Below Suggested Misaligned Outer
Tolerance Levels Ring
Diagnostics Training Manual Page 22 IR30—Miscellaneous Failures

IR30
Miscellaneous Failures
Preventative Measures
Identification:
Rollers locked in place,
large smeared flat on
many rollers and
severely discolored
(black, blue) bearing
components.
Cause:
The pilot in the
installation tool used to
install the full
complement bearing did not have a
functional ball detent. In shipping, a
full complement bearing’s rollers often
settle into a slightly skewed position. If
the bearing’s rollers are not aligned
prior to pressing the bearing into the
housing, the rollers will lock in place
at installation. The shaft then skids on
the locked rollers resulting in smeared
flats.
Install/replace ball detent on pilot portion of installation
tool.
Identification:
Bearing’s lip fractured off.
Cause:
The installation tool used to install the bearing is lacking Α 1/64" (0-4 mm) less than housing bore
the required 15° backangle. Β .003" (0.06 mm) less than shaft diameter
Without the 15° backangle the installation force is directed Χ distance bearing will he inset into housing; mini-
through the lip of the cup and will fracture it. Often the lip mum of .008" (0.2 mm)
is only cracked at installation and then breaks free in ∆ pilot length should be length of bearing less
service. When a 15° backangle is used, the installation 1/32" (0.5 mm)
force is directed through the cup’s wall, eliminating the
possibility of fracturing the cup’s lip.
Fabricate an installation tool with a 15° backangle.
Stamped end of bearing
Generous chamfer or rounding

for easy bearing installation
Tool with 15° Backangle, for Drawn Cup Bearing

Installation
Diagnostics Training Manual Page 23 IR30—Miscellaneous Failures

IR30
Terminology
Service Damage Terminology nuclei for a complete fracture.

Abrasive Wear
Indentations
Surface wear resulting from the lapping action of
The surface depressions caused by debris or foreign
abrasive contaminants. The affected areas usually
material.
appear frosty gray; however, they may be highly
polished if the abrasive particles are extremely
Pickup
small.
The welding and transfer of metal between rollers
and raceways during bearing operation. Pickup re-
Brinelling
sults from inadequate lubrication.
Permanent deformation of the bearing surfaces
where the rollers (or balls) contact the races. Brinel-
Pitting
ling results from excessive load or impact on station-
Small, roughly circular holes or craters resulting from
ary bearings. It is a form of mechanical damage in
corrosion, mechanical damage, or the passage of an
which metal is displaced or upset
electric current. Because these three types of pits
without attrition.
have distinctly different causes, the word pitting
should always be qualified.
Corrosion
Rust (corrosion) is the chemical attack of the bear-
Scoring, Scuffing, Seizing, Smearing
ing metal, almost always consisting of, or accompa-
All terms referring to transfer of metal from one com-
nied by, oxidation. It may cover a large or a small
ponent of a bearing to another under sliding contact.
area, or be limited to a well defined
This process, which is also called galling, is caused
line, such as the line of contact between a roller and
by lack of adequate lubrication under extreme unit
a race in a stationary bearing.
pressure.
False Brinelling
Spalling
False Brinelling of needle roller bearings is actually
A breaking away of metal from the raceway or rolling
a fretting corrosion of their raceway surface. Al-
element in flakes or scale-like particles. Also called
though its appearance is similar to that of Brinelling,
flaking.
False Brinelling is characterized by attrition of the
steel, and the load on the bearing is
less than that required to produce the resulting im- Bearing Failure Terminology (Cross References)
pression. It is the result of a combination of me- Fatigue
chanical and chemical action that is not completely • Flaking
• Macro Spalling
understood, and occurs when a
• Spalling
small relative motion or vibration is accompanied by • Rolling Contact
some loading, in the presence of oxygen. • Pitting
• Fatigue
Flaking • Peeling
See Spalling. • Surface Erosion
• Microcracking
Fretting, Fretting Corrosion, Friction Oxidation • Inclusion Origin Fatigue
These terms all describe a type of service damage • Subsurface Fatigue
that occurs under the same conditions as False
Brinelling
Brinelling. Red and black oxides of iron are usually • Denting
evident. In bearings, fretting usually takes place at • Impact Denting
the I.D. or O.D., but it may occur anywhere there is • Indentation
a close fit with some movement. • True Brinelling
Galling Misalignment
See Scoring. • Skewed
• Non-Tangent
• Cocked
Heat Checks
• Non-Square
Surface cracks resulting from heat generated by • Warped
sliding contact with another part. Heat checks are • Out-of-Round
oriented normal to the direction of motion. Depend- • Tilted
ing on the stresses present in the • Shaft-Slope
component, the cracks may remain small or become • Shaft-deflection
Diagnostics Training Manual Page 24 IR30—Terminology

IR30
Terminology
Electric Arcing Contamination–Moisture/Water

• Fluting • Corrosion
• Corrugation • Water Etch
• Corduroying • Staining
• Electric Pitting • Black Acid Etch
• Electro-etching • Rusting/Oxidation
• Electric Discharge Damage
• Electric Erosion
• Electric Arc Pitting
Contamination–Debris
• Pitting
• Debris Damage
• Bruising
• Roughening
• Denting
• Scratching
• Scoring
• Rollover of
• Glazing Debris
• Indentation
• Abrasion Failure
Thrust Failure
• Counterbore Failure
• Axial Failure
Lubrication Failure
General
• Peeling
• Seizure
• Smearing
• Pitting
• Fine Grain Spalling
• Microadhesion
• Surface Erosion
Inadequate Viscosity
• Glazing
• Frosting
• Fine Grain Spalling
• Surface Erosion
• Surface Peeling
• Point Surface Origin
• (PSO) Fatigue
Incorrect Amount of Lubrication

• Burn-Up
• Coking
• Churning Failure
• Heat Failure
False Brinelling
• Fretting Wear
• Friction Oxidation
• Vibration Damage
• Fretting Corrosion
• Vibration Brinnel
• Internal Fretting
• Fluting
Diagnostics Training Manual Page 25 IR30—Terminology


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Diagnostics Training Manual

SPM, Vibration Measurement and

The IR30 Sentinel

Diagnostics Training Manual Page 1 SPM and IR30

IR30 - Description and Function Buttons

Communication for COM

Set Key Enter Key

Up Arrow Key Right Arrow Key

Left Arrow Key Down Arrow Key

Input Connector SPM Input Connector Vibration

Input Connector Software

Diagnostics Training Manual Page 2 SPM and IR30

What is SPM (Shock Pulse Monitoring)?

There are 3 terms used in SPM. These are

Diagnostics Training Manual Page 3 SPM and IR30

2. Pulse magnitude is measured,

Diagnostics Training Manual Page 4 SPM and IR30

A high dBm and a

The IR30 indicates “bad

dBi is calculated using the inside diameter of the

We try to use bearing

IR30 - SPM measurement using stud clip on probe.

Diagnostics Training Manual Page 6 SPM and IR30

General Rules SPM in summary

dBm/dBc values are indicators of bearing condition

Rule 6 Ingersoll Rand units have a number of bearings

Diagnostics Training Manual Page 7 SPM and IR30

Thus, bad bearing condition can be shown by a

The fact that the service life of bearings is mainly

Very large sums can be saved if bearing life can be

The IR30 displays a value called dBc (decibel

Diagnostics Training Manual Page 8 SPM and IR30

Vibration Severity Measurement

• Vibration severity is defined as RMS (Root

Diagnostics Training Manual Page 9 SPM and IR30

Decision making is based on the data acquired. This

Each measuring point can be pre-determined and

1 From the Condmaster 2 to the IR30 3 and data is acquired from

then downloaded from

Manual recording of data can also be done on

Normally, data is taken monthly for the first three

Diagnostics Training Manual Page 10 SPM and IR30

Decision Making Process

Diagnostics Training Manual Page 11 SPM and IR30

Data Management with Condmaster Pro

Work schedules for any desired time span can be

The user can store bearing data, measuring

Diagnostics Training Manual Page 12 SPM and IR30

Using the IR 30, he established that the vibration

This air end would have

The IR30 helped the Air Center to bring in

Over a 6 month period, Guangzhou Air Center,

IR 30 is playing a key role in closing deals for

For example, one customer

SPM checks established that the dBM was at it’s

Diagnostics Training Manual Page 13 SPM and IR30

1 The basic principle of Shock Pulse Method is:

2 What does the abbreviated term dBi stand for?

3 What does the abbreviated term dBm stand for?

4 What does the abbreviated term dBc stand for?

6 What two types of machinery condition monitoring can be performed by IR30?

8 Why do sudden changes in dBC/dBM values need to be especially noted?

Diagnostics Training Manual Page 14 SPM and IR30