Analysis of Mechanical Vibrations: With SIPLUS CMS1200 - SM 1281

Theoretical Practical
basics examples
Analysis of mechanical
vibrations
with SIPLUS CMS1200 – SM 1281
Unrestricted © Siemens AG 2018 siemens.com/siplus-cms
Unrestricted © Siemens AG 2018

Basics
What are vibrations?
A body is deemed to be vibrating when it moves to and fro relative to a reference position.
The number of movements per time unit is referred to as the frequency and is measured in Hertz (Hz) – vibrations per second.
Motion that takes the form of a pure sine wave can be ascribed to a particular frequency.
Example: Amplitude/time diagram for a tuning fork

Time
In practice, movements comprise several components with different, simultaneous frequencies.
Example: Motion of a piston Example: Gear unit
Time Time

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Basics
Vibrations – Quantitative description
A vibration variable - acceleration (a), velocity (v) and distance (s) - can
be quantitatively defined in different ways.
peak The peak-to-peak value is the maximum value from the negative to the
positive peak.
value
RMS
value The peak value is the value of a half-wave from zero to the maximum.
In the case of a non-periodic variable, the peak value is also known as
peak-to- the maximum value ( v̂ ).
peak
The RMS (root mean square) is the squared mean value of a variable
that changes over time (oscillation). It takes into account the time curve
of a vibration as well as the energy content and is the most important
measurement for vibration analysis.
General designation of rms value of the vibration velocity in

SM 1281: vRMS
General designation of rms value of the vibration acceleration in
SM 1281: aRMS
General designation of peak-to-peak value of vibration acceleration in
One period of vibration
SM1281: aPEAK
Note:
aPEAK is only visualized, NOT monitored

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Basics
Vibrations – Measured values
Vibrations are normally recorded with the following measured values:
Subjective
Vibration variable Unit Vibration Frequency range
perception
Vibration displacement µm Shaft vibrations 1Hz to 0,4kHz
Vibration velocity mm/s Housing vibrations 2/10Hz to 1kHz
Vibration acceleration m/s² Gear/acoustic emission 2/10Hz to 20kHz
The frequency limit of human sensitivity is approximately 300Hz.
For vibration measurement normally acceleration sensors are used.

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Basics
When measuring vibration, the vibration acceleration itself does not have to be used as the parameter.
The acceleration signal can be transformed into velocity and displacement by mathematical integration.
Ideal mass-spring
system s
Vibration displacement s s =  vdt
t
v
Vibration velocity v v =  adt
90°phase-shifted to s
t
smax
a
Vibration acceleration a
90° phase-shifted to v
t 180° phase-shifted to s

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Basics
The three variables vibration displacement, vibration velocity and vibration acceleration have a fixed relationship to each
other and can be converted for sinusoidal vibrations as follows:
Vibration displacement Vibration velocity Vibration acceleration

Conversion
s [µm] v [mm/s] a [m/s2]
v a
Vibration displacement s 1 s= ω s= ω2
a
Vibration velocity v v=s*ω 1 v= ω
Vibration acceleration a a = s * ω2 a=v*ω 1
a = Vibration acceleration [m/s2]

f = Frequency [Hz]
n = Speed [rpm]
s = Vibration displacement [µm]
v = Vibration velocity [mm/s]
ω = Angular frequency [1/s] w = 2p * f = 2p * n
60
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Basics
The measurement of vibrations is normally done with acceleration sensors.

For the practical analysis the acceleration signal can be also transformed into velocity or displacement
ds d ²s
Where: v = ; a =
dt dt²
or: s =  v dt =  a dt²
v v a a
For harmonic vibrations: s= = = =
2 *p * f w (2 * p * f)² w²
For each integration, the signal is divided by ω = 2 * π * f ➔ the acceleration signal is highest at higher frequencies

Page 7
Basics
Example calculations
For an electric motor (mains operation) with the name plate data: A test stand for testing materials generates sinusoidal vibration
U 400V displacements with an amplitude of 500µm and a constant
I 40A frequency of 50Hz.
n 1492rpm
With ongoing rotation frequency a rms vibration velocity of
v = 1,8mm/s is measured.
What is the vibration displacement? What is the vibration acceleration that arises?
v1,8mm  s -1
s= = = 11,5µm
2
 1
w 2p 1492  s −1 a = s  w = 500µm   2p  50  = 49,3m / s ²
2
60  s

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Basics
Vibrations - Description
It is not possible to read off the frequencies that are present and their amplitudes from an amplitude-time diagram directly. In practice,
therefore, they are better described on a scale of frequency. The amplitudes are plotted in this case against frequency
➔ Frequency spectrum.
Splitting the vibration signals into individual frequency components forms the basis for the analytical diagnostic procedures.
Vibration variable Vibration variable Vibration variable Vibration variable
Time Frequency Time Frequency
Example: Description of periodic vibrations on a time scale and frequency scale

Page 9
Basics
Analytical diagnostic procedure - Overview
Time signal Frequency spectrum
The Fourier transform (FT) describes the mathematical relationship between time and frequency.
In the case of vibration, the time curve is available for a vibration variable.
According to Fourier, the time curve is composed of overlaid sinusoidal and cosinusoidal vibrations (infinite sequence of sine and cosine
terms).
A fast method is the so-called Fast Fourier Transform (FFT).

In place of n² (n: number of measured values) in the Fourier transform, 2n multiplications are used in the FFT.
FFT analyzers are standard today in vibration analysis.
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Basics
Legend:
The typical rotation frequency excitations lie within the frequency
Vibration displacement range of 2 or 10 to 1000Hz.
Vibration velocity
Vibration acceleration These are the most common frequency components of a measured
Amplitude of vibration variable
vibration.
Preferable Preferable evaluation
evaluation of of vibration This type of evaluation (rms value of vibration velocity) has also
vibration velocity acceleration been included in the standards:
ISO 20816-1
Mechanical vibration – Measurement and evaluation of machine
vibration, Part 1: General guidelines
It was established that in most cases the vibration velocity is
sufficient to describe the strength of vibration in a wide range of
operation speed of a machine.
time

Page 11
Basics
Legend:
Frequency spectra are normally evaluated using the velocity or
Vibration displacement acceleration as the parameter.
Vibration velocity
Vibration acceleration Standard classifications:
Amplitude of vibration variable
Spectrum vibration velocity

Preferable Preferable evaluation in the frequency range from 2 / 10 to 1000Hz (low-frequency
evaluation of of vibration vibration); designation SM 1281: v(f)
vibration velocity acceleration Spectrum vibration acceleration
in the frequency range from 1kHz to 10kHz
(high-frequency vibration); designation SM 1281: a(f)
Envelope curve spectrum of the vibration acceleration;
Filtered amplitude spectrum for analyzing roller bearing or gear
damage, designation SM 1281: e(f)
Note:
The envelope curve spectrum is always calculated in the frequency
range from 1kHz to 10kHz and is displayed in the range from 2Hz to
2/10Hz 400Hz 1kHz 3kHz frequency 1kHz.
(log. representation)

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Basics
Electrical and mechanical speed
4-pole machine, asynchronous
Electrical stator frequency

(given with 50Hz, variable with converter
drive)
Mechanical speed 1490rpm with an

electrical stator frequency of 50Hz
(this means 24,83Hz mechanical)

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Basics
Electrical and mechanical speed
For motors directly connected to the mains, the mechanical speed is given by the mains frequency and the pole pair number.
The speed of an asyncronous machine is calculated from:
n = (fMains * 60) / (number of pole pairs) – slip
➔ For pole pair number = 1 (2 poles) and mains operation at 50Hz: n = 3000rpm – slip
➔ For pole pair number = 2 (4 poles) and mains operation at 50Hz: n = 1500rpm – slip
For a synchronous machine the slip = 0rpm.
Important:
If the rotor speed is measured at the shaft, the number of pole pairs is not included in the calculation of the
rotation frequency of the rotor
Example: nmeas = 1490rpm
fRot = n/60 = 1490rpm / 60 = 24.83s-1 = 24.83Hz

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Basics
Possible causes of vibrations
These vibrations are mainly at rotation

Low-frequency vibration effects
frequency, in some cases with harmonics
(multiple of the fundamental frequency).
Design Electrical faults appear with twice the supply
Manufacture / Assembly Wear / Operational effects frequency of the stator winding (mains or
Mounting converter frequency). These vibrations can
normally be acquired for a wide band as rms
values.
A wide band vibration value (e.g. RMS value of

Foundation fault vibration velocity) is obtained from
Imbalance Thermal
Resonance Loosened drive
Rotor imbalance (wear) growth
components mathematical averaging of all vibration events
within a defined frequency range
(e.g. 10 to 1000Hz for RMS vibration velocity in
accordance with ISO10816-3).
Due to mathematical generation of the
Electrical
mean, individual frequencies (e.g. rotation
Blade passing Imbalance Thermal frequency and its harmonics) are NOT
Misalignment faults
frequency (caking) imbalance
monitored separately.

Page 15
Basics
Possible causes of vibrations
An analysis can be performed in the high-

High-frequency vibration effects
frequency acceleration spectrum (envelope
curve analyses in particular).
Design
Manufacture / Assembly Wear / Operational effects
Mounting The generation of characteristic values is also
a widely used method in the field of bearing
condition evaluation – but these methods have
not been incorporated into the standards.
Roller bearing Gear fault Lubrication deficit Roller bearing To generate a characteristic value for bearing
damage damage condition evaluation SM 1281 uses the rms
frequencies frequencies value of vibration acceleration (aRMS) or the
DKW-value (based on the K(t)-value) within the
frequency range from 1kHz to 10kHz.
Blade passing Gear fault

frequency

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Basics
Acceleration sensors
Piezoelectric Sensor MEMS Sensor Piezoelectric Sensor – IEPE:

IEPE: Industry standard for piezoelectric sensors
Typical design Typical design (Integrated Electronics Piezo-Electric)
A piezoelectric material generates an electric charge on its pole faces that is
Preload HF resonant circuit
spring
proportional to the applied force. The sensitivity of the sensor must be known
comprising Integrated
(e.g. typically 100mV/g).
Vibrating semiconductor electronics
mass elements
Piezoelectric
MEMS: Micro-Electro-Mechanical System:
element Fixed
electrode The displacement caused by acceleration enables a change in capacitance to be
Movable measured between the spring-mounted part and a fixed reference electrode
Mounting
thread electrode (approx. 1pF over the full measuring range).
MEMS was developed in the automobile sector for crash sensors, i.e. for releasing
airbags. Tripping should take place above a specific acceleration value, i.e. simple limit
Vibration force Vibration force monitoring with the limit for which the sensor was designed.
Difference of IEPE and MEMS:

▪ IEPE sensors have a significant higher dynamic range (more precise analyses), therefore better evaluation of damages / progress of damage especially at the envelope
analysis is possible
▪ MEMS-Sensors have a smaller frequency range
▪ MEMS-Sensors have a disposition to measuring errors in case of the higher fluctuation noise, especially in vibration velocity at lower frequencies
▪ MEMS-Sensors are subjected to Earth’s gravity. Therefore, MEMS-Sensors must always be balanced.

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Basics acceleration sensor
Connecting to measuring object – mechanical connection
Suitable adhesive for fixing a sensor:

Threaded bolts with a flat and smooth contact surface
Upper frequency limit 10 – 25kHz two-component adhesive
Adapter for uneven and/or coated surfaces

Upper frequency limit 10 – 25kHz
Fixing by gluing
Fixing with permanent magnets

Upper frequency limit acc. to holding force (approx. 5 – 15kHz)
Handheld test probe

Upper frequency limit approximately 2kHz

Seite 18
Threaded bolts with a flat and smooth contact surface

Adapter for uneven and/or coated surfaces Fixing recommendation

Upper frequency limit 10 – 25kHz for stationary mounting
Fixing by gluing
Fixing with permanent magnets

Upper frequency limit acc. to holding force (approx. 5 – 15kHz)
Fixing recommendation
for mobile measuring
Handheld test probe
Upper frequency limit approximately 2kHz

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Installation
21mm The installation of this accelerometer will be screwed by a threaded pin on the front
side of the sensor. Included in the scope of sensor delivery is a threaded pin with
UNF1/4-28 to M8-thread.
10 mm Before sensor installation the M8-thread and the contact surface of a measuring point
should be prepared:
Seating: Diameter 21mm x 1,3 ≈ 28mm
Blind hole: Bore diameter 6,8mm, Drill depth 10mm, Thread M8
Tightening torque: 2,7- 6,8Nm
If the surface of the measuring point is not planar, the sensor

can be mounted e.g. with an adapter (see picture).

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Connecting to module – electrical connection
Connection to IPLUS SM 1281
Red wire:
Positive pole PIN A at the sensor Connection to SM 1281
VIBX+ at the module
The connection of the
sensor is done at the
corresponding terminal
Black wire: block to SM 1281,
Negative pole PIN B at the sensor e.g. VIB1+ and VIB1-
VIBX- at the module

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Sensors that need more than 4mA (e.g. with integrated interference
suppression) cannot be used with SM 1281. The maximum current supply
of SM 1281 is 4mA per channel.
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There are made-up cables in length of 3m and 10m available for connecting the acceleration sensor to the measuring device.
The cable will be connected to the sensor by the moulded connector (MIL-C-5015-Style, two-pole) through a screwcap on the connector
side, second side open cable end.
For maximum distance between sensor and CMS unit, 30meters are approved.
Longer distances are possible, but this is in the responsibility of the user. In case of working with cable length more than 30 meters we will
take into account that:
▪ Cable specific inductance and capacity can take influence of the constant current source with the result that the sensor bias
point displaces
▪ The cable length might damp down the signal, miscalculations are possible
▪ The noise performance of the sensor-cable-system will get worse
Make up cables by customer:

▪ Recommended cable: Polyurethane cable, two-core, braided shield with shield wire
▪ Recommended connector: Screw connection MIL-C-5015-Style, two-pole, casting with epoxy

Page 23
Basics acceleration sensors
Choosing a suitable measuring point
Acceleration sensors normally have one reference The required direction of measurement must be
direction. compatible with the reference axis of the acceleration
sensor.
Cross-sensitivity
< 1 % of rated sensitivity
Reference direction
Reference direction

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The measuring distance between the machine bearing and the measuring point must be as short and as direct as possible;
vibration signals weaken as the signal path lengthens. In the field, the sensor should be mounted very close to the bearing.
The larger the axial distance of the acceleration sensor from the bearing, the larger the
damping.
Every material transition (e.g. joint) attenuates and/or reflects the signal to be measured,
so the signal path should therefore only comprise the material transition between the
bearing and bearing housing.
Acceleration sensors cannot always be mounted in accordance with theory alone.
The final position of the sensor must be determined by local conditions.
The notes above are intended for purposes of orientation.
Freely vibrating or elastically deformable housing or cladding components

(such as fan covers) are not suitable for measurement!
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When an online CM system is used, in practice there are not three sensors mounted (axial, vertical, horizontal), but only one sensor in a
radial direction (see also ISO20816-1). This sensor must be placed inside the load zone.
Using a coupling, the load zone depends on the alignment. In this case it is recommended to mount a sensor with a 45 degree angle in
the lower area of the machine. On this occasion, the vibrations can be monitored in horizontal and vertical direction and the weight force
of the rotor will be considered.
Definition of the load zone:

The load zone is the area, where the weight force of the rotor affects the bearing for design
reasons.
In this direction the input of oscillation-stimulation to the bearing is the highest.
Therefore it is recommended , to mount the sensor with its reference direction inside the
load zone.
If the limits for warning and alarm were defined by mobile measurement acc. ISO 10816-3
(axial, horizontal, vertical), working with one sensor in the load zone misinterpretations
would be possible.
Therefore it is recommended to measure the vibration values with one sensor in the load
zone again and define the limits for warning and alarm based on that measurement.

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Example gear wheel
Definition load direction:
The load direction is equal to the effective force direction

depending on the construction of the machine.
In this direction, the vibration energy is largest.
Therefore it is recommended to mount the sensor with its

reference direction against the load zone
Reference direction
Load direction

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Example belt drive
Reference direction
Load direction

Page 28
Example Alignment
Reference direction
Load direction
Load direction
Load direction Reference direction
Reference direction
Load direction
Reference direction

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Example Imbalance
Exception Imbalance:
Imbalance runs in accordance with the rotation.

A sensor mounted in any load zone is able to detect
an imbalance.
There is no special load direction for an imbalance.

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Basics
Frequency range of the whole measuring chain
The measuring system must be suitable for

measurement in the relevant frequency range.
appr. 34 – 36kHz
This range is determined by three factors:
▪ Usable linear frequency response of the
appr. 1 – 25000Hz acceleration sensor including tolerances
appr. 2 – 15000Hz
▪ Coupling of the acceleration sensor to the
measured object
Frequency response accelearation sensor Frequency response mechanical coupling
▪ Frequency response of the measurement
equipment
Corruption due to the resonance of the sensor

The usable frequency range is typically limited
appr. 2 – 15000Hz by resonance effects.
If the frequency to be measured lies within the

resonance range, the measuring result will be
appr. 0,3 – 23000Hz
corrupted.
Frequency response measurement equipment Frequency response measuring chain

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What does Condition Monitoring mean?
Trend monitoring of characteristic values
Maintenance
PreventiveMaintenance Control Repair
Control
check test investigation

of of of
temperatures electrical parts operating conditions
vibrations electr. and mechan. operation safety

connections
insulation resistance cooling system

Page 32
SIPLUS CMS – Real example
Bearing damage at a gear box
Drawing of the gear box Photo of the gear box Developing damage at the inner ring of the bearing
a [m/s²]
2,0
1,8 Trend monitoring
1,6
1,4 Warning
1,2
1,0
0,8
0,6
0,4
0,2
08.07.03
08.07.12 02.09.03
02.09.12 28.10.03
28.10.12 23.12.03
23.12.12 17.02.04
17.02.13 13.04.04
13.04.13 08.06.04
08.06.13 03.08.04
03.08.13 28.09.04
28.09.13 23.11.04
23.11.13 18.01.05
18.01.14 15.03.05
15.03.14 10.05.05
10.05.14
date

Page 33
Machines rarely fail without a previous warning.

Signs of a developing fault are usually
Failure noticeable a long time before the actual failure,
Characteristic value
e.g. with a steady rise of a vibration value.

The "bathtub curve" is a typical trace of a
vibration value over the time. With regular
measurements, developing damages can be
Repair performed detected as they occur and then can be
Alarm limit tracked. The trend is extrapolated from which a
limit violation and therefore the time for repair
can be derived
New machine (condition-dependent maintenance).
Repair necessary
Limits for the vibration velocity can be derived
Warning limit from the standards.
Running-in phase
Limits for the characteristic values of bearings
can be determined from previous experience
(bearing manufacturer, motor manufacturer,
Periodic maintenance Time user).

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How can damages be detected and over what timescale?
▪ Rise in trend over several weeks

Slow damage ▪ Also detectable from offline measurements
development
▪ Examples: Roller bearing damage – outer ring, tooth-edge wear
▪ Rise in trend over hours / days

Rapid damage ▪ Reliable detection is only possible from online measurements
development
▪ Examples: Roller bearing damage – inner ring, final break due to incipient crack in shaft
▪ Severe damage within minutes/seconds

Immediate ▪ Can only be detected online
damage (question: Which switching command switches off the machine, and how soon?)
▪ Example: Roller bearing cage crack, fragments jammed in the bearing, damaged frequency converter
➔ 100% risk protection is not possible

➔ A Condition Monitoring System is not made for machine protection and therefore must not be used for control
purposes (e.g. switching off)

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Comparison between mobile measurement and online measurement
Mobile measurement Online measurement
Different measuring tasks are possible with one device The measuring task depends on the type of hardware
Measurements at several points using one device Number of measuring points depends on the type of hardware
Measuring points not fixed, therefore higher variability in choosing Measuring points that are not accessible during operation using
suitable measuring points mobile measurement can be acquired
Reduced detection of damages: Slowly developing damages based

Damages can be detected almost in real time
on trend values

Page 36
Example: Fan unit
Motor Coupling Bearings
What kind of values

at what points of
measuring are
monitorable?
Foundation Mounting What kind of

information of the
damage can I get from
Fan with housing the vibration analysis?

Page 37
Getting started with SIPLUS CMS1200 SM 1281
Overwiew
Engineering system Work and watch with SIMATIC HMI SM1281 Frequency-selective analysis
TIA Portal ▪ Setting module parameters of SM 1281 Integrated web-interface:

▪ Hardwaresupport via HSP ▪ Setting channel parameters of SM 1281 ▪ Input of limit bands for the spectra
▪ SM 1281_Library ▪ Setting monitoring parameters ▪ Input of bearing data
▪ SIMATIC user software ▪ Establishing of the authorization of SM 1281 ▪ Analysis of the spectra
▪ Comparison with fingerprints
▪ Raw data recording
Profinet Ethernet
Backplane bus
TIA Portal CM-modules SIMATIC S7-1200 Standard SM-modules SM1281-Condition Monitoring modules

Page 38
Overwiew
Hardware requirements Software requirements Optional software
S7-1200 CPU Max. connectable SM 1281 SIMATIC STEP 7 SIMATIC WinCC

Programming languages Machine-level operating
CPU 1211C None KOP, FUP, SCL, AWL*, S7-GRAPH* and monitoring
STEP 7 Safety option package SCADA applikations

CPU 1212C 2
WinAC (inkl. Failsafe**) SCADA
CPU1214C / 1214FC 7
S7-300/400 (incl. Failsafe**) PC (single user)
CPU 1215C / 1215FC 7
Professional
Professional
S7-1500 Comfort Panels + x77
Advanced
(without Micro), Mobile
Comfort
CPU 1217C 7
Basic
Basic
S7-1200 Basic Panels
▪ TIA Portal is required to configure the ▪ If panels are used, optional use of the
Important: module corresponding WinCC version is
possible
▪ The lowest license, SIMATIC
➔ Browser functionality for panels is
SM 1281 is supported as of STEP 7 Basic, is sufficient for
S7-1200 NOT supported by SM 1281
FW version V4.1 for S7-1200 CPU *) Not available for S7-1200

Page 39
Overwiew
Own SM1281 Ethernet network
Networks for maintenance and

production can be separated
➔ detailed diagnostics WITHOUT load

on the production network
PROFINET Ethernet
Backplane bus

Page 40
Condition Monitoring Module
SM 1281 Condition Monitoring Module
Features Operating principle

• Characteristic-based diagnostics
• Frequency-selective diagnostics • Calculations are performed
• Export of raw data BERO continuously
• SIMATIC and web-based
• The 4 IEPE channels and
the speed sensor are read in and
Connections processed simultaneously
• Up to 4 vibration sensors (IEPE-sensors)
• 1 optional speed input (Bero) • No additional software is required
• Ethernet (2 ports)
• Power supply 24VDC • Communication via
• Profinet (Control unit)
• Ethernet (SM1281)
Expansion option • Backplane bus connector S7-1200
• Up to 7 modules can be connected • Webserver HTTP
(depending on the S7-1200 CPU used) • File transfer via FTP or WebDAV
IEPE-sensors

Page 41
Analysis methods
42
Characterístic values
Any signs of damage?

• Analysis of machine / bearing vibrations
• RMS value of vibration velocity vRMS / vibration acceleration aRMS,
bearing characteristic value DKW
• Simple representation, e.g. traffic light
• Trend charts vRMS, aRMS. aPEAK and DKW
Frequency selective analysis
What precise damage is imminent?

• Analysis of machine vibrations, such as resonance, unbalance,
alignment/coupling faults
• Analysis of roller bearing damage, such as damage to outer or inner ring,
cage, rolling element damage
• Trend monitoring of frequency bands

Page 42
Characteristic values, global diagnostic procedures
43
Engineering and configuration via SIMATIC S7-1200 CPU
Signal Operating priciples
Characteristic value Monitoring
• All monitoring parameters can
be set via the S7-1200 CPU
vRMS • Monitoring in the SM 1281
acc. ISO 10816-3 Alarm
vRMS: • Cyclic transfer to
S7-1200-CPU of:
Machine vibration Warning
vRMS • RMS value of vibration
freely cofigurable velocity (vRMS)
• RMS value of vibration
OK
acceleration (aRMS)
aRMS • Bearing condition
freely cofigurable characteristic value DKW
aRMS, DKW:
• Status messages
Bearings
DKW • Display on PC, panel, etc.
acc. VDI 3832
Advantages: Disadvantage:
Quick and easy to implement Type of looming damage is not detectable
Minor Condition Monitoring expertise required ➔ Troubleshooting required

Page 43
Global diagnostic procedures
Overview
Wide-band vibration measurements are useful

indicators to make a statement about the status of a
machine or the effectiveness of measures to
suppress vibration.
The actual measured vibration value can be

checked by comparing it against previously
acquired values (trend analysis) or against
published standards or manufacturer's data.
Deteriorating conditions can be detected, and the

progression of damages can be estimated.
Vibration of Vibration of
machine housing bearings Detailed troubleshooting is not possible, or only to a
limited extent.

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Overview
The following standards and guidelines are generally applicable to machine monitoring using wide-band characteristics:
Standards
Vibration measurement, acceptance test measurements at the manufacturer (shaft height ≥ 56mm,
EN 60034-14
rated output ≤ 50MW, nRated: 120 … 15000rpm)
Mechanical vibration – Measurement and evaluation of machine vibration

ISO 20816-1 Part 1: General guidelines
dated March 2017, replacement for ISO10816-1:1997-08 and ISO10816-1/A1:2010-06
Mechanical vibration – Evaluation of machine vibration by measurements on non-rotating parts

Part 3: Industrial machines with nominal power above 15kW and nominal speeds between
ISO 10816-3
120rpm and 15000rpm when measured in situ
dated Januar 2018
Guidelines
VDI 3832 Roller bearing condition, various procedures

Seite 45
Limits of EN 60034-14
46
The measurement according to EN 60034-14 provides information of the level of vibration of the manufactured machine
directly ex works.
The level of vibration measured at the manufacturer does not generally provide any information about the
vibration characteristics of the drive unit as a whole at site.
If excessive vibrations are recorded, some common reasons can occur:
• Imbalance, e.g. because of incorrectly balanced transmission elements
• Incorrect alignment
• Resonances from a torsional-weak base frame
• Distortion of the motor at the foundation fixing points
• Excitation from the driven unit / gear unit
➔ For the evaluation of machine vibrations at site there are other standards
➔ These values are defined with ISO 10816-3 „Evaluation of vibrations in situ“

Page 46
ISO20816 and ISO10816 – Overview
47
Notes of the standards ISO10816-3 and ISO20816-1 for the measurement of mechanical vibration:
▪ The preferred value for the measurement of mechanical vibration on non-rotating parts is the wide-band RMS-value of the vibration
velocity (this value can be related to the vibration energy).
▪ The values of RMS vibration velocity (vRMS) are measured and calculated over a defined frequency range. The range covers
frequencies from 2/10Hz to 1000Hz. Depending on the speed, the measuring range starts either at 2Hz (speeds from 120 to 600rpm) or
at 10Hz (speeds greater than or equal to 600rpm).
▪ There are two criterions for the evaluation of vibration condition:
Criterion 1 looks at the absolute value of vibration
Criterion 2 looks at the change of the vibration value (irrespective of whether there is a rise or a fall of the value of vibration)
▪ At many machines the measured wide-band RMS-value of the vibration velocity mainly consists of only one frequency component. This
is very often the rotational frequency of the shaft.
▪ The evaluation criteria (mainly the limits of the RMS-values of the vibration velocity) according to ISO10816-3 are applicable both for a
continuous and intermittent operations monitoring.
▪ The standards give some information about the appraisal procedures for roller bearing condition, but evaluation criteria (e.g. limit
values) are not determined.
Special kind of machines which are not covered by the named standards (e.g. electric motors with a nominal
power <15kW or a nominal speed >15000rpm) are evaluated according to ISO20816-1 appendix C.

Seite 47
ISO20816 and ISO10816 – Overview
Classification of the standards

Valid parts of ISO20816:
Part 1: General guidelines
Part 2: Land-based gas turbines, steam turbines and generators in excess of 40MW
Part 5: Machine sets in hydraulic power generating and pump-storage plants
Valid parts of ISO10816:

Part 3: Industrial machines with nominal power above 15kW and nominal speeds
between 120rpm and 15000rpm when measured in situ. Wind power plants are excluded.
Part 4: Gas turbine sets with fluid-film bearings
Part 6: Reciprocating machines with power ratings above 100kW
Part 7: Rotodynamic pumps for industrrial applications
Part 8: Reciprocating compressor systems

Seite 48
Global diagnostic procedures ISO20816-1 und ISO10816-3
Measuring points
Measuring points at electrical machines at the site of installation

Measurement at non-rotating parts of a rotating electrical machine at DE and NDE in all three planes: horizontal, vertical and axial
Definitions Electrical machine on site

vertical
NDE: Non Drive End
Causes of vibration:
Misalignment
Blade passing
axial horizontal frequency
DE: Drive End
H = shaft height Resonance

Imbalance

Page 49
Evaluation of vibration condition
Vibration velocity
v [rms]
mm/s inch/s
11 0,44
(2-1000Hz, n > 120rpm)

10-1000Hz, n > 600rpm
7,1 0,28
4,5 0,18
3,5 0,11
2,8 0,07
2,3 0,04
1,4 0,03
0,71 0,02
rigid soft rigid soft Foundation

Medium-sized machines Large machines
15kW < P ≤ 300kW 300kW < P < 50MW
Maschine type
Electric machines Electric machines
160mm ≤ H < 315mm 315mm ≤ H
Group 2 Group 1 Group
A Newly commissioned C Short time operation

B Unlimited long time operation D Vibration cause damage

Seite 50
Classification of the vibration zones
Evaluation of the strength of the vibration (rms value of vibration velocity)
Zone A Newly commissioned

Not analyzed here, because the vibration values are within the
permitted range.
Zone B Unlimited long time operation
The cause of the vibration must be investigated. The machine is

only permitted to be operated for a limited period in this state.
Zone C Short time operation
Shutdown should be planned in order to enable remedial
measures to be implemented.
Damage can arise.
Zone D Vibrations cause damage Immediate measures are necessary; the cause of the vibration
must be found and rectified.

Page 51
Classification of the machine groups
Classification according to machine type, rated output or shaft height
Electric machines with shaft height H >= 315mm

Group 1
Large machines with rated power outputs more than 300kW
Electric machines with shaft height 160mm <= H < 315mm

Group 2
Medium-sized machines with rated power outputs more than 15kW and up to 300kW
Small electric machines (< 15kW, especially series-manufactured electric motors) are evaluated in accordance with ISO20816-1 appendix C.
Currently, the following range of possible values are given by the standard (depending on the kind of operation/surrounding/application/etc.):
Upper limit zone B 1,8 … 9,3mm/s
Upper limit zone C 4,5 … 14,7mm/s
Proposal for the setting of the values for the warning and alarm limits (analogue to a former standard specification):
Warning limit (upper limit zone B) 2,8mm/s
Alarm limit (upper limit zone C) 4,5mm/s
Electric machines with nominal speeds >15000rpm are also evaluated in accordance with ISO20816-1 appendix C.
Special evaluation criteria are usually agreed between the supplier and the customer. These evaluation criteria should base on experience
of similar designed machines, which achieved a satisfactory operation up to now.

Page 52
Classification of the foundation
Vibration velocity
A soft foundation is able to absorb more
v [rms] energy of vibration compared to a rigid
mm/s inch/s foundation.
11 0,44
(2-1000Hz, n > 120rpm)

10-1000Hz, n > 600rpm
7,1 0,28
Therefore the limits of the rms values of the
4,5 0,18 vibration velocity of soft foundations are
3,5 0,11 higher than these for rigid foundations.
2,8 0,07
2,3 0,04
As defined in the standards, classification
1,4 0,03
of the foudation means:
0,71 0,02
The resonance point is either to be
evaluated with the finite element method or
to be calculated with a complex theoretical
15kW < P ≤ 300kW 300kW < P < 50MW model of vibration analysis.
Maschine type
160mm ≤ H < 315mm 315mm ≤ H


Page 53
Classification of the foundation
Classification according to the elasticity of the machine substructure in two groups:
Rigid substructures - Frequently concrete foundations
Soft substructures - Frequently frame mounting, mounting with vibration damping elements
These substructure types are assigned based on the elasticity of the motor and its foundations. When the lowest
natural frequency of the overall system comprising motor and foundations in the direction of measurement is at
Theory least 25 % above the main excitation frequency (this is normally the frequency of rotation), the substructure can be
termed rigid for this direction.
All other substructures can be termed soft.
EN 60034-14:
The substructure is soft when the values for RMS vibration velocity (in the same measuring direction) on the
substructure close to the mounting points of the motor feet are more than 25% of the values measured at the
Practice
motor itself.
ISO 10816 / 20816:
The substructure will be regarded as soft if it resonates within the operating range.

Page 54
Evaluation of the foundation
Evaluation of the machine foundation according to the elasticity into two groups: Practical relevance:
In case of not known behavior of the

foundation the (lower) limit values of
the rigid foundation should be used.
The easiest measurement to evaluate
the behavior of the foundation is a
comparison of rms values of the
vibration velocity measured at the
electrical machine and at the
foundation in the area of fixing the
housing feet
(pay attention to use the same
measuring direction).
rigid foundation soft foundation

Page 55
Evaluation of vibration condition – Criterion I
Vibration velocity
Criterion I: Absolute value of the vibration
v [rms]
➔ defined in the table of the standard
mm/s inch/s
11 0,44
(2-1000Hz, n > 120rpm)

10-1000Hz, n > 600rpm
7,1 0,28
4,5 0,18
3,5 0,11
2,8 0,07
2,3 0,04
1,4 0,03
0,71 0,02

15kW < P ≤ 300kW 300kW < P < 50MW
Maschine type
160mm ≤ H < 315mm 315mm ≤ H


Page 56
Evaluation of vibration condition – Criterion II
Criterion II, change of vibration value (evaluation of the vibration condition) based on criterion I
Recommendations regarding ALARM and SHUTDOWN limits according to ISO10816-3
Delivers evaluations of changes of vibration value as compared to a previously defined reference value and can
Criterion II therefore be recognized, for example, in a trend analysis. Considerable rises (or falls) of the vibration measured
are possible which can require rectification measures, even before Zone C is reached.
Recommendation of the If the rise (or fall) of vibration values will exceed 25% of the upper limit of Zone B, the change must be regarded
standard as significant, especially if it occurs suddenly.
Recommendation of the The limit should lie above the base value by an amount that is 25% of the upper limit of the respective Zone B
standard with regard to (the base value is obtained from previous operational experience at this measuring point). In general, the limit
ALARM limit should not exceed 1.25 times the upper limit of Zone B.
Recommendation of the
The limit generally lies within Zone C or D. In general, the limit should not exceed 1.25 times the upper limit of
standard with regard to
Zone C.
SHUTDOWN limit

Page 57
Evaluation of vibration condition – Criterion II
Example
Electrical machine with a rated power output of 20kW (group 2) with rigid substructure.
According to ISO10816-3 there are the following values (criterion I):
Zone A 1,4mm/s
Clearly lower limit value,
Zone B 2,8mm/s
Zone C 4,5mm/s more sensitive monitoring
Zone D > 4,5mm/s
From trend analysis with S1 operation, it was found that:

RMS vibration velocity = 0.9mm/s. This value corresponds to the base value of previous operating experience at this measuring point.
This results in the following settings (criterion II):
Alarm limit = 0.9mm/s + 0.25 *2.8mm/s = 1.6mm/s

Maximum shutdown limit = 1.25 * 4.5mm/s = 5.6mm/s
Explanation from the standard

The shutdown limits are determined, in general, from the requirement that the machine must not receive any mechanical damage
→ Recommendation: Shutdown limit = Upper limit of Zone C = 4.5mm/s

Page 58
Determining the warning and alarm limits
Rotational speed n Processes with constant speed:

A production process (e.g. mill drive for cement
production) is driven at constant speed.
➔ Constant value of rms vibration velocity
Vibration
Peak value
Rms value
Variable speed based on the example of a

Time t
traversing profile:
The speed increases continuously and then remains
Rotational speed n
constant.
The speed then falls and remains constant again for a
certain length of time.
Then the speed falls to zero and the traversing profile is
run through again.
Vibration ➔ Different values of rms vibration velocity as a
Peak value function of machine speed; normally the value
Rms value
of the vibration velocity is highest with the
maximum speed (exception: resonance).
Time t

Page 59
Exercise – Determining the warning and alarm limits
Drive for a big fan unit
▪ Coupling drive
▪ S1-operation
▪ Rated power output 200kW
▪ Operating speed range 1200 – 2500rpm

Page 60
Most probable causes

for too high vibrations Machine
group 2
I have only two
sensors for the
machine, where are
the best points to
measure
Steel plate substructure,

therefore soft foundation
With the known

information
determining of the Are there up to now any But substructure not clearly
limit values measured values or is the to determine ➔ take the
machine newly installed limits for a rigid foundation

Page 61
Machine group 2 rigid foundation Mounting of the sensor 45 degrees from the bottom Note
During initial commissioning or
initial installation of a machine, it is
necessary to evaluate the
machine vibration.
This is normally performed by
measuring the machine vibrations
with a mobile system in the three
planes (horizontal, vertical, axial).
Vibration velocity
v [rms]
Zone limits according to standard: mm/s inch/s
(2-1000Hz, n > 120rpm)

11 0,44
10-1000Hz, n > 600rpm

A = 1,4mm/s
7,1 0,28
B = 2,8mm/s 4,5 0,18
3,5 0,11
C = 4,5mm/s 2,8 0,07
2,3 0,04
D = >4,5mm/s 1,4 0,03
0,71 0,02

15kW < P ≤ 300kW 300kW < P < 50MW
Maschine type
160mm ≤ H < 315mm 315mm ≤ H
Page 62
Global diagnostic procedures ISO 10816 part 1 and 3
Limits for Criterion I Limits for Criterion II Note
Measured values in mm/s: If the measured reference value exceeds

the limit of the standard, a problem exists
x and the cause must be found (foundation,
DE 0.8 0.7 0.2 mounting, imbalance, stator, etc.) and the
appropriate rectification measures must
NDE 0.7 0.6 0.1 be taken.
Technical data: Examples: The sensor is mounted in the load zone and the reference If the measured reference value lies just
P = 200kW value is taught.
▪ Initial commissioning below the limit of the standard, the
Foundation = soft The taught value should lie between 0.7 and 0.8mm/s in this vibration conditions are still OK, but a
▪ Use for cases where a minimal rise in vibration will lead to
case
Group = 2 constant vibration value is damage. The limits must be set in
not available (e.g. hoist Rare exception: Resonance (taught value > 0.8mm/s) accordance with criterion I.
and crane applications,
Zone limits rolling mills, crusher
according to standard: drives, kneader drives) Determining limits: If the measured reference value is
A = 1.4mm/s ▪ Values of vibration near by Warning = Taught value + 0.25 * upper limit of Zone B extremely small, the warning limit distance
the limits of the standard = 0.8mm/s + (0.25 * 2.8mm/s) must not be too wide, otherwise damage
B = 2.8mm/s (warning) will not be detected in time. In this case it
Warning limit = 1.5mm/s should be set in accordance with
C = 4.5mm/s (alarm)
criterion II.
D = >4.5mm/s Alarm = 1.25 * upper limit of Zone C
= 1.25 * 4.5mm/s = 5.625mm/s
Recommendation for the alarm limit: Upper limit for Zone C
Alarm limit = 4.5mm/s

Page 63
Alignment faults, imbalance, displaced mounting of the housing
Alignment faults
Inadequately aligned machines result in early increased vibration, and consequently in damage and a shorter lifetime for
bearings, couplings, seals and shafts.
The vibration value is increased in the direction of the alignment fault. For this reason, it is advisable to check and
document the final alignment using vibration measurement.

Page 64
Alignment faults
An alignment fault can exist in different planes.

Parallel offset Angle offset
Apart from the conventional alignment methods of straight-edge and dial gauge, laser alignment tools are also available today.
Achievable alignment accuracy:
Straight-edge 1/10mm Dial gauge 1/100mm Laser 1/1 000mm

Page 65
Alignment faults
The alignment tolerances for motors, couplings and driven machines must be obtained from the respective machine manuals.
nmax = 1500rpm → xmax = 0,08mm
nmax > 1500rpm → xmax = 0,05mm
nmax = 1500rpm → ymax = 0,08mm / 100mm ØD
nmax > 1500rpm → ymax = 0,05mm / 100mm ØD
Extract from a machine manual for a four-pole 1LA4
Caution!
The permissible axial, radial and angular offset of elastic couplings is normally much larger than the motor bearing and
motor shaft permit. Therefore, even when elastic couplings are used, the accuracy required by the motor must be
observed when aligning shafts.

Page 66
Alignment faults
The thermal expansion of motors or driven machines must be taken into account during alignment.
100 °C
Alignment in the cold state
Alignment on reaching
thermal equilibrium
20 °C
Turbine Generator

Page 67
Imbalance ISO 1940-1 defines reference values for

evaluating the balance condition of
rotating rigid bodies. It defines classes of
Imbalance is understood as uncompensated centrifugal forces that cause oscillatory forces and balance quality. Each quality class
movements in the bearings of a rotating system. A distinction is made between: (identification letter G) is characterized by
a number.
The motor manufacturer assigns different
The center of gravity is located types of rotors to different balance
outside the axis of the shaft, e.g. due classes that have been shown to result in
Static Imbalance satisfactory running smoothness.
to eccentrically located bearing pins
Balance quality G6.3 is recommended for
rotors in electric motors without special
requirements, and balance quality G2.5
is recommended for rotors in electric
E.g. caused by bearing seatings motors with special requirements.
Torque
located at an angle to the rotor The rotor is normally balanced in at least
imbalance
two planes by attaching counterweights.
When balancing the rotor, it is important
to consider the type of mounting of the
output element; this is often implemented
Dynamic Overall imbalance of a rotor comprising static imbalance and torque with feather keys.
imbalance imbalance

Page 68
Frequent causes of imbalance
The balancing of the transmission medium (coupling half, belt disc) does not correspond to that of the motor rotor. This results in a high
residual imbalance combined with high vibration values.
The balancing method for the motor rotor is normally inserted in the end face of the shaft:
F = Full-key balancing
H = Half-key balancing
N = Balancing without feather key
If the balancing of the output element differs from that of the motor rotor, high vibration values can be expected.
Operational disturbances can also cause the balancing to change:

▪ Deposits on one side of the fan when motors are in a dusty environment with a high level of humidity
▪ Exhaust gas ventilators can become caked in fly ash and/or flaking clumps of ash
▪ Pumps for chemically aggressive media subject to uneven corrosion

Page 69
Displaced mounting of the housing
▪ When motor housings are mounted with displacement, vibration can increase.
This may be caused by, for example, a faulty motor foot support, or faults in the motor substructure.
▪ Housing displacement can be checked by means of a soft foot check. A measuring gauge is vertically aligned on a foot. The bolts of this
foot are loosened (all other feet remain firm). If this loosening results in a change in the vertical position of the motor foot, this is an
indication that the housing is mounted with displacement.
▪ Unless specified otherwise by the manufacturer, the change on the dial of the measuring gauge should not exceed 0.025 mm.
▪ If a displacement is detected, this must be corrected by adding or removing alignment plates.

Page 70
Test steps for fault analysis without frequency analysis

Start Possible imbalance or housing displacement:
Perform soft foot check
Measure housing vibrations under load:

DE and NDE horizontal, vertical and axial Yes
Vertical change of foot position
No Align housing
End Vibration values impermissibly high? No
Yes
Imbalance probable:
Measure housing vibrations Measure housing vibrations without an output element, insert End
with driven machine decoupled full key or half key in keyway in accordance with the balancing
method (secure feather key!)
No No
Vibration values significantly lower? Vibration values significantly lower?
Unbalance in motor rotor:
Yes Yes Balance motor rotor
Alignment fault probable: Cause is balancing state of output element:

Align coupling balance output element or check balance type for motor
rotor/output element
End End End

Page 71
Exercise, cause of vibrations
SM 1281 monitors a rms value of the vibration velocity clearly below the warning
limit of 1,5mm/s.
The machine was dismantled for overworking and was reinstalled.
After commissioning there is a warning, the level of vibration is higher than
1,5mm/s at DE and NDE.
2nd step:
Interpretation
1st step:
Measuring the vibration level The vertical direction seems to be
Values of vibration are increased ok. Therefore it is important, that
only in the horizontal direction. with the use of only one sensor per
Therefore a misalignment in the side (DE and NDE) this sensor is
horizontal vertical axial
horizontal direction seems to be mounted in a 45 degree direction.
probable. This could occur during So a detection of both directions –
DE 5,1 1,3 0,8
mounting of the machine. horizontal and vertical – is
NDE 4,9 1,5 0,7
achieved.

Page 72
Exercise, cause of vibrations
SM 1281 monitors a rms value of the vibration velocity clearly below the warning limit of 1,5mm/s.
The trend monitoring shows a constant increase of the values of the vibration velocity.
1st step: 2nd step:

Measuring the vibration level Interpretation
horizontal vertical axial

Values of vibration are increased in
DE 3,2 2,7 0,8 horizontal and vertical direction. So an
increasing imbalance seems to be
NDE 3,1 2,9 0,7 possible.

Page 73
Monitoring of rolling contact bearings
Internal clearance A roller bearing is the generic term for a bearing that comprises an
Relief zone
outer ring and an inner ring, between which a shaped part is
located that rolls.
This shaped part can be:
Outer ring Spherical, roller-shaped, cylindrical, conical or pin-shaped
Bearing weight
Belt tension Inner ring When rolling over a bearing damage (regardless of the type of
roller bearing), a shock is generated that can be detected in the
Rolling element higher frequency ranges.
Cage In practice, the most frequent damage is to the outer ring, followed
by the inner ring, cage and rolling element.
Global diagnostic methods for detecting bearing damages can only
Load zone = Measuring zone indicate that a damage is starting to occur. It is not possible to
determine the type of the damage.
When the type of a damage can be specified, the maintenance
technician can assess the urgency of bearing replacement, but this
is only possible using analytical diagnostic methods
(envelope curve analysis).

Page 74
Monitoring of roller bearings
a^ [m/s2]
v^ [mm/s]
Energy
imbalance
Electromagnetic components (stators, rotors)
Alignment faults
Couplings
Fan impellers
Gear wheels
Component resonances
Material resonances
2 x fMains
2 x fn2
1 x fn2
Defective roller bearing
fTooth Analytical diagnostics based on the velocity spectrum is less

suitable for early detection of bearing damage, because the
Bearing vibrations
extremely low-energy defective components of the roller bearings
are masked by the high-energy machine vibrations
➔ Measurement of bearing vibrations in the high-frequency range

1 2 3 5 10 20 30 50 100 200 500 1000 3000 10000 f(log) Hz (much higher frequencies compared to the normal housing
vibrations mainly with rotation frequency)
➔ Characteristic values especially for acceleration

Page 75
Monitoring of rolling contact bearings with characteristic values
Guidelines
Rolling contact bearings, various methods:

▪ Cumulative methods, such as Crest factor, Kurtosis value, Bearcon, BCU, Spike Energy,
SPM shock pulse, diagnostic characteristic value K(t)
▪ Frequency analysis, envelope curve analysis
Until now, no method for detecting problems in roller bearings has achieved inclusion in an
VDI 3832
international standard.
In practice, envelope curve analysis is the most frequently implemented method for the early
detection of bearing damage, and it is the most reliable method available.
76
Standardized limits are not available for evaluation, so a meaningful analysis can only be obtained from
evaluating the trend analysis.
A comparative measurement under good conditions is therefore always necessary.

Page 76
Overview - Crest factor / Kurtosis value / Bearcon, BCU (Bearing Condition Unit), Spike Energy
Crest factor / Kurtosis value / Bearcon, BCU (Bearing Condition Unit)
These characteristic values are generated from the ratio of peak value to RMS value. The Crest factor for roller bearings without damage
is approximately 3, it rises to approximately 20 as a defect develops, and it falls off to approximately 3 again for advanced damage.
It is therefore not possible to distinguish between an intact bearing and a heavily damaged bearing.
Spike Energy (unit: gSE)
This is a combination variable comprising amplitude mean, sum value of the envelope curve and Kurtosis value; evaluated as a function of
speed from 600 to 3600rpm:
0.1gSE no damage
< 0.5gSE warning
< 0.5gSE probable damage
< 1.0gSE serious damage
The methods presented here are not covered by this training

Page 77
Overview – Shock Pulse Method SPM Shock pulses are short pulses that are caused
by mechanical damage to rolling elements or
raceways, i.e. a shock pulse represents the
Bearing condition Measuring interval transfer of kinetic energy over an extremely short
time interval. During evaluation, the low-
frequency components (caused by alignment
Bad Measure frequently faults or imbalance) are suppressed.
Prepare for bearing replacement
The absolute value of shock pulses is measured
Limited Several days to 1 week in dBsv.
The normalized shock pulse value
dBn = dBsv – initial value dBi
Good 1 to 3 months
The initial value dBi is a calculated value for a
new, fault-free bearing and is dependent on the
Service life bearing geometry as well as the speed.
A certain distribution of measured values is normal, and can be traced back to temporary changes, The condition of the bearing is determined on the
such as basis of the normalized value dBn and it is
▪ motor load evaluated against specified limits.
▪ ambient temperature
▪ bearing temperature
▪ lubrication conditions
The method presented here is not covered by this course

Page 78
Characteristic value – rms vibration acceleration aRMS / aPEAK
The value of the rms vibration acceleration aRMS – calculated within a frequency range from 1kHz to 10kHz – can be used for monitoring
the bearing condition.
The proposed values for warning limit and alarm limit are based on practical experience. A limit value according to a standard does not
exist.
First the existing operating behavior of the bearing has to be measured and documented as the basic value. It must be assumed that the
bearing is without any damage at the time of the first measurement.
Than the further damage analysis is done with the envelope curve analysis (analytic diagnostic procedure).
Proposal for warning limit of aRMS within the frequency range of 1000Hz (high pass filter) to 10000Hz (low pass filter)
➔ Basic value plus 1m/s²
Proposal for alarm limit of aRMS within the frequency range of 1000Hz (high pass filter) to 10000Hz (low pass filter)
➔ Basic value plus 2m/s²
Further characteristic values for monitoring roller bearings are based on aRMS and aPEAK (e.g. Crest-Factor = aPEAK/aRMS).
For this reason, the peak to peak value of the vibration acceleration aPEAK is calculated by SM 1281 and displayed.

Page 79
Characteristic value – rms vibration acceleration aRMS / aPEAK
Spectra of vibration acceleration Spectra of vibration acceleration

Frequency range 1000Hz to 10000Hz Frequency range 1000Hz to 10000Hz
Bearing without damage Bearing with a damage of the outer ring
Global diagnostic procedure Characteristic value aRMS

➔ calculation of a rms value within a defined frequency range
Analytic diagnostic procedure Frequency selective analysis with the envelope curve analysis
➔ Looking for the bearing damage frequencies

Page 80
Diagnostic characteristic value K(t) according VDI3832
The K(t) method is referred to the literature* as the

arms (t = 0)  aPeak (t = 0) most reliable one.
K (t ) = The success of this diagnostic method is given
arms (t )  aPeak (t ) as > 95 %.
With:
arms (t=0) RMS value of vibration acceleration in the initial state (t=0)
aPeak (t=0) Peak to peak value of vibration acceleration in the initial state (t=0)
arms (t) Actual RMS value of vibration acceleration * Wälzlagerdiagnose an Maschinen und Anlagen (Roller bearing
diagnostics in machines and plants); Publisher: TÜV Rheinland, 1986;
Authors: Prof. Dr. Sturm,
aPeak (t) Actual peak to peak value of vibration acceleration Dr. Förster, Dr. Hippmann, Dr. Kinsky
The diagnostic characteristic value K(t) is the ratio of the product of peak value and RMS value of vibration acceleration
in the good state for a bearing to the product based on current values.
The evaluated frequency range is between 1kHz and 10kHz.

Seite 81
Diagnostic characteristic value DKW according to K(t)
Diagnostic characteristic value DKW for SM 1281:

According to the K(t) method, the characteristic value would decrease as the damage increases.
For the purposes of clarity, SM 1281 therefore generates the inverse value of K(t).
arms (t )  aPeak (t )
DKW =
arms (t = 0)  aPeak (t = 0)
The problem of all global diagnostic methods is lying in the unknown initial condition of the bearing at the beginning of monitoring.
When teaching the bearing it is assumed that the bearing condition is without a damage.
In case of a (slightly) damaged bearing, this state will be evaluated as the good initial condition.

Seite 82
DKW values
DKW * Bearing condition
<1 Improvement of the technical condition (e.g. running-in process)
> 1 to 2 Smooth running
> 2 to 5 Effect of factors that affect damage progression
> 5 to 50 Effect of the damage process
> 50 Formation of a damage with the risk of failure
* Wälzlagerdiagnose an Maschinen und Anlagen (Roller bearing diagnostics in machines and plants) Publisher: TÜV Rheinland, 1986; Authors: Prof. Dr. Sturm, Dr. Förster, Dr. Hippmann, Dr. Kinsky

Seite 83
Vibration analysis with SIPLUS CMS1200 SM 1281
Exercise 1
Global diagnostic procedure, characteristic value (vRMS) with the example of an imbalance
Global diagnostic procedure, characteristic value (aRMS) at rolling contact bearings
Global diagnostic procedure, characteristic value (DKW) at rolling contact bearings
Settings of SIMATIC HMI
Getting started with the web-Interface SM 1281

Page 84
Exercise 1
Work and watch with SIMATIC HMI
Presettings:
Configuration of the static and dynamic parameters
Establishing of the authorization of SM 1281
Determining and monitoring of the limit values:
Determine the good state, define limits
Measurement:
Actual values under good conditions
Actual values under conditions of damage
SM 1281, getting started with the web-Interface

Initial commissioning:
Homepage, log in, basic configurations
Measurement:
Actual values under good conditions
Actual values under conditions of damage
Display archived values (trend analysis), check messages
Page 85
Exercise 1
Work and watch with SIMATIC HMI Analytic diagnostics, configuration via web-interface
Characteristic value Monitoring for Spektra, trend analysis
Machine and bearing

vRMS, aRMS, DKW
vibration
vRMS acc. ISO20816-1 and

ISO10816-3
Work and watch with SIMATIC HMI Integrated web-interface

A visualization of the
▪ Settings of the network actual monitoring and ▪ Settings for monitoring the spectra
▪ Speed measuring state is ▪ Input of bearing data
▪ Sensor sensitivity possible in both ▪ Analysis of the spectra,
▪ Limit values of vRMS, aRMS and DKW
modes – SIMATIC HMI fingerprints
and web-interface. ▪ Data management system

Page 86
Exercise 1
SIMATIC HMI – Page „Overview“
The page „Overview“ shows a summary of the

configured condition monitoring system.
In this example one module SM 1281 with four

measuring channels is connected to the SIMATIC
module. It is possible to connect a maximum of seven
modules SM 1281 with four measuring channels each.
Click to the button „messages“ opens the
belonging message list. The query of messages is The module SM 1281 is ready for operation and actual
possible from each page. in the „RUN:Monitoring“-mode. Channel 1 is configured
and ready for operation.
Change device language on the footer line
In addition, the function to enable/disable the electric
(German or English).
drive is located on this page.

Page 87
Exercise 1
SIMATIC HMI – Page „Overview“
Click to the button of the

corresponding module
opens the belonging menu.
First the page „Actual
Values“ will appear.

Page 88
Exercise 1
SIMATIC HMI – Page „Actual Values“
The page „Actual Values“ shows a

complete visualization of the configured
condition monitoring system.
The functionality of the header line and the

footer line is available on every page.
A recording of the raw data and of the

fingerprints of the spectra can be started.

Page 89
Exercise 1
SIMATIC HMI – Page „Actual Values“, header line
Buttons for all available pages of the actual module; the header line and its
functionality is available on every page
Establishing of the authorization of SM 1281 between SIMATIC HMI and web-

interface
Selection of the operating mode from the

dropdown-list
SIMATIC HMI – Page „Actual Values“, footer line
Button for page „Overview“, pending messages and changing of the device language

Page 90
Exercise 1
In general, it is displayed:
▪ Actual speed
▪ System state
For each channel, it is displayed:

▪ Actual calculated characteristic values vRMS, aRMS, aPEAK and DKW
▪ Monitoring state of the characteristic values
▪ Monitoring state of the spectra (in case of configuration via the web-interface)
▪ Actual state of the sensor
Remarks
The measuring range of SM 1281 is limited to a voltage input between 6,2 and
15,0V. Values outside this range are not included in the calculation. The operating
point of the used IEPE-Sensors can be checked in the operating mode
„RUN:System diagnostics“.
A broken cable is monitored at „Sensor state“.

Page 91
Exercise 1
A recording of the raw data (configuration via web-interface) and of the fingerprints of the spectra can be selected
directly. The recording of the fingerprints of the spectra is done for the at the same time calculated spectra of vibration
velocity, vibration acceleration and envelope curve. Additionally, the value of the speed and the characteristic values of
vRMS and aRMS are recorded.

Page 92
Exercise 1
SIMATIC HMI – setting of the static and dynamic parameters
The values of the warning level and alarm
level of the characteristic values vRMS,
aRMS and DKW are called „Dynamic
Parameters“. All other parameters are called
„Static Parameters“.
Button to open the page „Parameters“
Button „Set All Parameters“ to save the

settings. SM 1281 changes to the operating
mode „STOP: Configuration“ and sets the
parameters. After this, SM 1281 changes to
the operating mode that was used last.
If only dynamic parameters have to be

saved, click to the button „Set Dynamic
Parameters“. SM 1281 changes to the
operation mode „RUN: Inhibited“ and sets
the parameters. After this, SM 1281 changes
to the operating mode that was used last.
Page 93
Exercise 1
SIMATIC HMI – setting of the „Module Parameters“
The communication data for the access via web-interface is settable.

Generally:
For the input of figures the will always be faded in a special input mask.
SM 1281offers three possibilities to detect the speed: You can define a hysteresis value for each alarm and
warning limit that you can activate or deactivate.
1. The speed can be imported via the SIMATIC backplane bus, in this example the
speed is given from the drive. Further values (e.g. fixed speed) can be realized On Off On Off On Off
v
within the program in the plc. Warning limit = 4
2. Digital input „SM 1281- DI“. The pulses per revolution can be adjusted from 1 to
100. With 1 pulse per revolution the highest detectable speed is 16000rpm. The
higher the number of pulses per revolution, the more accurate is the speed 4
detection and the lower is the highest detectable speed. Hysteresis = 1
3
3. The PLL-Algorithm allows to determine the speed of line guided motors directly
from the incoming vibration data. Necessary settings must be set via the
t
corresponding web pages of SM 1281.
Page 94
Exercise 1
SIMATIC HMI – setting of the parameters related to the measuring channel
Enable Activation/deactivation of the measuring channel
Input of the sensitivity of the sensor

Sensitivity
(normally the sensitivity is written directly at the sensor)
SpeedRatio Input of the speed ratio with a fixed ratio to the measured speed
Evaluation time of Evaluation time for the calculation of the characteristic values vRMS, aRMS and DKW.
vRMS, aRMS or DKW You can set the value „3 revolutions“ and the time ranges from 1 to 60 seconds.
Setting of the Highpass filter and the Lowpass filter for calculating the characteristic values
vRMS, aRMS and DKW:
Setting the frequency vRMS ➔ evaluation of the values according to standards
range for calculating Highpass filter 2Hz (with speed 120 < n < 600rpm) or 10Hz (with speed > 600rpm),
the characteristic Lowpass filter has a fixed setting with 1000Hz
values aRMS / DKW ➔ analysis of bearing condition, proposal for the Highpass filter 1000Hz and
the Lowpass filter 10000Hz
Setting of the dynamic Setting of the values of the Warning level and the Alarm level of the characteristic values
parameters vRMS, aRMS and DKW

Page 95
Exercise 1
SIMATIC HMI – setting of the dynamic parameters
Button to open the page „Parameters“
Input of the selected or calculated limit

values for warning and alarm
(separately for each measuring
channel); limit values should be set
according to the results of a teaching
process resp. according to the standard
ISO10816
Button to save the settings

Page 96
Exercise 1
SIMATIC HMI – Page „Maintenance“
Button to open the page

„Maintenance“
With the operating mode

„RUN: System diagnostics“
the bias voltage of the sensors
is shown
FAQ in progress

Page 97
Exercise 1
SIMATIC HMI – Page „Backup“
With every successful change to the operating

mode “RUN:Monitoring” SM 1281 will store the
complete last set parameters automatically in the
data block “Backup”. The change to this operating
mode is only possible with valid parameters, for this
reason only valid parameters are stored.
In case of invalid parameters and no idea of an

correct parameter-setup, please restore the latest
correct parameters by click on “Restore
Parameters”.
SM 1281 changes to the operating mode „STOP:

Configuration“ and sets the parameters. After this,
SM 1281 changes to the operating mode that was
used last.

Page 98
Exercise 1
SIMATIC HMI – measurement under good condition (without additional imbalance)
The monitoring state of the spectra of
velocity v(f)
acceleration a(f)
envelope curve e(f)
is only displayed in case of configuration via

the web-interface.

Page 99
Exercise 1
SIMATIC HMI – measurement under condition of damage (with additional imbalance)
1. Stop motor
2. Increase imbalance on flywheel using a

screw to generate a warning or alarm
3. Start motor
4. „Warning“ or „Alarm“ is displayed by

yellow or red color. The warning or alarm
color can be seen at Channel 1 and also at
the exceeded value itself. „Warning“ or
„Alarm“ is also displayed at the spectra in
case of exceeding the resp. values
(configuration via the web-interface).
5. Click to the button „Messages“ opens the

belonging list.

Page 100
Exercise 1
SIMATIC HMI – no or disturbed speed control
This will give the information, that the actual

operating condition of the shaft does not
correspond to the monitored condition.
Example:
The nominal value of the speed is given by
the SIMATIC. The actual value of the speed is
acquired by the input of SM1281.
Is the operating mode of SM1281 „Stop“, the
value of the speed is not calculated any
longer and is visualized with the value „0“. But
the real shaft is still turning.
Furthermore, this message can point to a
broken cable of the speed sensor or to a
disturbed acquiring of the sensor.

Page 101
Exercise 1
Configuration via the web-interface
Start the browser and enter the IP of the

SM 1281 in the address line (setting of the IP
with SIMATIC HMI).
On the "Home" page, an image of the device

is displayed in which the actual status is
shown.
There is also an overview here of the
number of pending messages:
"Active Warnings" and "Active Alarms" show
the number of active warnings and alarms
respectively.
For these counts, overlapping between
warnings and associated alarms has to be
taken into consideration.

Page 102
Exercise 1
Software and hardware requirements
▪ The web pages are optimized for the browser:

▪ Mozilla Firefox > v38; Internet Explorer > v10
▪ If other or older browsers are used, display problems may occur
▪ Deactivate the cache function of the browser
▪ The website uses cookies. You must therefore accept the use of cookies in the browser settings
▪ Deactivate the compatibility view of Internet Explorer
▪ The web pages have been optimized for a screen resolution of 1280 x 1024 pixels.

Page 103
Exercise 1
Login area
Name of the logged in user, login-/logout function
Titel area
Device name, date and time, current operating mode, switching
of the operating mode
Navigation area
Navigation tree that displays all the web pages
that can be selected for the device
Work area, device name

and data, operating mode,
pending messages
Page 104
Exercise 1
Login and logout is done via the login area and is only possible on the „Home“ page (default password: 0000, 4 times zero).
It is only possible to save changes and transfer them to the device in the logged-in state.
Page 105
Exercise 1
Navigation bar for SM 1281: The blue text indicates the SM 1281 page that is currently being displayed
Display of computer name as well as Login/Logout

Access to “Home” page
Display of possible diagnostic evaluations and system messages
Selection of the diagnostics to be performed

Setting the required parameters, warning and alarm limits
Input of the monitored bearings
Module specific settings (language, name, password, …)

Download area for backed up data, restoring factory defaults
Settings for rawdata handling

Page 106
Exercise 1
Cleanup, reset to factory settings
1. Stop SM 1281
2. Reset to factory settings
▪ Deletion is only possible in STOP mode.

▪ During deletion, it is not possible to operate the device
▪ Do not switch off the device during deletion

Page 107
Exercise 1
Cleanup, reset to factory settings
Trends All the traces recorded up to and including the specified date can be removed.
All messages up to and including the specified date can be removed.

Messages Exception: Messages that require acknowledgement, but which have not yet been acknowledged, will not be deleted in this
procedure.
Raw data
All raw data files up to and including the specified date can be removed from the device.
records
Fingerprints Fingerprints are saved under a name. After a fingerprint has been selected, it can be deleted using the "Delete..." button.
Monitoring The following diagnostic parameters are deleted or reset to their default values:
parameters ▪ Limit value settings for methods of analysis and channels
▪ Bands of limits
The following actions are performed using this button:

▪ Deletion of all recorded data (historical data, messages, raw data, fingerprints, teaching results), all diagnostic parameters
and the hardware configuration
Reset device to ▪ Resetting the device parameters, the password and the operating hours counter of the device
factory settings
Notes:
Bearing data are excluded from this function. These are always retained.
Reset to factory settings can also be done via Simatic.

Page 108
Exercise 1
Device name and channel name, change device language, change password, restart device
Change device language
Change device name

Page 109
Exercise 1
Device name and channel name, change device language, change password, restart device
Device name You can enter the name of the device here. It will appear in the title area, e-mails and in the "identification" menu.
Change language of the web surface between English and German. Choose language and click „Save“. The change of the
Language language needs about 10 seconds. During this time the connection to the device will be interrupted temporarily and the user
will be logged off.
In order to change the password stored in the device, click the "Change password…" button.
The appropriate dialog box will then be displayed. Enter the old and new password, and repeat the new password.
Password
If you forget your password, you can restore the password to factory settings via Simatic..
A system restart can be performed by clicking the "Restart…" button.
Restart device Notes:

During the restart, operation via the browser is not possible because the connection to the device has been interrupted.
After a restart, you will have to log in again!

Page 110
Exercise 1
Raw data recording
Raw data recording
On this site, the record duration and

decimation factor can be set:
• Record duration from 1 to 90 seconds
• The decimation reduces the sampling rate

and therefore the size of the raw data file.
This means that more raw data recordings
are possible. The maximum recording
duration is independent of the decimation
factor.
Note
Stored rawdata can be used for further offline
diagnostic with external software
e.g. CMS X-Tools

Page 111
Exercise 1
X-Tools setup
X-Tools setup
On the "X-Tools" page, you set the parameters

for the online data interface to X-Tools.
Note
An Ethernet connection to a X-Tools server is
required.

Page 112
Exercise 1
PLL configuration
PLL configuration
On this page, following settings can be done:
Center frequency
Base frequency with which the PLL algorithm
starts the search for the rotation frequency and
thus the speed. The further away this is from
the expected actual speed, the longer it takes
Recommendation for presetting ! to determine the speed
Center frequency Since drives usually run under load, it is recommended to set the center frequency Loop gain and DFrequency
according to the nominal speed (nameplate specification), taking into account the number
of pole pairs: Internal calculation values, changes only by
Siemens staff.
Center frequency [Hz] = Nominal speed [1/min] / 60 [s/min)
In general
Loop-Gain 0,7 Negative values are not allowed.
D frequency 0,1 Only one decimal place is allowed.
The default settings for loop gain and DFrequency are the most
useful for line guided drives and should not be changed
without reason

Page 113
Exercise 1
Save and restore
Save and restore
In the “Save and restore" menu, you can

download data that is stored in the device.
These data can then be exchanged with other
SM 1281 devices, or with other software, such
as CMS X-Tools for further processing of
backed up raw data.
Note
Data saving is also possible in RUN.
To prevent loss of data it is recommended to
restore the data only in STOP.

Page 114
Exercise 1
Save and restore
Export of data
Export as CSV-file:
• trend values
• messages
• fingerprints
Parameters are exported to a TXT-file.

The file contains the device name as well as
the monitoring settings of the characteristic
values and spectra for each vibration channel.

Page 115
Exercise 1
Diagnostic of characteristic value vRMS – good condition
1. Start motor
2. Select „Measuring mode“
3. Select the sensor channel
4. Choose the measuring

value
5. Start
All actual values of the system are visible on one page

Page 116
Exercise 1
Monitoring mode
All set diagnostic works will be performed and analyzed.
Measuring mode
The measuring mode is mainly for testing purposes and
supports the commissioning. The set measuring values
are recorded and are being visualized, but there is no
monitoring.
Process data are recorded, it is possible to save
fingerprints of the spectrum and also to record raw data.

Page 117
Exercise 1
Color identification
Correctly calculated values are highlighted using different
background colors to indicate any limit transgressions.
Color Meaning
The value was not configured and will not be

Empty
monitored/calculated
The value has been configured, but the diagnostics has

Marked with
not been finished . Maybe there is a failure of the sensor
„?“
or the connecting cables.
Measured value acquisition has not been performed or

Grey
is faulty
Measured value acquisition is OK. Value is not being

Light blue
monitored, however
Measured value acquisition is OK. Value is being

Green
monitored. There has been no limit transgression.
Measured value acquisition is OK, value is being

Yellow
monitored, and a warning limit has been transgressed
Start, select monitoring mode Measured value acquisition is OK, value is being
Red
monitored, and an alarm limit has been transgressed

Page 118
Exercise 1
Actual values in case of damage
1. Stop motor
Warning
2. Increase imbalance on
flywheel using a screw to
generate a warning or alarm
3. Start motor
Alarm

Page 119
Exercise 1
Diagnostic of characteristic value vRMS – display the trend
On the page „Trends“ you can If a value was not recorded

visualize recorded values (vRMS, over the full display interval,
aRMS, aPEAK, DKW, set values or if the device was not in
of the spectra, speed) RUN for a certain period, the
curve display will be
This page is available either via interrupted accordingly. The
the button „Trends“ or directly via value axis is automatically
the page „Actual values“ and the scaled on the basis of the
corresponding value values available in the
monitored interval.
For the horizontal position of the

cursor the numeric values are
shown („Chart data“).

Page 120
Exercise 1
Diagnostic of characteristic value vRMS – display the trend
For the primary trend you can visualize the warning and alarm limit.
You can use a separate Max. 4 channels (trends) can The period of time is selectable („Trend data buffer“). The resolution
y-axis for the reference trend be seen at the same time dependent on the period of time is as follows:
Last day 1 min
Last week 10 min
Last month 30 min
Last six month 3h
Last ten years 24 h
Page 121
Exercise 1
Diagnostic of characteristic value vRMS – displaying trends with two y-axis
1. Select primary and Choosing Using mouse wheel or

reference trends extract lasso (mark rectangle
with left mouse button
over favored area) a
2. Select use separate certain extract can be
y-axis (useful with shown enlarged
values that have big
numerical differences, Moving Considered image
e.g. vRMS and speed) extract section can be moved
by keeping the mouse
button hold
3. Update chart
Fading-in Pointing out bend base.
data points Not pointing out bend
base
Resetting Restores initial zoom,

zoom i.e.the whole spectrum
is shown

Page 122
Exercise 1
Check messages
Active exceeding of limit values are displayed at „Pending

messages“. With falling short of the limit values the message is
being expired.

Page 123
Exercise 1
Check messages
All messages are stored in the message

log and are available there.

Page 124
Exercise 1
Diagnostic of characteristic value aRMS at roller bearings
Setting with SIMATIC HMI,

configuration of the SM1281-Modul:
Highpass filter aRMS: 1000Hz
Lowpass filter aRMS: 10000Hz
aRMS of a bearing without damage:

0,79m/s²
The envelope curve analysis does

not detect any damage

Page 125
Exercise 1
Diagnostic of characteristic value aRMS - exceeding the warning limit

Warning Level aRMS 1,8m/s²
Alarm Level aRMS 2,8m/s²
aRMS exceeds the warning level
The envelope curve analysis

detects a damage, warning level is
exceeded

Page 126
Exercise 1
Diagnostic of characteristic value aRMS - exceeding the alarm limit

Warning Level aRMS 1,8m/s²
Alarm Level aRMS 2,8m/s²
1,67
aRMS exceeds the alarm level
The envelope curve analysis

detects a damage, alarm level is
exceeded

Page 127
Exercise 1
Diagnostic of characteristic value aRMS – display the trend
1. Select trend
2. Update chart

Page 128
Exercise 1
Characteristic value DKW for roller bearings: Determining the good state, speed profile
Insert lines and speed; the

speed profile depends on the
operating conditions

Seite 129
Exercise 1
Characteristic value DKW for roller bearings: Determining the good state, speed profile
Speed according to the Recommended teaching

Acquired speed range If the speed of 1000rpm is not reached during
operating conditions speed
monitoring, SM 1281 will make the comparison with
n1 200 180 180 ≤ n < 380 the next lower teaching value (in this case
800rpm).
n2 400 380 380 ≤ n < 580
n3 600 580 580 ≤ n < 780
n4 800 780 780 ≤ n < 970
n5 1000 970 970 ≤ n < 1170
n6 1200 1170 1170 ≤ n < 1350
n7 1400 1350 1350 ≤ n < 1430
n8 1480 1430 1430 ≤ n

Seite 130
Exercise 1
Characteristic value DKW for roller bearings: Determining the good state, teaching
1. Mount vibration sensor The values calculated during the teaching process are
on a good bearing updated cyclically.
The values of the table cannot be changed while the system
2. Select measuring mode is in teaching mode. When the teaching process has finished,
the values can be loaded into the "Reference values" column
3. Select sensor channel by clicking "Apply". It is also possible to enter the values
manually in the "Reference values" column based on the
taught values shown in the "Teach reference values" column.
4. Select values
Orientation values for duration of measurement:
Cyclic processes with variable speeds: Duration of
5. Start measurement ≈ 3 process cycles
Processes with constant speed: Duration of measurement ≈
6. Start motor, get up to the 20 hits
defined speed ranges
7. After finishing the taught values must be

accepted by clicking the button „Apply“
Seite 131
Exercise 1
Characteristic value DKW for roller bearings: Defining and activating limits
2. Activate warning and alarm

limit
1. Define limit values, proposed

settings for warning limit 2 and
for alarm limit 6

Seite 132
Exercise 1
Characteristic value DKW for roller bearings: Actual values in the good state / under condition of damage
1. Mount vibration sensor at a

good bearing
good state
2. Start motor
1. Mount vibration sensor at a

condition of damage
damaged bearing
2. Start motor
3. DKW exceeds alarm limit

Seite 133
Summary
Characteristic value Frequency range Monitorable
vRMS
(RootMeanSquare) 2 / 10Hz – 1 / 2kHz Housing vibration
RMS vibration velocity
DKW
1kHz – 10kHz Roller bearing condition
Diagnostic characteristic value
aRMS
RMS vibration acceleration 1kHz – 10kHz Roller bearing condition

Page 134
Summary
Overview of faults that occur on different system units, arranged according to fault frequency
Damage is detected by measuring the rms vibration velocity
High Fault frequency Low
Resonances
Imbalance Field fault rotor/
Electric motor Alignment fault Faulty installation (soft Belt fault
(drive elements) stator
substructure)
Fans Blade passing

Imbalance Alignment fault Resonances Turbulances Coupling fault Faulty installation Belt fault
Blower frequency
Blade passing
Pumps Alignment fault Coupling fault Turbulances Imbalance Resonances Faulty installation Belt fault
frequency

Page 135
Analytic diagnostic procedures
Overview
A constant increase of the values of the vibration velocity is detected .

But what is the reason for this?
Analyzing the vibrations with analytic diagnostic procedures

Root cause diagnostics
Defining of remedial measures

Page 136
Analysis methods
137
Characterístic values
Any signs of damage?

• Analysis of machine / bearing vibrations
• RMS value of vibration velocity vRMS / vibration acceleration aRMS,
bearing characteristic value DKW
• Simple representation, e.g. traffic light
• Trend charts vRMS, aRMS and DKW
Frequency selective analysis
What precise damage is imminent?

• Analysis of machine vibrations, such as resonance; unbalance,
alignment/coupling faults
• Analysis of roller bearing damage, such as damage to outer or inner ring,
cage, rolling element damage
• Trend monitoring of frequency bands

Page 137
Frequency selective analysis, analytic diagnostic procedures
138
Frequency selective analysis, analytic diagnostic procedures Signal How it works

• Settings for monitoring the
Engineering and configuration via spectra are made in SM 1281
SIMATIC S7-1200 CPU and SM 1281 Web interface • Monitoring in SM 1281

• Cyclic transmission of
• Characteristic values
Monitoring for machine
Examples of detectable mechanic damages • Status messages
vibration
to S7-1200 CPU
• Display on PC, panel, etc.
Resonance Misalignment
• Access to Web interface
SM 1281 shows
Imbalance Coupling fault
Frequency-selective • Spectra
analysis with • Trend analysis
Monitoring for roller

SM1281
Detectable mechanic damages
bearing damage
Rolling element
Outer race defect
damage
Advantages:
Inner race defect Cage damage Type of damage identifiable
→ Corresponding maintenance

Page 138
Overview
Time signal Frequency spectrum
The Fourier transform (FT) describes the mathematical relationship between time and frequency.
In the case of vibration, the time curve is available for a vibration variable.
According to Fourier, the time curve is composed of overlaid sinusoidal and cosinusoidal vibrations (infinite sequence of sine and cosine
terms).
A fast method is the so-called Fast Fourier Transform (FFT).

In place of n² (n: number of measured values) in the Fourier transform, 2n multiplications are used in the FFT.
FFT analyzers are standard today in vibration analysis.
Page 139
Overview
Vibration diagnostics – Frequency analysis
Frequency analysis splits the vibration signal into its separate frequency components.
When machine vibrations are investigated, a number of dominant periodic frequency components that are directly
related to the operating motions of various machine parts can usually be found.
Therefore frequency analysis can be used to detect the source of unwanted vibrations.
It forms the basis of diagnostic vibration analysis.
The spectrum contains all distinct periodic processes from the entire shaft train comprising motor, gear unit and driven
machine.
The individual frequencies present themselves here not just in their fundamental frequency, but also in integer multiples,
known as harmonics.
To fully interpret a spectrum, it is essential to have detailed knowledge of the entire shaft train.

Page 140
Definition of variable speed for bearing monitoring
Meaningful measurement is not possible in the sections of the

Rotational 2 Variable speed based on curve marked with 1 . A CM system is unable to detect
speed n the example of a frequency-dependent damage (e.g. bearing damage, blade passing
1 traversing profile: frequency, rotor bar breakage) in these cases, because the damage
The speed increases frequencies change as a function of speed.
1 2 continuously and then
remains constant.
The speed then falls and Meaningful measurement is possible in the sections of the curve
remains constant again for a marked with 2 .
1
certain length of time. It is important to note the following with regard to bearing damage:
Then the speed falls to zero For reliable detection of bearing damage, the damage location must
and the traversing profile is be rolled over at least 10 times during the measuring cycle. SIPLUS
run through again. CMS1200 calculates the time required for this number of rollovers
from the speed. If the speed changes by +/- 3% during the
time t
calculated measuring time within the measuring cycle, the
measurement is rejected.
Rotational Variable speed based on
speed n the example of different For processes with different speeds:
2 production processes: Monitoring of speed-dependent damage frequencies requires that
For production of 40g paper, a constant speed prevails for a defined measuring period.
a process operates at a
2 constant speed of 1000rpm.
Then the machine is
changed over for 80g paper, This is a feature of all condition monitoring systems,
and a constant speed of
with the exception of those that perform order analysis.
1500rpm is used.
time t

Page 141
SM1281
Block diagram signal flow and filter settings
The picture shows in a simple way the signal flow and filter settings of SM 1281
Lowpass
10kHz
a(f)
Range X-Axis
0Hz to 10KHz
Integrated
Highpass
10Hz in
Firmware
Rectification
Lowpass Range X-Axis
RPM and e(f)
10kHz 0Hz to max. 10KHz
demodulation
Sensor signal
Highpass
2Hz
Lowpass Range X-Axis
Integrator v(f)
1kHz / 2kHz 0Hz to 1KHz / 2kHz
DKW
aPEAK To be set as a parameter by user
Highpass Lowpass
variabel variabel
vRMS
aRMS

Seite 142
Overview of SIPLUS CMS1200 SM 1281
Spectrum Frequency range Resolution Monitorable
2Hz – 1kHz
0,2Hz
Speed range 120 … 6000 1/min
Spectrum velocity v(f) Given speed independent limits
10Hz – 2kHz Given speed dependent limits
0,4Hz
Speed range 6000 … 16000 1/min Given mask limits for undefined ranges
Spectrum acceleration a(f) 2 / 10Hz – 10kHz 2,8Hz
2Hz – 1kHz
0,2Hz
10Hz – 2kHz
0,2Hz
Envelope curve analysis: Speed range 2400 … 4800 1/min Bearing damage frequencies, speed-dependent
Envelope spectrum e(f) 10Hz – 5kHz and their harmonics
0,4Hz
10Hz – 10kHz
1,0Hz

Page 143
Typical spectra of the most common vibration causes
Imbalance
Machine speed n = 1488rpm

Number of pole pairs p=2
Rotation frequency frot = 24,8Hz
1 x frot 2 x frot 3 x frot

^
v [mm/s]
Amplitude of frequency of rotation is similar in horizontal and

24,8 74,4 f [Hz] vertical measuring directions
49,6

Page 144
Alignment fault
Machine speed n = 1488rpm Machine speed n = 1488rpm

Rotation frequency frot = 24,8Hz Rotation frequency frot = 24,8Hz
First and second/third frequency of rotation are considerably

v^ [mm/s] 1 x frot 2 x frot 3 x frot increased. The rise depends on the direction of measurement, in
accordance with the direction of the alignment fault.
Check by decoupling.
Rigid coupling:
First and second frequency of rotation are increased
Elastic coupling:
24,8 49,6 74,4 f [Hz] First and third frequency of rotation are increased

Page 145
Faulty mechanical installation

v^ [mm/s] 1 x frot 2 x frot 3 x frot
First and second frequency of rotation are considerably increased,

usually in every direction of measurement
(horizontal, vertical, axial).
Check by means of "soft foot check".
24,8 49,6 74,4 f [Hz]

Page 146
Bent shaft


v^ [mm/s]
First and second frequency of rotation are considerably increased,

usually in every direction of measurement
(horizontal, vertical, axial).
24,8 74,4 f [Hz] Check by means of true-run measurement on the shaft extension.
49,6

Page 147
Mechanical loosening

v^ [mm/s] 3 x frot 4 x frot

1 x frot 2 x frot
First frequency of rotation is practically non-existent, multiples

(especially twice the frequency of rotation) are clearly visible.
24,8 49,6 74,4 99,2 f [Hz]

Page 148
Field fault stator
Possible causes:
▪ Eccentric rotor alignment

▪ Short circuit in the windings
▪ Asymmetric supply
▪ Switching fault in the windings
Increased level of twice the mains frequency. Mains frequency is

50/60Hz for direct drives. This varies in the case of converter
operation.
1 x fmains 2 x fmains
^ 2 x frot for 2-pole maschines (slip!)
v [mm/s] ^
v [mm/s]
2 x fmains
50,0 100,0 f [Hz] 99 100 101 f [Hz]

Page 149
Field fault rotor
Possible causes:
▪ Bar break
▪ Loose bar
▪ Broken connection between bar and short-circuit ring
These faults can be detected by:

▪ Bar passing frequency with side bands of twice the mains
frequency
▪ Twice the mains frequency with side bands of the slip frequency
Number of bars = 58; n = 1488rpm

Bar frequency fbar = 58 x frot =1438Hz
a^ [m/s2]
Side bands at a Side bands at a

spacing of 2 x fmains spacing of 2 x fmains
1338 1438 1538 f [Hz]

Page 150
Field fault rotor
Possible causes:
▪ Bar break
▪ Loose bar
▪ Broken connection between bar and short-circuit ring
These faults can be detected by:

▪ Bar passing frequency with side bands of twice the mains
frequency
▪ Twice the mains frequency with side bands of the slip frequency
v^ [mm/s] 2 x fmains
Side bands at spacing of the slip frequency

fslip= fmains/p – frot = 0,2Hz
99,8 100 100,2 f [Hz]

Page 151
Blade passing frequency
Machine speed n = 1488rpm The blade passing frequency is the product of the
Rotation frequency frot = 24,8Hz number of impeller blades and the rotation
frequency.
Number of blades 17
Interference occurs on the housing:
Blade passing frequency If the amplitude of the blade passing frequency
fSP = 17 x fRot = 422Hz increases, each blade generates a vibration peak,
e.g. when every blade passes a defective point in
the housing and experiences a shock caused by a
variation in pressure.
Possible causes:
^
a [m/s2]
fSP ▪ Turbulence
v^ [mm/s] IMPORTANT:
▪ Suction pressure incorrectly Not to be confused with imbalance!
dimensioned In the case of imbalance, one part of the rotating
section causes a vibration with rotational
▪ Adjustable blades have not been
frequency, e.g. when a deposit of material on a
set accurately
blade causes asymmetrical distribution of the load
The amplitude of the blade passing with respect to the center.
422 f [Hz] frequency has increased

Page 152
Meshing frequency
Machine speed n = 1488rpm The most important factors in gear unit diagnostics:
Rotation frequency frot = 24,8Hz Knowledge of the gear unit construction is required for monitoring the
meshing frequencies, e.g. number of teeth of the individual gear stages,
Number of teeth 33 mounting sensor options.
Detailed analysis of the spectrum of the meshing fault is performed by
means of side band analysis in the spectrum.
Meshing frequency The faults are located in the high-frequency range, so the acceleration
fZ = fRot x 33 = 818Hz spectrum is required.
The resolution of the acceleration spectrum in CMS1200
SM 1281 is, however, lower than the velocity spectrum.
Gear unit diagnostics is and will remain exclusively the domain of
specialists, due to the wide range of different types of gear units and
a^ [m/s2]
mountings.
v^ [mm/s] 1 x fZ 2 x fZ 3 x fZ
Gear unit spectra How SIPLUS CMS1200 SM 1281 supports this:
comprise numerous SIPLUS CMS1200 SM 1281 therefore offers the possibility of raw data
meshing frequencies recording and downloading in the form of a WAV file.
and their harmonics, Raw data downloading supports further/in-depth analysis with suitable
as well as side bands. software tools that are able to import WAV files. Siemens offers the X-Tools
software for this purpose.
Evaluation is complex
X-Tools and the comprehensive module library can be used to create
and extensive. corresponding analysis models from which conclusions can be
drawn regarding this damage.
818 1636 2454 f [Hz]

Page 153
Meshing frequency
Local damage at gear teeth Wear of the tooth flanks at the whole circumference
➔ once per turn there is a meshing ➔ even damaging of the tooth flanks
You can see the meshing frequency with side bands. The
side bands occur at a spacing of the rotation frequency of You can see the meshing frequency with harmonics. The
the shaft with the damaged wheel. With this information the amplitude heights of the harmonics compared to the first
damaged wheel can be found out exactly. The amplitude meshing frequency is a measure of damage.
height of the side bands is a measure of damage.

Page 154
Appendix
Raw data export for expert analysis
155
Raw data export for expert analysis Signal How it works
• Raw data recording by user

• Raw data recording by event ▪ A message signals that a
meshing fault was detected
Monitoring for ▪ The raw data of the sensor

Detectable mechanical damage channel is recorded and saved
gear unit wear
▪ Exporting of the raw data

Raw data export
Meshing faults
Advantage:
Analysis of exported raw data is always an
Raw data used for analysis models that are exactly
OFFLINE analysis
tuned to the gear unit

Page 155
Belt damage frequency

Diameter of the driven disk 200mm
Belt length 800mm
f rot  diameterdriving disk  p

f belt = = 19,5Hz
belt length
v^ [mm/s]
fBelt frot Worn or damaged belts result in an increase in amplitude of the
belt damage frequency
19,5 24,8 f [Hz]

Page 156
Resonance
v^ [mm/s] fnatural
Resonance
range
speed n [1/min]
Within a certain speed range, vibration levels escalate suddenly. When this sensitive speed range has been passed, vibration levels falls
back again.
The system has its own natural frequency.
Possible causes:
▪ Natural frequency in the substructure as a result
of mounting
▪ Natural frequency of the rotor

Page 157
Resonance
Within a certain speed range, vibration levels escalate

suddenly. When this sensitive speed range has been
passed, vibration levels falls back again.
The system has its own natural frequency.
Possible causes:
▪ Natural frequency in the substructure as a result
of mounting
▪ Natural frequency of the rotor

Page 158
Practical example for root cause analysis
CMS1200 SM 1281 monitored a

rms value of the vibration velocity
vRMS clearly below the warning
limit of 1,5mm/s.
The trend monitoring shows a
constant increase of the values of
the vibration velocity.
Spectrum of
vibration velocity Spectrum of The peak of the basic
up to 1000Hz vibration velocity rotation frequency is
up to 100Hz increased. The reason
for the increased level of
vibration is therefore an
imbalace.

Page 159
Exercise 2
Frequency analysis using imbalance as an example

Page 160
Exercise 2
CMS1200 SM 1281 Analytic diagnostic procedures
Determining and monitoring the limits:

Velocity spectrum under good conditions
Create a band of limits
Configure band of limits
Activate band of limits
Measurement:
Actual measured values under condition of damage
Analysis:
Compare good condition and damage condition
Display the trend of a set value of the spectrum

Page 161
Exercise 2
Actual spectrum of vibration velocity v(f) under good condition
1. Mount vibration sensor

at good bearing
2. Select measuring mode
3. Select sensor channel
4. Select value
5. Start
6. Start motor without

imbalance

Page 162
Exercise 2
Save fingerprint under good condition
1. Wait until spectrum

appears on screen
2. Click „Save“
3. Enter name
4. Click „OK“

Page 163
Exercise 2
Change the scaling of the x-axis
The x-axis can be displayed with different values:

▪ Frequency of the vibration in Hz
▪ Speed of the machine in revolutions per minute rpm
▪ Order (corresponding to the multiples of the rotation
frequency
Normally, the x-axis is displayed with the frequency of the

vibration in Hz.
Frequency [Hz]
Speed [rpm]
1. Activate button „Use alternative x-axis“
and select „Order“ or „RMP“
Order
2. Update chart
Page 164
Exercise 2
Limit bands: Overview
Monitoring of defined frequency ranges, e.g. in case of separate mounted

units (separately driven fans, aso.)
Monitoring of speed dependent frequencies. The tolerances of these

frequencies can be specified absolute in Hz and relative in percent.
Mask limits to cover the remaining frequencies not monitored by one of the
procedures mentioned above
Page 165
Exercise 2
Limit bands: Frequency ranges, trend monitoring
For each monitoring of the limit bands it is possible to activate a

trend recording. The trend must be defined by a name.
The recording and visualization is done in the same way to the
already known values (vRMS, aRMS, aso.)

Page 166
Exercise 2
Limit bands: Configure and saving
1. Click “New” to open and

3. Save
name a new limit band
2. Configure the limit band:

▪ Put in a Message text
▪ Set the speed factor or define a frequency range for monitoring
frequencies
▪ Set the limits for each warning and alarm
▪ Optional mask limits can be set
▪ Activate trend recording by giving a trend name
In case of exceeding warning- or alarm levels, the Message text is

shown in the belonging message log.
Page 167
Exercise 2
Limit bands: Activating
1. Activate monitoring
2. Select band of limits
3. Activate reactions
4. Save settings
Activation/deactivation of the monitoring method

Warning and alarm
NOTE: This box must be checked in order to facilitate performance of limit monitoring!
A limit transgression results in the recording of raw data. This raw data can be evaluated later with further tools. To save memory resources, a maximum of three
Record raw data values per limit are recorded for limit transgressions during a RUN phase.
It is possible to set the length of time of recording the raw data for each vibration channel. Permissible values are between 1 and 90 seconds.
Trend values The calculated values (e.g. vRMS, aRMS, set values of the spectra) for this monitoring method are archived automatically.

Page 168
Exercise 2
Actual values under good condition
1. While no imbalance is
added to the flywheel, the
spectrum v(f) will be
displayed green

Page 169
Exercise 2
Actual values under condition of damage
1. Stop motor
2. Add imbalance to flywheel
3. Start motor
4. Click on spectrum
(yellow or red)

Page 170
Exercise 2

Page 171
Exercise 2
Comparing good condition and damage condition
1. Select latest spectrum

(primary spectrum)
2. Select fingerprint
(reference spectrum)
3. Display limits
4. Start motor with imbalance 5. Update chart

Page 172
Exercise 2
Trend of a defined frequency range

Page 173
Exercise 2
Practical advice – Cable for sensors broken or connected with false polarity

Page 174
Frequency analysis of the acceleration spectrum
Setting of the limit bands of the acceleration spectrum is the same as of the velocity spectrum
Differences and common points:
2Hz – 1kHz
0,2Hz
0,4Hz

Page 175
Overview of SIPLUS CMS1200 SM 1281
2Hz – 1kHz
0,2Hz
0,4Hz
2Hz – 1kHz
0,2Hz
10Hz – 2kHz
0,2Hz
Envelope curve analysis: Speed range 2400 … 4800 1/min Bearing damage frequencies, speed-dependent
Envelope spectrum e(f) 10Hz – 5kHz and their harmonics
0,4Hz
10Hz – 10kHz
1,0Hz

Page 176
Damages of roller bearings
Energy
imbalance
Electromagnetic components (stators, rotors)
a^ [m/s2]
Alignment faults
v^ [mm/s] Couplings
Fan impellers
Gear wheels
Component resonances
Material resonances
Damaged roller bearing

2 x fMains
2 x fn2
1 x fn2
fTooth Analytical diagnostics based on the velocity spectrum

is less suitable for early detection of bearing damage,
because the extremely low-energy defective
Bearing vibrations components of the roller bearings are masked by the
high-energy machine vibrations.
1 2 3 5 10 20 30 50 100 200 500 1000 3000 10.000 f(log) Hz

Page 177
Envelope curve spectrum
The envelope curve method is used for analyzing roller bearings.

A suitable frequency range is filtered out of the acceleration spectrum that contains the
running noises of the roller bearing.
The signal curve is then checked for those disturbances that are generated when bearing
damage is rolled over. An envelope signal is superimposed on the roller bearing noise.
If the time intervals of the periodically occurring shocks match one of the bearing damage
frequencies, this shows that the corresponding type of bearing damage exists.
a[m/s²] a [m/s2] Damage frequency

∆f = damage frequency and harmonics
a[m/s²]
time
Bearing vibrations Envelope curve
3.000 10.000 f [Hz] t [s] f [Hz]

Page 178
Envelope curve spectrum vibration acceleration

Filtered amplitude spectrum of the time signal of vibration acceleration for analyzing roller bearing damage
In the ideal machine, the envelope for this time signal is a horizontal straight line. When a defect is rolled over, however, shock pulses
arise periodically that overlay the machine vibrations, i.e. the horizontal straight line described above as the envelope curve is interrupted
periodically or overlaid by these pulses.
Curve without damage Curve with damage Envelope curve spectrum
∆f = damage frequency a [m/s2] Damage frequency

a [m/s2] a [m/s2] time and harmonics
Envelope
curve
f [Hz]
t [s] t [s]
The resulting envelope curve only contains information about defects. The smallest defects are therefore visible, regardless of the much
more energy-rich machine vibrations that do not modulate the vibration signal in the frequency ranges observed. The damage frequencies
become visible when the time signal is converted into a frequency signal.

Page 179
Internal clearance
Relief zone α
Outer ring axial

Bearing weight
Belt tension Inner ring DW
Rolling element
DPW
Cage
Speed rpm
f Rot = Rotation frequencyHz  =
Load zone = Measuring zone 60
Z = Number of rolling elements
DW = Diameter of rolling elements
DPW = Pitch circle diameter
fRot  = Contact angle

Page 180
Roller bearing geometry and calculation of the bearing damage frequencies based on the example of a bearing of type 6004:
1  D    Note
1 D
f Outer ring =  f Rot  Z  1 − W  cos  f Cage =  f Rot  1 − W  cos  Bearings of the same type can
2  DPW  2  DPW  have different damage
frequencies, depending on the
1  D  1 D   D  
2
manufacturer.
f Inner ring =  f Rot  Z  1 + W  cos  f Rolling element =  f Rot  PW  1 −  W
 cos  
2  DPW  2 DW   PW D  
Calculation example for a roller bearing of type 6004

Speed rpm frot = 1488rpm = 24.8Hz fouter ring = 88.8Hz
f Rot = Rotation frequency Hz  =
60 Z=9 finner ring = 134.4Hz
Z = Number of rolling elements
DW = Diameter of rolling elements DW = 6.35mm fcage = 9.9Hz
DPW = Pitch circle diameter DPW = 31mm frolling element = 58,0Hz
 = Contact angle
Contact angle α = 0°

Page 181
Outer ring damage

Damages frequently develope first in the raceway of the outer ring.
These faults can normally be detected using envelope curve analysis
several months before a critical condition develops.
The damage frequency is visible in the envelope curve spectrum
without modulation.
a[m/s²]
1 x fOR
2 x fOR
Damage frequency of the outer ring 88.8Hz at a 3 x fOR
motor speed of 1488rpm = 24,8Hz 4 x fOR
f [Hz]
88,8 177,6 266,4 355,2

Page 182
Inner ring damage

These faults can normally be detected using envelope curve analysis
several weeks before a critical condition develops.
Inner ring damage runs through the load zone periodically. Therefore the
damage frequency is visible in the envelope curve spectrum with side
bands at a spacing of the frequency of rotation fRot.
a[m/s²]
1 x fIR
Envelope curve spectrum 2 x fIR

3 x fIR
Inner ring damage frequency 134.4Hz at a motor speed of
1488rpm = 24,8Hz
Side bands at spacing of the mechanical rotation frequency
(24,8Hz),
134,4 268,8 403,2 f [Hz]
SM 1281 monitors harmonics of inner ring damage (red lines); the side bands (blue lines) cannot be monitored explicitly with SM 1281.
If the side bands are spaced within the resolution range of the vibration acceleration spectrum, they are visible in the spectrum.

Page 183
Cage damage
Cage damages result in failure of a bearing within a very short period of
time.
The damage frequency is visible in the envelope curve spectrum without
modulation. An online-monitoring is possible, the reaction in case of such a
damage is temporarily limited.
a[m/s²]
1 x fCage
2 x fCage
3 x fCage
4 x fCage
Damage frequency of the cage 9.9Hz at a motor f [Hz]
9,9 19,8 29,7 39,6
speed of 1488rpm = 24,8Hz

Page 184
Rolling element damage

Rolling element damages result in failure of a bearing within a very short period of time.
In the envelope curve spectrum, the damage frequency is visible with side bands at a
spacing of the cage rotation frequency. In practice the 2.,4.,6th., … order of damage
frequency of an occurring rolling element damage is shown in the envelope spectrum.
The example above and the calculation in SM 1281 show the first order of the damage
frequency.
a[m/s²]
2 x fRolling element
1 x fRolling element 3 x fRolling element

Damage frequency of rolling element 116Hz
at a motor speed of 1488rpm = 24,8Hz
Side bands with spacing of the cage f [Hz]
frequency (9.9Hz) 116 232 348

Page 185
Appendix – Bearing damages, cause analysis
The classic fatigue failure (to begin with cracks below the surface) is rarely in practice. In about 75% of the cases,
bearings are damaged directly at the surface of the rolling contact areas because of insufficient lubrication or
contamination.
Further causes:
▪ Excessive radial load (e.g. overhung belt load)
▪ Vibrations during operation
▪ Bearing service life exceeded

Page 186
Track with strong axial offset and consequently track break-outs
Possible causes:
▪ Excessive axial load (see
information of the motor
manufactures)
▪ Axial geometry deviation of
the bearing assembly
▪ Loss of the function of the
floating bearing

Page 187
Slanted tracks, the track of standing bearing ring (in this case the outer ring) is not exactly vertical to the axial direction.
Possible causes:
▪ Non parallel bearing seat surfaces
▪ Diagonal distorting of bearing due to incorrect
mounting

Page 188
Fretting rust on outer ring (brown outlooking of the

seat surfaces).
Because of the outlooking of the areas with fretting
rust one can conclude the position and the
dimension of the load zone.
Possible causes:
▪ Bearing seat position in bearing shield above
permissible tolerances
▪ High vibrations during operation

Page 189
Current flow through the bearings is caused

either by a magnetical asymmetry (inductive
bearing currents) and/or with operation with a
frequency converter (capacitive bearing currents).
You can see this as corrugation in parallel with
axis.
Remedial measures:
▪ Insulate NDE bearing (e.g. with a ceramic layer on the surface of the outer
ring)
▪ Ensure EMC compliant grounding concept
▪ Use of output filter on converter

Page 190
Exercise 3
Frequency-selective bearing diagnostics

Page 191
Exercise 3
CMS1200 SM 1281 Analytic diagnostic procedures, configuration via web-interface
Presettings:
Create and configure bearing type
Activate monitoring and responses
Determining and monitoring the limits:

Save fingerprint on undamaged bearing
Create a band of limits
Configure band of limits
Activate band of limits
Measurement:
Actual values measured under good conditions
Actual values measured under conditions of damage
Analysis:
Use cursor mode
Compare spectrum with fingerprint
Check system messages

Page 192
Exercise 3
Create and configure bearing type
1. Create new bearing type
2. Select bearing type name
3. Confirm

Page 193
Exercise 3
Configure bearing type – enter fault frequencies directely
For direct entry of the frequencies, enter a speed as the reference

value and the bearing fault frequencies for outer ring, inner ring,
rolling elements and cage. Bearing manufacturers offer frequency
calculators at the internet.
We propose determining the fault frequencies for a speed of
60rpm and entering the values in SM 1281.
Incomplete entries of the fault frequencies are also accepted, but
in this case you will be unable to activate bearing monitoring for a
particular type of damage.
The "Bearing types" menu includes a rollover frequency

calculator. After a speed (revolution per minute) has been
entered, the rollover frequencies for outer ring, inner ring, rolling
elements and cage are displayed.
Calculated fault frequencies

Page 194
Exercise 3
Configure bearing type – enter bearing geometry
Enter the bearing geometry
For the bearing geometry it is necessary to

set the four classification figures
▪ contact angle
▪ pitch circle diameter
▪ ball diameter
▪ number of rolling elements
Calculated fault frequencies For this configuration you have to know the
bearing geometry in detail.

Page 195
Exercise 3
Configure bearing type – enter as data base with .csv – file format with a text-editor app
Bearing type BPFO BPFI FTF BSF

Reference speed [rpm]
Outer ring Inner ring Cage Rolling element
6004_60 3.58 5.42 0.4 2.34 60
6004_600 35.8 54.2 3.98 23.4 600
▪ Input of the bearing data in the format „Bearing type;damage frequency outer
ring;damage frequency inner ring;damage frequency cage;damage frequency
rolling element;reference speed“, in this example e.g.
6004_60;3.58;5.42;0.4;2.34;60 or 6004_600;35.8;54.2;3.98;23.4;600
▪ The input of the bearing data is done without any blanks, separated by a
semicolon, with figures using in every case a dot instead a comma
▪ Open the web surface SM 1281 and do a login
▪ Go to „Administration“, then „Save and restore“
▪ Go to „Download settings“, click the button „Import CSV…“
(click left mouse button)
▪ Windows-Explorer, navigate to the created file .cvs, choose file with click left
mouse button and confirm with „open“
▪ The data will be imported. There is no feedback with successful import.
▪ If bearing types with the same name are imported once again, the old data will
be overwritten without further inquiry

Page 196
Exercise 3
Limit bands: Defining, saving, trend monitoring
1. Click “New” to open and name a new limit band
2. Select bearing type from the existing list
3. Configure the limit band:

▪ Select the bearing damage frequency that should be monitored
as a message text
▪ Set the speed factor to define the harmonics
▪ Set the limits for each warning and alarm
▪ Optional mask limits can be set
▪ Activate trend recording by giving a trend name
In case of exceeding warning- or alarm levels, the Message text is

shown in the belonging message log.
You can record and visualize the set values of the spectrum according
to the known trends (vRMS, aRMS, speed, ...).
Monitoring of the parameters

For the parameters of warning and alarm level of the envelope analysis, there does not exist any normative demands. These parameters depend on the size of
the bearings, operating conditions, temperatures, ...
In practice the shown values have proved themselves to be used as starting guidance values.

Page 197
Exercise 3
Limit bands: Defining, saving, trend monitoring
4. Enter value for hysteresis
5. Enter value for the frequency tolerance (absolute

in Hz or relativ in percent)
6. Mask limits to cover the remaining frequencies not

monitored by one of the procedures mentioned
above
7. Save settings

Page 198
Exercise 3
Save fingerprint of bearing without damage
1. Mount vibration sensor on

bearing without damage
2. Start motor
3. Start SM 1281, select measuring

mode
4. Select spectra
5. Select vibration channel and

Envelope
6. Save fingerprint, enter name

Page 199
Exercise 3
Activate limit band
1.Activate monitoring
2. Select limit bands for each

operation states
3. Activate reaction (optional)
4. Save
Select a limit band from the list of defined bands. This band contains information about which frequencies must be monitored as well as
the associated limits, taking into account the bearing data.
A band of limits contains information from all four types of damage to be considered, and you can also make the settings for monitoring the
warning and alarm limits and for the hysteresis of the warning and alarm limit.

Page 200
Exercise 3
Actual values under good condition

bearing without damage
2. Start motor
3. Start SM 1281, select

monitoring mode

Page 201
Exercise 3

damaged bearing
2. Start motor
3. Start SM 1281, select

monitoring mode

Page 202
Exercise 3
Identify the damage (Cursor Mode)
2. Select cursor and identify

the damage with only a few
1. Display envelope curve clicks

Page 203
Exercise 3
Checking pending messages

Page 204
Working method using a drive train as an example
Pump / Fan Gear unit Drive Damage frequencies
Inner ring
fI = 134,5Hz
Outer ring
fA = 88,7Hz
Rolling element
fW = 58,0Hz
Cage
fK = 9,9Hz
Technical data:
Speed n2 = 963rpm Speed n1 = 1488rpm
z1 = 33 teeth; z2 = 51 teeth Number of bars = 58
Number of blades = 17
Calculating the frequencies:

Rotation frequency fn2 = 16Hz Rotation frequency fn1 = 24,8Hz
Blade passing frequency Meshing frequency Twice rotation frequency 2fn = 49,6Hz
fSp = 17 x fn2 = 272Hz fz = fn1 x 33 = fn2 x 51 = 818Hz Bar frequency fbar = 58 x fn1 =1438Hz

Page 205
Technical data: Roller bearing Drive

Speed n1 = 1488rpm Damage frequencies
Number of rotor bars = 58
Inner ring fI = 134,5Hz
Calculation of the frequencies: Outer ring fA = 88,7Hz
Rotation frequency fn1 = 24,8Hz Rolling element fW = 58,0Hz
Double rotation frequency 2fn1 = 49,6Hz Cage fK = 9,9Hz
Bar frequency fBar = 58 x fn1 = 1438Hz
a^ [m/s2]
v^ [mm/s]
2 x fmains
2 x fn1
1 x fn1
fBar
Envelope spectra analysis
1 2 3 5 10 20 30 50 100 200 500 1000 3000 10.000 f(log) Hz

Page 206
Technical data:
Gear unit
z1 = 33 Teeth; z2 = 51 Teeth
n1 = 1488rpm; n2 = 963rpm
fn1 = 24,8Hz; fn2 = 16Hz
Calculation of the frequencies

Meshing frequency:
fz = 1488rpm x 33 = 963rpm x 51 ≈ 818Hz
a^ [m/s2]
v^ [mm/s]
fTooth
1 2 3 5 10 20 30 50 100 200 500 1000 3000 10.000 f(log) Hz

Page 207
Technical data:
Speed n2 = 963rpm
Pump / Fan
Number of blades = 17
Calculation of the frequencies:

Rotation frequency fn2 = 16Hz
fSp = 17 x fn2 = 272Hz
a^ [m/s2]
v^ [mm/s]
2 x fn2
1 x fn2
fSp
1 2 3 5 10 20 30 50 100 200 500 1000 3000 10.000 f(log) Hz

Page 208
Pump/ Fan Gear unit Drive
2 x fmains
1 x fn2
1 x fn1
fTooth
fBar
a^ [m/s2]
fSp
v^ [mm/s] Envelope spectra
2 x fn1
frequencies
2 x fn2
analysis
Bearing
1 2 3 5 10 20 30 50 100 200 500 1000 3000 10.000

f(log) Hz

Page 209
Practical example – Monitoring of a fan system with SM 1281
Drive Coupling Bearings Why monitoring a fan?
Applications for fan monitoring can be e.g.

• Paint Shop to ensure the quality of the paint
• All kind of exhaust extraction systems
➔For this reason, a unimpressive fan will become a essential element

for production
AND SHOULD NOT BECOME INOPERATIVE
Following key data should be effective
• Motor power: 20kW

• Motor speed: 2970rpm
• Shaft height: 100mm
• Number of blades: 30
• Number of rotor bars: 17
• The fan runs in a housing
• Fan and motor are direct coupled
• The fan is supported by two roller bearings
• The basement is rigid
• The fan is newly commissioned
Foundation Mounting Fan with housing

Page 210
Preliminary considerations
Drive Coupling Bearings To define the necessary hardware, the following questions
should be answered
• What components can be monitored?

• What mechanical damages can occur?
• What electrical damages can occur?
• What kind of sensors are recommended?
• How many sensors are necessary?
• Where to place the sensors?
To define useful values for monitoring, the following

questions should be answered
• Monitoring via characteristic values, frequency-selective or

both?
• What frequencies are calculated by the system, what
frequencies have to be calculated by the user?
Foundation Mounting Fan with housing

Page 211
Preliminary considerations
Drive Coupling Bearings

For this example, the following key data should be effective:
• What components can be monitored?

• Both, motor and fan can be monitored
• What mechanical damages can occur?
• Imbalance
• Alignment fault
• Mechanical looseness/ Mounting faults
• Blade passing frequency
• Bearing damages at all bearings
• What electrical damages can occur?
• Broken rotor bar
• Field error stator
To define usefull values for monitoring – following key data

should be effective:
• Monitoring via characteristic values, frequency-selective or both?

• Monitoring via characteristic values AND frequency-selective for easier
determination of the damage
• What frequencies are calculated by the system, what frequencies have to be calculated
by user?
• Based on the measured speed, the system calculates the rotation frequency
Foundation Mounting Fan with housing • Blade passing frequency and bar frequency must be calculated

Page 212
Possible sensor mounting and measurable values
Electrical field
Mounting
Bearing
Resonance
Page 213
Electrical field Imbalance
Mounting Alignment
Bearing
Resonance
Page 214
Imbalance Blade passing frequency
Alignment
Bearing
Resonance
Page 215
Imbalance
Bearing
Resonance
Page 216
Mounting

Page 217
Imbalance Blade passing frequency
Alignment Mounting
Bearing Electrical field
Resonance
Page 218
SM 1281 – Practical implementation
Determining the limits of vibration velocity
Vibration velocity
Basic data for determining the limits v [rms]
according to ISO10816-3 mm/s inch/s
11 0,44
Motor nominal power: 20kW
(2-1000Hz, n > 120rpm)

10-1000Hz, n > 600rpm
7,1 0,28
Shaft height: 100mm 4,5 0,18
Foundation: rigid 3,5 0,11
The fan was newly commissioned. 2,8 0,07
2,3 0,04
1,4 0,03
0,71 0,02
Limit values
15kW < P ≤ 300kW 300kW < P < 50MW
Alarm limit: 4,5 mm/s Maschine type
160mm ≤ H < 315mm 315mm ≤ H
Warning limit: 2,8 mm/s

Page 219
CMS1200 SM 1281 – Practical implementation
Determining the damage frequencies
Basic data for determining the damage frequencies Bar frequency Blade passing frequency
• Motor speed: 2970rpm fbar = 17 x frot =841,5Hz fSP = 30 x fRot = 1485Hz
• Number of blades: 30
• Number of rotor bars: 17
➔ fRot = 2970rpm / 60 = 49,5Hz
^ ^
v [mm/s] a [m/s²]
This seems to be easy to enter, why do I have to
calculate the damage frequencies first? fbar fSP
841,5 f [Hz] 1485 f [Hz]
Spectrum Spectrum
Vibration velocity Vibration acceleration

Page 220
Pracitcal experience
My motor is equipped
I get always messages for
with a double bearing
warning and alarm, but
on the DE-side … how
with the drive train
can I monitor this
everything is fine.
bearing system, I have
Does the converter
only one sensor for
influence the
each motor side?
measurement?

Page 221
Influence on the machine by the converter operation
Advantages of a high frequency:

• Generation of a nearly sinusoidal motor current
• Lower remagnetizing losses (hysteresis and eddy-current losses)
Umotor • Lower motor warming
Ugrid
Uintermediate circuit • Torque with lower oscillation
t t
t Disadvantages of a high frequency:
• Higher edge steepness of the voltage impulses, resulting higher and more
frequent load on the windings of the electric machine.
= • Faster aging of IGBT and winding, which limits the life span
≈ ≈
= ➔ Lower frequencies treat the windings gently and generate lower losses and
warming, but do not induce a good sinusoidal shape.
The solution
Siemens converters create a good current form at lower frequencies, because of their special modulating methods; the result is a perfect current form performance as well as a
gentle treatment of the winding system of the electric machine. So they treat the windings gently, increase the life span and are energy-efficient.
The solution problem

The windings of the electric machine are remagnetized with the clock frequency, which means there are current forces fed into the winding. As a result measurable high-frequency
mechanical vibrations are generated. Often a further result is the occurrence of disturbing noises of the converter.
Now, for the bearing monitoring an analyzed frequency range is important. CMS2000 as well as SM 1281 monitor the acceleration values within the range from 1kHz to 10kHz with
the following analysis (global characteristic value, analytical procedure envelope curve analysis). If the frequency of the converter lies within the frequency range, the magnetically
induced housind vibration is visible at the vibration acceleration spectrum.
In the case, a bearing monitoring by means of characteristic values is NO LONGER possible. Further this effect is clearly visible in the envelope curve spectrum.
And that is the solution problem!

Page 222
Converter caused HF-interferences
at the vibration acceleration spectrum
a [m/s²]
Vibration acceleration spectrum

with converter influence and
Analyzed frequency range of the filters:
vibration acceleration spectrum Clock frequency = 12kHz
LPF: 1kHz
HPF: 10kHz
2 4 6 8 10 12 14 f [kHz]
a [m/s²]

with converter influence, filters
and drawn in envelope curve:
Analyzed frequency range of the Clock frequency = 12kHz
vibration acceleration spectrum LPF: 1kHz
HPF: 10kHz
2 4 6 8 10 12 14 f [kHz]
Page 223
Converter caused HF-interferences
at the vibration acceleration spectrum
a [m/s²]

with converter influence and
filters:
Clock frequency = 2kHz
LPF: 1kHz
HPF: 10kHz
2 4 6 8 10 12 14 f [kHz]
a [m/s²]

with converter influence, filters
and drawn in envelope curve:
Clock frequency = 2kHz
LPF: 1kHz
HPF: 10kHz
2 4 6 8 10 12 14 f [kHz]
Page 224
Converter caused HF-interferences at the vibration acceleration
spectrum - Influences on the characteristic value analysis
a [m/s2] DKW / aRMS
frequency [Hz] time
Depending on the converter functioning, the frequency SM 1281:

and its multiples are visible in the acceleration spectrum. The charakteristic value DKW as well as the effective (RMS) value of
vibration acceleration aRMS increases.
The amplitudes are extremely fluctuating and cover
significantly the lower-energy bearing vibrations.
➔ Thus a monitoring of the bearings by means of characteristic value
RMS and peak of the vibration acceleration are increased
procedures (DKW / aRMS) is no longer valid.
although there is NO mechanical damage.

Page 225
spectrum - Influences on the envelope curve analysis
a [m/s²]
Depending on the converter functioning, the frequency and its multiples are
visible in the acceleration spectrum (here at 2, 4, 6 and 8kHz).
The frequency typically modulates with an integral multiple of the electrical
stator frequency. This modulation of the frequency is visible in the
acceleration spectrum.
Thereby they generate corresponding peaks in the envelope curve

2 4 6 8 f [kHz] 10 analysis (main peak and harmonics). There confusions with the
a [m/s²] individual damage frequencies and their harmonics can apply.
Modulation of the frequency

with distance ∆f
≈
∆f 2∆f 3∆f 4∆f
f [kHz]
Page 226
spectrum - Influences on the envelope curve analysis
Picture 1 Picture 2
Picture 1 shows the envelope curve spectrum, recorded with HF-influence of the converter
Picture 3
clock and undamaged bearing.
Picture 2 shows an enlarged view of the frequency range from 2Hz to 200Hz with
superimposed bearing damage frequencies. It is visible, that at the range from 100Hz to
120Hz, there is obviously an overlap between modulation of the converter clock and the
bearing frequencies ➔ misinterpretation possible.
Picture 3 shows this overlap detailed, it is the second harmonic of the outer race
frequency ➔ Remove it from the monitoring settings!

Page 227
spectrum - Customizing of the monitoring settings
Delete this line
Resulting monitoring settings:

2nd order outer race defect is removed

Page 228
Monitoring of double bearings
Instructions
In practice it may happen, that a shaft needs a double bearing, because of mechanical reasons.
In this case the bearings are often not identical (type and manufacturer)
This example shows how an active monitoring of both bearings is possible with only one sensor.
Prerequisite:
▪ This example is only applicable for different bearing types.
6004 NKIS 20
▪ If both bearings are identical, SM1281 can NOT distinguish, at
which of both bearings a damage comes up.
The following bearing types by the manufacturer SKF

are used in this example:
▪ Deep groove ball bearing, type 6004

▪ Needle-roller bearing, type NKIS20
Possible sensor mounting: Between the bearings

Page 229
Derivation of the settings for the envelope curve monitoring
The bearing 6004 is set at the bearing database. Based on the speed captured during operation the system
calculates the rotation frequency, which is automatically
repositioned.
So the system can always monitor the actual damage frequency.
For the set bearing, four damage types respectively five variables
are automatically defined (example outer race):
1. Outer race defect 1st order
2. Outer race defect 2nd order
3. Outer race defect 3rd order
4. Outer race defect 4th order
5. Outer race defect 5th order
The corresponding damage frequencies are automatically

Please note: determined in relation to the captured speed and assigned to the
For monitoring of double bearings only ONE bearing type can be variables.
set.

Page 230
Mode of operation on the example outer race damage frequency: If a bearing is once set correctly, the integrated
bearing calculator can calculate the bearing
For a speed of 1488rpm this is valid:
frequencies for the given speed.
▪ Rotation frequency fRot [s-1 = Hz] = speed [rpm] / 60 = 24,8Hz
▪ Outer race damage frequency of 1st order fA = 88,4Hz
𝒇𝑨 𝒓𝒆𝒇𝒆𝒓𝒆𝒏𝒄𝒆 𝒔𝒑𝒆𝒆𝒅
𝒇𝑨 𝒂𝒄𝒕𝒖𝒂𝒍 𝒔𝒑𝒆𝒆𝒅 = × 𝒇𝒓𝒐𝒕 𝒂𝒄𝒕𝒖𝒂𝒍 𝒔𝒑𝒆𝒆𝒅
𝒇𝑹𝒐𝒕 𝒓𝒆𝒇𝒆𝒓𝒆𝒏𝒄𝒆 𝒔𝒑𝒆𝒆𝒅
It is recognizable, that at an actual speed, which is equal to the reference speed, the
outer race damage frequency must be: fA = 88,4Hz
At a speed of 1000rpm, by following the equation above, results an outer race damage
frequency of 59,4Hz.
The damage frequencies of the 2nd to 5th order are the corresponding multiples of
the 1st order.
For example:
Damage frequency of the 2nd order = Damage frequency of the 1st order * 2

Page 231
At the limit band of the envelope curve spectrum, the bearing damage frequencies have to be set with a speed factor.
If the bearing type is set in the system, the values are preset with e.g. “Outer race defect” 1st order.
For the second bearing user defined message texts have to be entered.
Therefore “User defined” has to be selected at the message text.
Now, the speed factor must be calculated, therefore this formula is valid:
𝒇𝑨 𝒓𝒆𝒇𝒆𝒓𝒆𝒏𝒄𝒆 𝒔𝒑𝒆𝒆𝒅
𝒇𝑨 𝒂𝒄𝒕𝒖𝒂𝒍 𝒔𝒑𝒆𝒆𝒅 = × 𝒇𝒓𝒐𝒕 𝒂𝒄𝒕𝒖𝒂𝒍 𝒔𝒑𝒆𝒆𝒅
𝒇𝑹𝒐𝒕 𝒓𝒆𝒇𝒆𝒓𝒆𝒏𝒄𝒆 𝒔𝒑𝒆𝒆𝒅
Speed factor ➔ The speed factor is a constant value

Page 232
Now the damage frequencies as well as the speed factors of every damage type must be determined for the second bearing.
Step 1:
Select the appropriate bearing at the bearing calculator of the manufacturer (Internet), set the reference speed and note the damage
frequencies
Please Note: The reference speed can be different to the one of the set bearing.
In this example the identical reference speed was chosen.
Step 2:
Calculating the speed factor
Values for the bearing of this example:

𝒇𝑫𝒂𝒎𝒂𝒈𝒆 𝒕𝒚𝒑𝒆 𝒓𝒆𝒇𝒆𝒓𝒆𝒏𝒄𝒆 𝒔𝒑𝒆𝒆𝒅
𝒔𝒑𝒆𝒆𝒅 𝒇𝒂𝒄𝒕𝒐𝒓 =
Parameter NKIS 20 Speed factor 𝒇𝒓𝒐𝒕 𝒓𝒆𝒇𝒆𝒓𝒆𝒏𝒄𝒆 𝒔𝒑𝒆𝒆𝒅
Reference speed 1488rpm 24,8Hz
Outer race damage frequency 160,2Hz 6,46 Important:
The speed factor has to be calculated for each damage type
Inner race damage frequency 211,8Hz 8,54
separately.
Rolling element damage frequency 87,8Hz 3,54
Cage damage frequency 10,7Hz 0,43

Page 233
Setting of the parameters for the envelope curve monitoring
To enter the user-defined bearing data, at the limit band of the envelope curve spectrum has to be chosen the entry user-defined.
The text user-defined can be edited by the user.
It is also possible, to enter your own text for the outer race – fault frequencies, like in this example up to the second order.
Important:
▪ The input of the user-defined bearing – damage

frequencies have to be assigned to the set
bearing type (here type 6004)
▪ The specification of the limits for warning and
alarm is oriented at the local and constructive
conditions.
▪ There are no damage-cursors shown for the
user-defined bearing.
Example of the naming for the user-defined bearing here: damage type_bearing type_order

Page 234
Summary
▪ This example is only applicable for different bearing types. If both bearings are identical, SM 1281 can
NOT distinguish at which of both bearings a damage comes up.
▪ At double bearings only ONE bearing type can be set.
▪ The speed factor has to be determined for every bearing damage type separately.
▪ The input of the user-defined bearing damage frequencies have to be assigned to the used bearing type
of the set bearing (here type 6004).
▪ The specification of the limits for warning and alarm is oriented at the local and constructive conditions.
▪ There are no damage-cursors shown for the user-defined bearing.

Page 235
Summary
Mechanical fault types and patterns
Fault type Vibration velocity spectrum Vibration acceleration spectrum Envelope curve spectrum Char. Val. Method
Imbalance First rotation frequency fn Possible, but normally not used Not relevant
Alignment fault First rotation frequency fn

Possible, but normally not used Not relevant
Coupling fault Second rotation frequency fn
RMS
First rotation frequency fn
Mounting fault Second rotation frequency fn Possible, but normally not used Not relevant
Third rotation frequency fn
Blade passing
fSP ≤ 1kHz fSP > 1kHz Not relevant
frequency
Meshing error fZ ≤ 1kHz fZ > 1kHz Not relevant Not relevant
Belt fault fR ≤ 1kHz fR > 1kHz Not relevant

RMS
Excited by e.g. rotation frequency, el.
Resonance Possible, but normally not used Not relevant
frequency, aso.
Bearing wear Not relevant 1kHz ≤ fLE ≤ 10kHz Not relevant

DKW
Blade passing Geometry dependend for: Outer ring,
Not relevant Basis for envelope curve analysis
frequency inner ring, cage, rolling elements

Page 236
Summary
Electrical fault types and patterns
Fault type Vibration velocity spectrum Vibration acceleration spectrum Envelope curve spectrum Char. Value Method
Electrical
Double mains frequency fmains Not relevant Not relevant
stator fault
fbar ≤ 1kHz fbar > 1kHz Not relevant

RMS
Electrical
rotor fault Double mains frequency fmains
Not relevant Not relevant
modulated with slip frequency fslip
Electrical faults are often detected by series-connected motor protection devices, for example, due to different phase
currents, varying stator current or tripping of short-circuit monitoring.
In contrast to mechanically excited machine vibrations, vibrations caused by electrical faults disappear immediately after
switch-off.

Page 237
Appendix: Settings for wind power turbines
▪ With wind turbines, a calculation of the characteristic values (e.g. vRMS and aRMS ) is required in the frequency range of
0,1Hz to 10Hz with an evaluation time of 10 minutes at the measuring points of the nacelle and the tower (according to VDI3834).
▪ At the measuring points of the rotor bearings, of the gear box and the generator, a calculation of the characteristic values (e.g. vRMS
and aRMS ) is required in the frequency range of 10Hz to 1000Hz with an evaluation time of 1 minute.
▪ The limit values are given with VDI3834. These limit values are not identical to the values given with the standard ISO10816.
▪ SM 1281 offers the possibility of a low-frequency monitoring (frequency range of 0,1Hz to 10Hz) of the rms-value of the vibration
velocity vRMS resp. the vibration acceleration aRMS.
▪ For the low-frequency monitoring of the characteristic values vRMS- and aRMS, special sensors are required
(frequency range beginning with 0,1Hz, sensitivity 500 to 1000mV/g).

Page 238
Appendix: Settings for wind power turbines
Example for the settings SM 1281 for a low-frequency monitoring (frequency range of 0,1Hz to 10Hz) :
▪ Analysis Mode „floating vRMS-value“ or „floating aRMS-value“. The „floating RMS-value“ (calculation with an evaluation time of max.
10 minutes) is used to rate a vibration with certain time constants. The „floating RMS-value“ contains a temporis weighting of former
energy proportions with a decrease at an exponential rate.
▪ There are only two measuring channels availabe for setting „floating vRMS“ and „floating aRMS“. The two other channels per modul
SM 1281 can be used as described in this training.
▪ Setting of the Highpass filter 0,1Hz and of the Lowpass filter 10Hz
▪ Evaluation time 10 minutes
The parameters mentioned above are not accessible in this example project.
Please refer to the SM 1281 manual for correct settings of these parameters.

Page 239
Appendix: Raw data
Raw data for offline-diagnostic

▪ Raw data can be stored in the module and sent from the module for detailed offline-diagnostic. Record duration and decimation factor for raw data recording
can be set on the SM1281 web interface „Raw data recording“. The set values are valid for all channels of the SM1281-Module.
▪ The parameter „EnableRawDataRecording“ of the function call FC SM1281_Channel enables or disables the raw data recording for each channel separately.
The parameter „RawDataRecording“ of the function block FB 1281_Module“ triggers raw data recording.
▪ Raw data are recorded in the .WAV file format and stored in the directory „rawdata“ of the module SM1281.
▪ Downloading the raw data files can de done:
a. Via web interface of SM 1281, page „Save and restore“

b. Via FTP connection directly from the module to the PC
c. Sending on demand from SM1281 to a connected FTP-Server
Raw data streaming

▪ By using operation mode „RUN:X-Tools“, X-Tools can connect to the module and SM 1281 is able to stream raw data to the software X-Tools continiously.
▪ In the operation mode "RUN: X-Tools", monitoring with SM 1281 is NOT possible.
For detailed information please refer to the manual

Page 240

Analysis of Mechanical Vibrations: With SIPLUS CMS1200 - SM 1281

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Theoretical Practical

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Example: Amplitude/time diagram for a tuning fork

In practice, movements comprise several components with different, simultaneous frequencies.

Example: Motion of a piston Example: Gear unit

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General designation of rms value of the vibration velocity in

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Vibrations are normally recorded with the following measured values:

Vibration displacement µm Shaft vibrations 1Hz to 0,4kHz

Vibration velocity mm/s Housing vibrations 2/10Hz to 1kHz

Vibration acceleration m/s² Gear/acoustic emission 2/10Hz to 20kHz

The frequency limit of human sensitivity is approximately 300Hz.

For vibration measurement normally acceleration sensors are used.

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Vibration displacement Vibration velocity Vibration acceleration

Vibration acceleration a a = s * ω2 a=v*ω 1

a = Vibration acceleration [m/s2]

The measurement of vibrations is normally done with acceleration sensors.

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Vibration variable Vibration variable Vibration variable Vibration variable

Time Frequency Time Frequency

Example: Description of periodic vibrations on a time scale and frequency scale

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Time signal Frequency spectrum

A fast method is the so-called Fast Fourier Transform (FFT).

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Spectrum vibration velocity

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4-pole machine, asynchronous

Electrical stator frequency

Mechanical speed 1490rpm with an

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n = (fMains * 60) / (number of pole pairs) – slip

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These vibrations are mainly at rotation

A wide band vibration value (e.g. RMS value of

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An analysis can be performed in the high-

Blade passing Gear fault

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Piezoelectric Sensor MEMS Sensor Piezoelectric Sensor – IEPE:

Difference of IEPE and MEMS:

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Suitable adhesive for fixing a sensor:

Adapter for uneven and/or coated surfaces

Fixing with permanent magnets

Handheld test probe

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Threaded bolts with a flat and smooth contact surface

Adapter for uneven and/or coated surfaces Fixing recommendation

Fixing with permanent magnets

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If the surface of the measuring point is not planar, the sensor

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Make up cables by customer:

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Freely vibrating or elastically deformable housing or cladding components