®

DLI Watchman DCX

User's Manual

By DLI Engineering
Information in this document is subject to change without notice and does not represent a commitment on the part of
DLI Engineering Corporation. No part of this manual may be reproduced or transmitted in any form, or by any
means, electronic or mechanical, including photocopying, recording, or information storage and retrieval systems,
for any purpose other than the purchaser's personal use, without the express written permission of DLI Engineering
Corporation.

© Copyright 2007 DLI Engineering

Corporation All rights reserved.
Printed in the United States of America.

DLI WATCHMAN is a registered trademark of DLI Engineering Corporation.

All product names mentioned in this document are trademarked or copyrighted by their manufacturers.

Copyright © 1999 – 2007 by DLI Engineering Corporation – All rights reserved.

Contact DLI Engineering Corporation at 800-654-2844 or support@DLIengineering.com for further information.

This manual covers version 3.10 of the DCX software.

Product Number: 2709 Version: 3.10.1D Date: August 2007

Welcome

Thank you for purchasing the DLI’s Watchman® DCX – Diagnostic Data Collector /
Real Time Analyzer.
Please check the support section of our web site frequently for updated information
and supplements or revisions to these manuals at www.DLIengineering.com.

Inspect Your System

Please check all parts of your shipment against the enclosed packing list. The serial
and model numbers appearing on the list are on file with DLI Engineering. Should
you find anything missing, please contact DLI Engineering or your local
representative.

If any of your company, or point of contact information is incorrect or incomplete,

please contact technical support at support@dliengineering.com so that we can
update your account records. Accurate information helps us to keep you informed of
product updates and bulletins.

Trademarks and Copyrights

DLI WATCHMAN and PDM EXPRESS are registered trademarks of DLI
Engineering Corporation, d.b.a DLI Engineering. ExpertALERT, AdvancedALERT,
StandardALERT, ViewALERT, SignalAQ, DCX, DCX-XRT, DCX Convertible,
Sprite, SpriteMAX and DLI Online are trademarks of DLI Engineering. Microsoft,
Microsoft Windows, Microsoft Office, Excel and Internet Explorer are registered
trademarks of Microsoft Corporation. ICP is a registered trademark of PCB
Piezotronics Inc. All other trademarks mentioned in this document are the property
of their respective owners.
No part of this document may be reproduced or transmitted in any form without the
prior written permission of DLI Engineering.

DCX User's Manual Welcome • i

Software and Firmware License Agreement
Your use of the software included with this product indicates your acceptance of the
following terms and conditions and you should read them carefully. If you do not
agree with them, you must not use this product, and should promptly contact DLI
Engineering Corporation or your DLI Engineering sales representative.
DLI Engineering provides the use of any associated software program to this product
and its licenses to you. No title to or ownership of any program, except the media, is
transferred to you. You assume responsibility for the selection of the program to
achieve your intended results and for the installation, use and results obtained from
the program.
Any unauthorized duplication or use of DLI Engineering software or firmware in
whole or in part, in print, or in any other storage and retrieval system is forbidden.

Software Support
Your software system purchased from DLI Engineering includes:
• LIFETIME UNLIMITED e-mail support for software troubleshooting.
• FREE user assistance for proper use of the software, software troubleshooting,
and understanding of software features and functions for one year following the
purchase by technical support personnel via telephone, e-mail, or online chat
sessions.
• FREE software updates for one year to the current version of the DLI
Engineering ALERT operating software family.
• One complimentary registration to attend our regularly scheduled online
Webinar training courses. Visit www.dliengineering.com for course schedule
and registration.
• Extended upgrades and support (U&S) agreements are available from DLI
Engineering.

Hardware Warranty
DLI Engineering Watchman Data Collectors, field analyzers, and online monitoring
hardware include:
• 30-Day Replacement Guarantee. DLI Engineering warranties your hardware
against defects in materials and workmanship for 30 days of receipt by offering
a full replacement exchange.
• Guaranteed repair. DLI Engineering commits to correcting a defect in materials
and workmanship. If your hardware cannot be repaired following three returns
to our shop within one year, DLI Engineering will offer a full replacement
exchange.
• FREE repair service for FIVE years. The limited repair service covers defects in
hardware operation and performance. Free repair service does not include
calibration, or damage caused beyond normal wear and tear.
• FREE firmware and/or software updates for one full year.

ii • Welcome DCX User's Manual

 • Extended Service and Support Agreements are available from DLI Engineering.

Contacting Technical Support

Troubleshooting suggestions and Frequently Asked Questions (FAQ) for the ALERT
software family or any of the DLI Watchman data collectors can be found on the
DLI Engineering website at www.DLIengineering.com. If you do not find a solution
for the problem you have encountered and need additional assistance, technical
support can be reached by doing to following:
• E-mail support@DLIengineering.com. Be sure to include a detailed description
of the trouble, what lead up to the trouble, any error messages or codes, and the
software and/or hardware versions, model number, and serial number.
• Chat Session can be launched using our online support center and knowledge
base at www.DLIengineering.com.
• Call the DLI Engineering Technical Support Hotline, 800-654-2844. Technical
Support live staff is available between 5:30 am and 4:30 PM Pacific Time,
Monday through Friday. Users outside the USA or within the states of Alaska
or Washington must call 206-842-7656. Outside these hours a detailed message
can be left and a support member will return your call at the first opportunity.

Warranty Statement
DLI Engineering Corporation extends worldwide support for its hardware and
software products and warrants that its products are functional for the stated intended
purposes of vibration monitoring and predictive maintenance.
Data collectors are shipped with calibration traceable to the United States National
Institute of Standards and Technology (NIST).
EXCEPT AS SPECIFICALLY STATED IN THIS AGREEMENT, THE
INSTRUMENT AND SOFTWARE IS PROVIDED AND LICENSED WITHOUT
WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING
BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
IN NO EVENT WILL DLI BE LIABLE TO YOU FOR ANY DAMAGES
INCLUDING ANY LOST PROFITS, LOST SAVINGS, OR OTHER
INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE USE
OR INABILITY TO USE THE INSTRUMENT/SOFTWARE EVEN IF DLI OR
AN AUTHORIZED DLI REPRESENTATIVE HAS BEEN ADVISED OF THE
POSSIBILITY OF SUCH DAMAGES OR FOR ANY CLAIM BY ANY OTHER
PARTY.
Should you have any questions regarding this agreement, you may contact DLI
Engineering at 253 Winslow Way West, Bainbridge Island, WA 98110, USA.

Disclaimer of Warranty
DLI Engineering Corporation will use its best efforts to answer questions from its
customers in a prompt and accurate manner. However, DLI Engineering does not
make any warranty concerning the effectiveness of the telephone support program
for your particular purpose, and the telephone support service does not modify the

DCX User's Manual Welcome • iii

 limited warranty of DLI Engineering, or create any new warranty concerning your
DLI Engineering software program.
This manual is provided for informational purposes only. DLI Engineering does not
make any warranty concerning the effectiveness of this material.
DLI Engineering shall not be liable for any loss or indirect, special, or consequential
damages resulting from DLI Engineering rendering or your using the telephone
support service.
This information is subject to change without notice.

Warranty Returns
Instruments returned under warranty will be repaired or replaced at no charge if
returned shipping is prepaid within the time period and conditions of DLI
Engineering's warranty policy. Be sure to obtain an RMA (return material
authorization) number from DLI Engineering before returning equipment. DLI
Engineering will prepay the shipping back to the customer.

Out of Warranty Repairs

DLI Engineering Corporation maintains repair and calibration support for out of
warranty instruments as long as parts are available. Repair and shop time charges
are shown in the price list. Out of warranty items must be sent to DLI Engineering
shipping prepaid. Return shipping will be prepaid by DLI Engineering and added to
the service invoice. Be sure to obtain an RMA number from DLI Engineering before
returning equipment.

How to Return Equipment for Repairs

To obtain calibration or repair services, FIRST CALL DLI Engineering
TECHNICAL SUPPORT AND GET A RETURN MATERIALS
AUTHORIZATION (RMA) NUMBER. Then, carefully pack the instruments and
send with shipping and insurance prepaid to DLI Engineering. DLI Engineering will
charge for repairs for damage caused by improper packing. To avoid delays, be sure
that the RMA number is clearly written on the outside of the box!
A purchase order for the appropriate amount, showing the ship to and bill to
addresses or otherwise required payment must be received before a repair service can
be completed and returned.

Ship your service item to:

DLI Engineering Corp.
Attn.: (RMA Number)
253 Winslow Way West
Bainbridge Island, WA 98110

iv • Welcome DCX User's Manual

Safety Caution
The DCX comes with a protective fabric case and a carrying strap that can be used as

!
a shoulder strap. To avoid the possibility of serious personal injury, it is not
recommended that the DCX be carried over your shoulder or neck while measuring a
machine with rotating parts that could snag the accelerometer cable or the barcode
cable.

DCX User's Manual Welcome • v

Contents
Welcome i
Inspect Your System ................................................................................................................... i
Trademarks and Copyrights ....................................................................................................... i
Software and Firmware License Agreement .............................................................................. ii
Software Support ....................................................................................................................... ii
Hardware Warranty................................................................................................................... ii
Contacting Technical Support .................................................................................................. iii
Warranty Statement .................................................................................................................. iii
Disclaimer of Warranty .............................................................................................. iii
Warranty Returns ....................................................................................................... iv
Out of Warranty Repairs ............................................................................................ iv
How to Return Equipment for Repairs ....................................................................... iv
Safety Caution ........................................................................................................................... v

DCX Data Collection 3

Using the DCX as a data collector ............................................................................................. 3
Switching between Advanced and Basic modes.......................................................... 5
Quick tour .................................................................................................................................. 6
Selecting the machine .................................................................................................. 7
Five tabs ...................................................................................................................... 7
The icons ................................................................................................................... 11
Data collection options ............................................................................................................ 18
Collecting data ......................................................................................................................... 20
Select the machine ..................................................................................................... 20
Repeating a test ........................................................................................................................ 24
Using the Repeat icon ................................................................................................ 24
Re-testing a tested location ........................................................................................ 24
Collecting process measurements ............................................................................................ 25

DCX Real time analysis 28

Introduction ............................................................................................................................. 28
Performing live analysis .......................................................................................................... 28
Setting up the test..................................................................................................................... 30
Update mode.............................................................................................................. 30
The settings in depth ................................................................................................................ 31
Performing a rundown test....................................................................................................... 33
Setting up the test ...................................................................................................... 33
Starting the test .......................................................................................................... 33
Saving data .............................................................................................................................. 34

Preparing Your Machine 35

Sensor Attachment Pads and Barcode Labels .......................................................................... 35
Sensor Attachment Pads ............................................................................................ 35

DCX User's Manual Contents • i

 Transducer Orientation .............................................................................................. 39
Barcode numbers and labels ...................................................................................... 41

Index 43

Notes 45

ii • Contents DCX User's Manual

DCX Data Collection

Using the DCX as a data collector

Click to move to data collection When you are ready to collect data from your machines, you should move to the data
mode collection screen within the DCX software. To do this, click the DCX icon on the
main toolbar.

Main DCX screen

The screen will then be transformed to display the DCX data collection screen. There
are actually two different formats for this screen: basic and advanced mode.

DCX User's Manual DCX Data Collection • 3

 In basic mode there are fewer options to confuse a less experienced operator.

DCX in basic mode

In advanced mode there are many more options available, and more information is
presented during the test.

DCX in advanced mode

4 • DCX Data Collection DCX User's Manual

 Switching between Advanced and Basic modes
Whether you are in advanced mode or basic mode, you can click the Options icon
and a new screen will be displayed.
The Options icon

The Options dialog

If you check the box Operate in “advanced mode”, then the additional icons will
appear and the software will act in advanced mode. If you uncheck the box, some of
the icons will be removed and the operation will become less complicated.

The Basic mode of operation

The “basic mode” of the DCX is intended for users who are perhaps less experienced
with this data collector, or with computers and “high technology” products in general.
The basic mode has been designed to simplify the steps necessary to collect data, while
ensuring that data is collected correctly.
The basic mode only supports a barcode for test location identification. To use the
DCX, the user would move to the machine to be tested, attach the sensor, identify the
location using the barcode icon, and the test would begin. All of the axes would be
tested simultaneously, and the two frequency ranges (if the test is set up this way),
would be tested sequentially.
Once in the Options Screen, the options icon will have changed to DONE. Click
this icon to remove the options screen. The software will remember whether you use
advanced mode or basic mode. When you next use the DCX, it will already be in the
preferred mode.

DCX User's Manual DCX Data Collection • 5

Quick tour
The following section summarizes the main options used to operate the DCX data
collector.

The DCX screen after data collection has taken place

You can see that the window is made up of a series of icons along the top, and a set of
tabs that reveal important information and allow you to select the point or location to
be tested.

6 • DCX Data Collection DCX User's Manual

 Selecting the machine
On the display above you will notice that the currently selected machine and location is
displayed at the top of the window. In the example above, the machine is “Lube Oil
Purifier #2” and the location is “Motor (DE)”. Many of the options described below
will apply to this location. The location (or point) can be changed in one of four ways:
1. You can click the Barcode icon and manually enter the barcode number.
2. You can select the location or point from the tree when the Tree tab is
displayed.
3. You can select the point or location by clicking on the icon over the image
when the Picture tab is displayed.
You can set the machine in two ways:
1. When you set the barcode, by entering the barcode manually, as described
above, the machine will be selected as well as the point or location. The Tree
and other tabs will be updated with the information for this machine.
2. If you click the Search icon, you can select the machine from a list.

Five tabs
In advanced mode, there are five tabs on display. The tabs are used to display helpful
information, and give you different ways of identifying the location and point to test.

Tree tab
The Tree tab, as shown below, will display the machine along with the locations and
process points. You may click one of the locations or points to start the test.

Tree tab

DCX User's Manual DCX Data Collection • 7

 Status tab
The Status tab shows a summary of the machine condition. When the machine is
initially selected the current status of the machine (OK, slight, moderate, serious or
extreme) will be displayed. After the machine has been tested, the results of the expert
system will be displayed.

Details tab
The Details tab will display the same information as is displayed in Detail view when
in the normal EA/DCX view. This information can become very useful out in the field,
and if there is any information that you believe would be useful while performing a test
then it should be added to the detail page.

Details tab

8 • DCX Data Collection DCX User's Manual

 Picture tab
The Picture tab is very useful if you have saved a photograph or drawing with this
machine. After selecting the machine, you can go to this tab to view the photo or
drawing and then start the test by clicking on one of the buttons associated with the test
locations.

Picture tab

The example displayed above has two location icons and one process point icon. One
of the icons indicates that the location has been tested within the last 24 hours.
The icons can be positioned in the correct location by holding down the right mouse
button (or the small button on the side of the pen) and dragged.
You can now click on one of the icons on the picture to begin the test.

DCX User's Manual DCX Data Collection • 9

 Facts tab
The Facts tab shows the normal running speed of the machine as well as the test
conditions that have been entered against the selected machine.

The facts tab

10 • DCX Data Collection DCX User's Manual

 The icons
Not all of the icons are available in the basic mode of operation, however they always
perform the same function regardless of the current mode.

Start icon
The Start icon is used to begin a test on the currently displayed location or point. If
the location has been tested within 24 hours you will be prompted whether this is a new
test or a repeat of the previous test. If you repeat the test, the previously collected data
will be erased.

A test in progress

When the test is in progress the icon will change to Stop. Clicking the icon will cause
the test to be canceled.

DCX User's Manual DCX Data Collection • 11

 Barcode icon
When you click the Barcode icon you will be offered a simple way to enter the
barcode number using the DCX pen.

Manually entering the barcode number

Simply click on the arrow above or below each digit to set the number. As the number
is changed, the DCX software will check the database and report whether the barcode
number corresponds to a machine in the current plant. If there is no match for the
barcode entered the message will be as follows:

12 • DCX Data Collection DCX User's Manual

 The barcode screen when an unassigned barcode is entered

When the barcode number is entered correctly, click the Start test button to begin the
test. If you wish to return to the previous point or location, click the CANCEL icon
(previously the Barcode icon).

DCX User's Manual DCX Data Collection • 13

 Notecode (N’code) icon
While collecting data you may observe an oil leak or some other event that should be
recorded. Notecodes are short messages used to summarize events such as oil leaks,
strange noises, damaged barcode labels, and so on. The screen will list the available
notecodes for selection.

Selecting the notecode

To select the notecode, click on an item in the list and click Save. If you do not wish to
select a notecode, click on the CANCEL icon (previously the N’code icon).

Note: The notecode will be added to the currently selected machine.

Note: You may add more than one notecode to a machine.

The notecode entered can be viewed in the history view back at the full EA/DCX
screen. (Refer to the EA manual for further details)

14 • DCX Data Collection DCX User's Manual

 Note icon
If the notecode messages are insufficient you may prefer to add a note.

Entering a note

When you enter a note on the DCX, you may actually write the note with the pen or
simply right click in the box to enter text with the aid of a virtual-keyboard.
Once you have entered the note, click the Save button. Click CANCEL (previously
the Note icon) to cancel the note.
The note entered can be viewed in the history view back at the full EA/DCX screen.

Repeat icon
If you have performed a test on a location on a machine and during the test the machine
changed conditions (or for some other reason rendered the test invalid), then you may
like to repeat the test. Simply click the Repeat icon and after confirming your
intention, the previously collected data will be deleted and the new test data will be
saved.

Options icon
The Options icon gives you access to the options page where you can specify how the
DCX should work while collecting data. You can specify whether measurements
should start automatically when the location is identified; you can specify whether the
expert system should be run on the machine when all of its locations are tested; you
can specify whether the spectral averages should be displayed; and you can toggle
between advanced and basic modes.

DCX User's Manual DCX Data Collection • 15

 The data collection options

Click the DONE button (previously the Options button) to remove the options page.

Search icon
If you do not use the barcode icon to select the location (and machine) then you need
another way to identify the machine. The Search icon will display the machine
selection wizard.
The first step is to select the source of your machines: a plant, a survey, one of the
master lists, or a group of machines based on their MID.

Select the source of machines

16 • DCX Data Collection DCX User's Manual

 Simply click the option of choice. If you were to click the plant, the areas of that plant
will be listed.

Selecting an area

If you have made the wrong selection, simply press < Back and you will be returned
to the previous list. Once you select an area, the machines in that area will be listed.

Selecting the machine

DCX User's Manual DCX Data Collection • 17

 When you click on the machine, or click Finish, the machine will be recalled and you
will be returned to the previous screen.
The next time you click Search, the wizard will reappear, however this time the list of
machines viewed last time will again be displayed. This should make it easy to select
the machine to be tested next.

Exit icon
This icon will return you to the main EA/DCX window.

Data collection options

There are a number of options that you can set that control the operation of the DCX
during data collection. As you set these options they are automatically saved so that
you will not need to set them again when you next collect data.
The options are set as described earlier when switching between basic and advanced
modes. To set the options, click the Options icon.

The data collection options

18 • DCX Data Collection DCX User's Manual

 Begin data collection automatically when location is
identified
When you identify the location to be tested you can have the data collection begin
automatically. This is the fastest and possibly most convenient way to use this system.
You can identify the location in one of two ways:
1. Select the location from the tree of locations for the machine on the Tree tab.
2. Click on the button on the image on the Picture tab.
Alternatively, if you leave this option unchecked, when you identify the location the
system will display the name of the machine and location, however you will then have
to click the Start icon to begin the test.

Run the expert system when machine test is complete

One of the great features of the DCX is that you can have the expert system analyze
the data from a machine while you are still out in the field. If the expert system
determines that a problem exists, you can take some immediate action. For example,
you could perform additional tests to confirm the diagnosis, you could ask questions
of a local operator to see if any further information could be added to the situation,
and you could raise the attention of others in the maintenance or planning groups so
that appropriate action could be taken.
DCX is able to determine when all of the locations on a machine have been tested.
At this point it can immediately have this new data analyzed by the expert system.
The results are then displayed on the screen. If you are in basic mode, a dialog box
will appear displaying a summary of the results. In advanced mode the results will
display on the Status tab.

Show the averages (uncheck for fastest measurements)

It is often useful to view the spectra as the averages are being accumulated. As each
spectrum is collected it is added to the average, and you should see the noise and some
external vibration being removed. However, there is a small price to pay - time. While
the spectra are being collected and displayed in this way, additional time is required to
perform each test.

Note: This option does not apply while operating in basic mode, as the spectra are
not displayed in this mode.

For the greatest performance, the averages are computed in a more efficient manner
and are not displayed. In advanced mode, the final average will be displayed so that
you can see the final result.

Note: Overlap averaging is not performed when the averages are displayed on the
screen.

Operate in “advanced mode” (more options available)

As described earlier, if this option is checked, you will have more options available,
and you will see the spectra as the data is collected.

DCX User's Manual DCX Data Collection • 19

Collecting data
There are a number of simple steps required to collect vibration and process data from
the machines in your plant.

Select the machine

First you must walk to the machine to be tested and select a test location. It is not
important which order the locations are tested. It is important, however, that the
machine is in the correct operating condition. In most cases, if the machine is running
at all, you can begin the test without further delay. However, if the machine operates
intermittently, or if the machine operates under variable speed or load, then you must
ensure that the machine is tested while it is operating in the same condition as it was in
previous tests.
Once the sensor is correctly attached (discussed in greater detail in the Advanced
Concepts section), you must then identify the location to be tested. If the option has
been set to automatically begin the test (recommended) then the test will begin once the
location has been identified. If not, you must click the Start icon to begin the test.
There are four ways to identify the location or point.

Enter the barcode number

You can click the Barcode icon and manually enter the barcode number. This would
be done when the barcode can not be read by the reader, however you still visually read
the number.

Manually entering the barcode number

20 • DCX Data Collection DCX User's Manual

 Use the tree
With the tree visible (at the Tree tab) you can simply click the location or point.

Use the picture

With the picture visible (at the Picture tab) you can click the location or point icon. If
it has been set up correctly, the icon will be located over the appropriate position on the
machine.

The Picture tab

DCX User's Manual DCX Data Collection • 21

 In the case of the Picture tab and Tree tab, the DCX needs to know which machine to
display. When you enter a barcode, the machine will be recalled automatically.
However if you are not using barcodes you must use the Search option. The machine
selection wizard makes it very easy to select the machine to be tested. When you click
Search the wizard will appear. You start by selecting the group of machines to be
tested. If you have grouped your machines together into surveys then you should select
the MACHINE SURVEYS option.

The machine selection wizard

The surveys saved in the database will be displayed.

Selecting a survey

22 • DCX Data Collection DCX User's Manual

 With the survey selected, the machines in the survey will be listed.

Selecting the machine

With the machine selected, you can use either the Tree tab or Picture tab to select the
location or point.
When you have completed the tests on the machine, you can move to the next machine
by again clicking the Search icon. The wizard will begin with the list of machines
displayed. So if the next machine to be tested is on the same survey (or whatever
group you last selected), then it will be a simple case of selecting that machine from the
list.

DCX User's Manual DCX Data Collection • 23

Repeating a test
There will be many situations when a test must be repeated. For example, if a test was
performed but the test conditions were not correct (or they changed during the test),
then you may like to delete the previous test results and collect new data. There are
two ways to achieve this goal.

Using the Repeat icon

If you click the Repeat icon, the data for the currently select location will be erased
and a new test will begin. First you will be asked to confirm this action.
The Repeat icon

If you click OK, the data will be deleted and a new test will begin. Click Cancel to
return to the data collection screen.

Re-testing a tested location

If you begin a test on a location that has been tested within the last 24 hours (its icon
will have a check mark) you will be asked whether this is a new test on the machine, or
whether you want to repeat the test – erase the previous test and start again.

‰ If you select Yes, then the previous test will be deleted and a new test
will begin (after confirming this action).
‰ If you select No, the test will proceed, and the previous test data will
NOT be deleted.
‰ If you select Cancel, you will be returned to the data collection screen.

24 • DCX Data Collection DCX User's Manual

Collecting process measurements
The DCX can be used to collect scalar process readings in addition to vibration
readings. Readings such as temperatures, pressures, and other values can be easily
entered into the system.
When you select a process point, a field will be provided for the new reading.

Entering a process reading

All you must do is click the digits of the reading, then click Save. As you click each
of the digit buttons, you can also click the backspace symbol “<” to erase the digit to
the left of the cursor.
To cancel the reading, click the Cancel button and nothing will be saved.

DCX User's Manual DCX Data Collection • 25

DCX User's Manual DCX Data Collection • 27
DCX Real time analysis

Introduction
Although you can learn a great deal from the data collected during routine testing, it
is often insightful to view spectra and time waveforms in real time. You can take the
DCX out to a machine, install the transducer, and then view the dynamic data. In
some cases it is desirable to change the test set up; increasing the resolution,
changing the frequency range, etc. In other circumstances, it can be helpful to move
the sensor from one location on the machine to other to see how the data changes.
This chapter will examine how this can be done, and it will suggest different tests
that you may find useful.

Performing live analysis

You can view live data right in the same window as you would normally use to
review saved data. All of the controls used to analyze spectra and time waveform
data are also used to analyze and document live data. All you have to do is switch to
Graph view.

Note: You may not use the double triax display mode in live mode, as only one
frequency range at a time is collected.

28 • DCX Real time analysis DCX User's Manual

 The main DCX screen in graph view

The Play icon To start a measurement, simply click the “play” icon on the analysis toolbar. The
test will be set up according to the current settings and the data will be displayed on
the graph window. The data displayed will depend entirely on the current settings.
In the example above, the spectra for the low range in the vertical direction will be
displayed.

Note: There is no connection between the location selected and the test setup.
You must set up the measurement parameters, as described on the following page.

In the following example, all three axes of time waveform data will be displayed live.

Three axes of time waveform data in live display mode

DCX User's Manual DCX Real time analysis • 29

 Press the Play icon to start the When you click the Play icon, the test will be set up and the display will be updated.
reading At that time, the Play icon will change to a Pause icon. Selecting this icon will
halt the measurement.

Note: The refresh rate of the display is controlled by the test parameters. If the
test is set up with a higher resolution (for example 3200 lines) and/or a low
frequency range then the spectra will take longer to collect and the display will
update less frequently. Lower resolution, higher frequency range data will update far
more quickly.

Setting up the test

To display the settings dialog To set the frequency range, resolution and other test parameters, click the settings
icon. You will see the following dialog appear.

The settings tab

You can move this dialog anywhere on the window that you like, and when you have
set up the test, you can click on the close icon or click the Setting icon once again.
The dialog will be hidden, however the settings will not be lost.

Note: You can start the test (by pressing Play) while the settings dialog is visible,
and you do not have to stop the test before you hide the settings dialog.

Update mode
You will notice the three options on the top of the settings dialog. They control how
the window will be updated.

Free run
In free run mode, the spectra or waveforms will be constantly updated, without any
averaging. The tests will not stop until you press the Pause icon.

30 • DCX Real time analysis DCX User's Manual

 Show averages
The requested number of averages will be performed, with each average being
displayed on the screen. In the previous example, 6 averages will be performed and
you will see each average displayed sequentially, with less noise in each spectrum.
After the averages are complete, the test will stop automatically.

Fast average
In this mode the averages will be performed at high speed and the final result will be
displayed. After the averages are complete the DCX will start the next measurement
automatically.

The settings in depth

There are a number of parameters that you can control to set up for the test – you can
even change the settings while the test is in progress.

The settings tab

Frequency range
Select from one of the supported frequency ranges (in Hertz). The spectrum will
always start from zero Hertz, but you can control the full bandwidth.

10Hz hi-pass filter

The DCX circuitry has a 10 Hz hi-pass filter that can be switched in or out.

Note: If the signal will be integrated, then the filter must be turned on. Thus you
will notice that it is checked and disabled with the Integrate signal options is
checked.

Resolution
This number represents the number of lines (or samples) left in the spectrum after
signal processing takes place. For example, if you selected 800, the time waveform
would have 2048 samples.

DCX User's Manual DCX Real time analysis • 31

 Window type
Windowing reduces an effect called leakage – a subject that is covered in a number
of training texts. Suffice to say that in 99% of cases, you must use a window. That
window will change the frequency and amplitude accuracy.
In most cases the Hanning (or Hamming is very similar) window is the best in this
application.

Average type and Number of averages

In order to reduce noise and other unwanted sources of vibration, the data collector
can perform averaging.
Linear averaging is the typical type of averaging used where the sum is computed at
each line in the spectrum, then it is divided by the number of averages performed.
Peak hold averaging will keep the highest amplitude at each line in the spectrum,
and is quite useful for performing “bump” tests.
You must specify how many averages the data collector should perform. The more
averages performed, the more noise is reduced; however the longer will be the
measurement.
Typically 6 averages will be acceptable in a normal environment, however in a noisy
environment 8 to 14 averages may be required. You should perform some
experiments in order to determine the best value.

ICP Current source

Check this box if your transducer is of the ‘ICP’ type. ICP stands for Integrated
Circuit Piezoelectric, and requires that a current be supplied to it during operation.

Note: The transducer typically supplied by DLI Engineering is ICP, so check this
box.

32 • DCX Real time analysis DCX User's Manual

Performing a rundown test
In order to determine the affects of changing speed, load or time on a machine, a
rundown or runup test can be very useful. Click the Rundown tab to set the two
simple parameters.

Setting up the test

Setting up a Runup/Rundown test

Number of spectra to collect

You may enter a number from 1 to 99. This determines the number of spectra that
will be collected during the test

Time delay between spectra

This field determines the number of seconds to wait after each spectrum is collected.
For example if you wanted to collect data over one hour and wanted one spectrum
per minute, you would enter 60 in the first field (for 60 minutes) and 60 in the
second field (60 seconds in a minute).

Starting the test

When you click the Start test button the test will begin. A dialog will show the test
progress. You can click Cancel to stop the test.

Test status – click Cancel to stop

DCX User's Manual DCX Real time analysis • 33

 At the end of the test, the spectra will be displayed in waterfall mode.

Waterfall plot after the test

Saving data
Whenever you perform a live measurement or rundown test, you can click the Save
icon to save the test. You can later recall this data for review. When you click the
analysis icon to select the test date, you will see different icons according to the
source of the data, as indicated in the following illustration.

Test data selection: adhoc, routine and rundown test data

34 • DCX Real time analysis DCX User's Manual

Preparing Your Machine

Sensor Attachment Pads and Barcode Labels

Sensor Attachment Pads

Attachment pads (of bronze or stainless steel) are located on the machines where
measurements are required, and are available from DLI in quantities from 25 to
1000. The triaxial accelerometer is attached to these pads for vibration data
collection. The item 4300 AK-BR pads are of silicon bronze, and are general
purpose pads recommended for most applications. The item 4305 AK-303 pads are
of AISI 303 stainless steel, and are highly non-corrosive. They are recommended for
the nuclear industry. The item 4310 pads are of AISI 416 stainless , and are not as
inert as the 303 stainless pads, but are magnetic.

Item 4300 Attachment Pad

The alignment notch ensures that the transducer is correctly oriented. The
attachment pad also ensures a good transfer of vibration data through to the
transducer and sees to it that the sensor is always in exactly the same position.
Spare transducer attachment pads and adhesive are available from DLI to permit
replacement if necessary. The transducer pad surface must be clean prior to
attaching the transducers. Use a rag or a scraper as necessary to remove any paint or
other debris. A 5/32 tap drill and a 10-32 tap are provided to clean the threaded
holes in the pads if necessary.
Note that the transducer must be firmly attached to prevent data contamination. The
recommended torque value for the 10-32 captive attaching screw is about 18 in-lb.
Using the "ball driver" tool provided, estimate the installation torque.

DCX User's Manual Preparing Your Machine • 35

 If it is necessary to replace a pad, exercise care that the replacement pad is in the
correct location and that the pad notch is also correctly oriented. Failure to observe
this requirement will result in inconsistent vibration data and incorrect machine
condition diagnosis.
It is highly recommended that you keep accurate records of the machine
configuration, along with details of attachment pads locations and orientations. See
the section on transducer orientation for a suggested format.

Installing and replacing Attachment Pads

There are three main issues to consider when selecting the location for an attachment
pad:
o Vibration Transmission Path
When the accelerometer is connected to the attachment pad for data
collection, you are in fact measuring the vibration of the attachment
pad as a result of the vibration of the machine. When a component in
the machine is deteriorating, its vibration will change in response to the
wear it is undergoing. The rest of the machine also will change its
vibration characteristics in response to this component. You, in turn,
are monitoring the change in vibration of the attachment pad, which is
in response to the change in vibration of the machine, which is in
response to the change in vibration of the problem component. It is
imperative that this path be as short as possible, so that the changes in
the attachment pad's vibration mimic as closely as possible the changes
in vibration of the component itself.
So, it is important to mount the attachment pad as close as possible to
the component that it is intended to monitor, and make sure that the
transmission path is as solid as possible. Don't, for example, mount the
attachment pad on a coupling or fan guard, or a sheet metal cover.

No No

Correct

No

Accelerometer Location
o Frequency Response
Once the pad is located in the best position for data transmission, it is
also critical that the contact between the pad and the machine be as
strong and hard as possible. The surface of both machine and pad
should be clean and as flat as practical. The frequency response will
also be affected by how the transducer is connected to the pad. Make
sure that the surface of both the pad and transducer are clean, and that
the transducer is always attached with the same amount of torque.

36 • Preparing Your Machine DCX User's Manual

 o Repeatability
The success of vibration analysis depends on the repeatability of the
collected data. There are a number of ways that repeatability can be
maximized:
o The alignment notch on the attachment pad ensures that the
NOTE transducer is always connected to the pad in the same orientation.
However, if it is necessary to replace a missing or damaged pad, it
is critical that the pad be replaced in the same orientation and
If the pad is rotated 180 degrees position. Obviously, if the pad is replaced with the notch in a
around the radial axis, the data on all different direction, data that had previously been stored as Axial
channels will not be affected if phase
data is not desired.
data, may now be stored as Radial data and so on. If the pad is not
replaced in the same position, the vibration signature will be
different (even if only slightly) and this may cause erroneous
results from the diagnostics.
o The contact surface between the pad and transducer should always
be wiped clean prior to data collection.
o The same torque is applied with the ball driver each time the
transducer is attached.
So here are the steps required to mount a new attachment pad or replace one that is
missing.

STEP 1 Locate measurement location

If you are attaching a new pad, find an appropriate location on the machine, ensuring
that the criteria outlined previously are met as well as possible.
If you are replacing a missing pad, be sure that the pad is replaced in the same
position and orientation as the old one to ensure repeatability of the data.
o Look for visual signs indicating where the pad was previously located.
Can you see where a patch has been previously filed? Adhesive
patches? Barcode nearby?
o If there are no visual signs, or if you are still unsure, review the
location description stored in the DCX. The location description
should indicate where this pad should be, for example "Motor, Free
End" or "Position 1".

STEP 2 Determine Orientation

If you are attaching a new pad, choose an orientation that is convenient.

If you are replacing a missing pad, it is critical that the pad is replaced in the same
orientation to ensure repeatability of the data.
o Review the test description in the location set up in DCX. To do this,
NOTE
when the current location is displayed, press Open and the location
will be displayed. You will see the orientation listed.
See the section on transducer
orientation in this chapter and the EA
manual for details on defining
orientations.

DCX User's Manual Preparing Your Machine • 37

 STEP 3 Prepare Machine Surface

Prepare the spot on the machine for mounting of the pad. It is important that the
machine's surface be as clean and as flat as possible. Use a file to bare the metal if
the surface is painted. Make sure that the cleared contact area is larger than the
surface of the pad. Clear off any filings produced by your preparation.

STEP 4 Prepare Attachment Pad

Once the machine surface is ready, make sure that the surface of the pad is also
clean, and use the file to rough up the contact surface a little to ensure that the
adhesive will hold.

STEP 5 Apply Speed Bonder™ Accelerator

WARNING
Do not allow accelerator to make
contact with your skin.
Paint the contact surface of the attachment pad, and the prepared surface of the
machine liberally with the Speed Bonder Accelerator. Let the accelerator dry for 20
seconds or so. Speed Bonder is a trademark of the Loctite Corporation.

STEP 6 Apply Speed Bonder™ Adhesive

Apply a small amount (about the size of an ISO standard chocolate chip) of adhesive
to the contact surface of the pad.

STEP 7 Mount Attachment Pad

Press the attachment pad firmly in place with your thumb until you can feel metal to
metal contact. Do not move the pad around once it is in place. The adhesive takes
five minutes to dry, is ready for data collection in about an hour, and is fully cured in
24 hours.

STEP 8 Check Orientation

NOTE Check that the pad has been mounted with the correct orientation. If not, remove
the pad, and perform the entire procedure again.
If, for some reason it is not possible to
replace the pad with the same
orientation, then you must edit the
location at the main DCX screen.

38 • Preparing Your Machine DCX User's Manual

 STEP 9 Record Changes

If you have replaced a missing pad, make a note of the changes you made. The
information you should record includes:
o The Machine Name
o The Location Name
o The Barcode Number
o The Orientation
You should also enter a note (or select an appropriate notecode) against this location
in the DCX.

Transducer Orientation
The orientation tells the DCX which channel of the data collector is measuring which
axis. There are six possible orientation combinations:

RAT ART TRA TAR RTA ATR

where: A = AXIAL
R = RADIAL
T = TANGENTIAL

Note: DCX also supports VHA (Vertical, Horizontal and Axial) and XYZ for the
x, y, and z orientations.

The data are collected by the DCX from channel one of the accelerometer through to
channel three. The host software and sensor process the data in the same order.
(Remember that the channel axes are marked on the transducer.)
For horizontal machines, 'R' is considered to be Vertical, 'T' is considered to be
Transverse, and 'A' is considered to be parallel to the shaft:
R
RAT

ATR
T A
RTA RAT

ART

TRA TAR

Side view showing slot orientation for attachment pad

Top view showing slot orientation for attachment pad

DCX User's Manual Preparing Your Machine • 39

 For vertical machines, 'R' is Radial, 'T' is Tangential, and 'A' is vertical:

TAR
RAT
RAT
RTA
RTA
TRA

ART ATR

R T

Side view showing slot orientation

for attachment pad

Top view showing slot orientation

for attachment pad

So, for example, an orientation of "RAT" on a horizontal machine would mean that
Channel 1 of the accelerometer was oriented in the vertical direction, Channel 2 was
oriented along the shaft, and Channel 3 was oriented in the transverse direction:

NOTE VERTICAL
= CHANNEL 1
RADIAL
IMPORTANT: =
If an attachment pad falls off, you must CHANNEL 1 CHANNEL 2
ensure that you replace the pad in the
same orientation. See the previous CHANNEL 3
page for a description of the steps
required to replace an attachment pad.
TRANSVERSE
PARALLEL
=
TO SHAFT
TANGENTIAL
=
=
AXIAL
CHANNEL 3
=
CHANNEL 2

40 • Preparing Your Machine DCX User's Manual

 Barcode numbers and labels
Barcodes provide a simple way to correctly identify test points on machines. When
setting up your measurement parameters in the DCX or EA, each measurement
location may be identified by a unique number. The barcode label, DLI item 4320, is
of anodized aluminum with a photo etched, number code. It is affixed to the
machine and encodes the number for that unique measurement point. This allows
the DCX to automatically set up its measurement parameters to those determined by
the operator when the location was defined in the database.

WATCHMAN TEST POINT

DO NOT PAINT
The item 4320 Barcode Label

Attaching a New Barcode Label

If it is necessary to attach a new barcode label, the steps you should take are as
follows:

STEP 1 Clean the machine surface

Make sure that the surface of the machine is clear of oil and dirt. The selected
location for the barcode should be:
o Easily accessible
o Easily seen
o Clear of any oil leaks or other conditions that may cause the barcode to
become dirty quickly.
o Not on a rotating or moving component
o Not on a component (for example a coupling guard) that may be
removed, or replaced in a different position.
o Close to the vibration sensor attachment pad location, but not so close
that swiping the barcode wand is difficult because the transducer or
cabling is in the way.

STEP 2 Apply adhesive and press the label in place

Make sure that the back of the barcode label is also clean, and then apply silicone
adhesive. Press the label firmly in place at the selected location.

DCX User's Manual Preparing Your Machine • 41

 STEP 3 Record changes

In order to update the database with the new barcode number, it is critical that you
record these changes that you made. The information you should record includes:
o The Machine Name
o The Location Name
o The New Barcode Number
o The Old Barcode Number (if available)
You should also enter a note (or select an appropriate notecode) for this test location
in the DCX. You should ideally make the changes to the database immediately.

42 • Preparing Your Machine DCX User's Manual


Index
1 Free run ....................................................................... 29
10Hz hi-pass filter ...................................................... 30
A
Accelerometer........................................... 35–36, 39–40
Advanced mode – a summary....................................... 4
Analysis
Real time ................................................................. 27
Attachment pad, Block .......................... 35–38, 40–41
Automatic data collection ........................................... 19
Automatically running the expert system ................... 19
Average type and Number of averages ....................... 31
Averages, watching as they are collected ................... 19
B M
Ball driver ............................................................. 35–37
barcode .................. v, 5, 7, 12, 13, 14, 16, 20, 22, 41, 42
Barcode
Manual entry ..................................................... 12, 20
Barcode icon ............................................................... 12
Barcode label .............................................................. 41
Basic mode – a summary .............................................. 4
Basic mode of operation ............................................... 5
Begin data collection automatically when location is
identified ................................................................. 19
C O
Coastdown test............................................................ 32
Collecting data ............................................................ 20
Contact phone ................................................................ i
Customer Support ......................................................... ii
Cut-off frequency ....................................................... 30
D Picture tab ............................................................... 9, 21
Data collection ............................................................ 20
Data collection options ......................................... 15, 18
Data collector mode ...................................................... 3
DCX
As a data collector .................................................... 3
Basic mode ............................................................... 5
DCX User's Manual
Collecting process readings..................................... 25
Data collection ........................................................ 20
Moving to data collector mode ................................. 3
Quick tour ................................................................. 6
Simplifying operation ............................................... 5
Details tab ..................................................................... 8
Diagnostics .................................................................. 37
E
Exiting the DCX collection screen .............................. 18
Expert system, running automatically ......................... 19
F
Facts tab ...................................................................... 10
Fast average ................................................................ 30
Frequency range .......................................................... 30
G
Graph view .................................................................. 27
I
Icons, the function of .................................................. 11
ICP Current source ...................................................... 31
L
Leakage ....................................................................... 31
Linear averaging ......................................................... 31
Machine
Selection .................................................................. 22
Machine selection wizard...................................... 16, 22
Machine, selecting the................................................. 20
Manually entering the barcode number ....................... 12
Moving the buttons ....................................................... 9
N
N’code (Notecode) icon .............................................. 14
Note icon ..................................................................... 15
Operate in .................................................................... 19
Options icon ............................................................ 5, 15
P
Pause icon ................................................................... 29
Peak hold averaging .................................................... 31
Play icon ..................................................................... 28
Process readings
Collecting ................................................................ 25
Q
Quick tour ..................................................................... 6
Index • 43
R
Real time analysis ....................................................... 27
Repeat icon ........................................................... 15, 24
Repeating a test..................................................... 15, 24
Resolution ................................................................... 30
Return Equipment ........................................................ iv
Run the expert system when machine test is complete19
Rundow test ................................................................ 32
Runup ......................................................................... 32
S
Saving a note .............................................................. 15
Saving a notecode ....................................................... 14
Search icon ........................................................... 16, 22
Select the machine ...................................................... 20
Selecting machines ..................................................... 16
Selecting the machine ................................................... 7
Seting up live analysis ................................................ 29
Setting data collection options .................................... 18
Setting the data collection options .............................. 15
Settings
10Hz hi-pass filter .................................................. 30
Average type ........................................................... 31
Frequency range ..................................................... 30
ICP Current source ................................................. 31
Number of averages ................................................ 31
Resolution ............................................................... 30
Summary................................................................. 30
Window type .......................................................... 31
Settings tab ........................................................... 29, 30
Show averages ............................................................ 30
Show the averages ...................................................... 19
Start icon ..................................................................... 11
Starting live analysis ................................................... 28
Starting the test ..................................................... 11, 20
Status tab ...................................................................... 8
Stop icon ..................................................................... 11
Stopping the live display ............................................ 29
Stopping the test ......................................................... 11
Surveys ....................................................................... 22
T
Tab options ................................................................... 7
Test conditions...................................................... 10, 20
Trademarks and Copyrights .......................................... i
Transducer orientation .......................................... 37–39
Tree tab ................................................................... 7, 21
W
Window type .............................................................. 31

44 • Index DCX User's Manual

Notes

DCX User's Manual Notes • 45

46 • Notes DCX User's Manual
DCX User's Manual Notes • 47
48 • Notes DCX User's Manual