Instruction Manual

IR30 BEARING MONITOR

“Sentinel” Model

APDD 766A
MARCH 2003
 IR-30 SENTINEL

IR 30 Shock Pulse Instrument

Manual Contents List

Section Title
1 IR 30 Sentinel Instrument Parts List
2 Shock Pulse Monitoring, A Snapshot
3 Data Acquisition with the IR30
4 When Is There A Problem?
5 Required Documentation for Airend Replacement
6 Measuring Points on Ingersoll-Rand Units
7 Data Acquisition on a Nirvana
8 dBi and dBm values for Ingersoll-Rand Units
9 SPM Logs

Confidentiality

The contents of this publication may not be reproduced in any

form without the permission of Ingersoll-Rand.

IR30
 2003 Ingersoll-Rand Company
Date of Issue: March 2003
 IR-30 SENTINEL

IR 30 “SENTINEL” Shock Pulse Instrument

54636536 Kit Contains:

Quantity CCN Part Name

1 54636519 IR 30 Sentinel Instrument

1 39262837 TRA 22 Probe

6 39262928 9022 Batteries (AA Size)

( Installed In Instrument )

1 54636527 Instruction Manual Package

APDD 766A

1 CAS-09 Carrying Case

Possible Upgrades

CCN Part Name

39262845 TRA 31 Quick Connector (for stud mounted units)

38034872 Vibration attachment kit

38332284 IR30 Sentinel Upgrade to Logger (unit upgrade only, no

additional attachments included)

42464602 Set of 50 Adapters and Caps to stud mount units

39262993 Chamfer Drill (to drill holes for studs)

IR30
 2003 Ingersoll-Rand Company
Date of Issue: March 2003

IR Confidential: The contents of this publication may not be reproduced, in any form, without the permission of Ingersoll-Rand.
 IR-30 SENTINEL

SHOCK PULSE MONITORING, SPM INSTRUMENTS, IR-30

"A SNAPSHOT"
Unless an individual is involved with some form of machinery vibration analysis, the term "Shock
Pulse" (Monitoring) is unknown and somewhat foreign. Officially, and accurately, it is a technology
relying on the physical principle that sound travels undiminished through metal objects for great
distances. The second principle involved is that of resonance. The measuring instrument is
equipped with a 30,000 Hertz electrically tuned device, which resonates and records certain shock
frequencies emitted by roller bearings.

This explanation, while accurate, loses most people, and leaves them cold.

A simpler, if somewhat inaccurate, illustration enables an easier visualization, and invites very
good credibility.

Using a freight train as an example, visualize sitting at a rail crossing waiting for the train to pass.
We've all done this at one time or another. As the train cars pass, you hear the usual sound of the
wheels rolling against the steel tracks, and the normal "clickety-clack" as the wheels cross the rail
joints. The sound varies, louder as the heavier cars pass, less intense as the empty cars pass. That
is the usual sound, and can be called in Shock Pulse terminology as "Decibel Carpet". Floor,
bottom, average sound of a freight train rolling by, if you will.

While the train is passing, a car, loaded with coal approaches. This particular car has a flat spot
on one of its wheels. Rail car wheels get flat spots when the car is empty, has been sitting in the
yard for a long time, and a brake shoe sticks to a wheel rim. The car is coupled to a train for use,
and when it starts to move, the wheel can't turn because of the stuck brake shoe. Eventually, speed,
vibration and sheer impact will tear the brake loose and the wheel begins turning. However, after
being dragged for some distance on a steel rail unable to turn, the wheel now has a flat spot.

It is easy to imagine how this flat spot will sound as it hits the rail with each revolution. This
sound, a repetitive "banging",
heard well above the "Decibel
Carpet", now becomes
"Decibel Max", (maximum), the
second term to be understood
in Shock Pulse terminology.
The third term is "Decibel
Initial", and this is a factor,
which can be likened to
calibrating the listener's ear as
the train passes. This
"calibration" regulates the
intensity with which ear
perceives Decibel Max, and
Decibel Carpet. These terms are abbreviated, "DBI", "DBM", and "DBC".

IR30 – Snapshot 1
 2001 Ingersoll-Rand Company
Date of Issue: January 2001

IR Confidential: The contents of this publication may not be reproduced, in any form, without the permission of Ingersoll-Rand.
 IR-30 SENTINEL

Applying the technology to steel roller bearings requires only reasonable access to the outside
diameter of the monitored bearing through an uninterrupted metal path. Permanently attached metal
studs are best for this purpose. A mechanical "clip-on" accelerometer is used to anchor to and read
the acoustical signature from the bearing, through the housing to the studs.

A hand held, contact probe can also be used with good results. The Instrument, which reads the
shock pulse DBM/DBC values and displays them as two numerical values is called the "IR-30". Any
type of steel roller bearing can be monitored.
The technology has no application to sleeve bearings.
Data acquisition is a simple process. First, Decibel Initial value for the particular bearing(s) must be
determined. For this, the inside diameter of the bearing must be known. Shaft diameter upon which
the bearing is mounted is usually easiest to determine. Where two different diameter bearings are
used on a shaft with near equal loads on both ends, an average of both diameters is used. Shaft
rotative speed is also needed. Entering these figures into the IR-30 yields the Decibel Initial (DBI)
value for those bearings.

The sites on the machine for bearing probe points are then determined. We try to use bearing
housing flange edge surfaces, since these areas have ample depth, are free of air or oil passages,
and provide a direct (if somewhat curving) solid metal path to the outer race of the subject bearing.
Studs are fitted by drilling and tapping sites with M8 or 5/16" - 18P threads, 1/2" deep, with a 90
Degree entering chamfer.

Manual data acquisition consists of operating the machine in loaded and in unloaded condition,
while measuring DBM/DBC values with the instrument. As each site value is determined, it can be
electronically stored in the instrument for later downloading to a PC and printing. Electronic
recording requires use of "CondMaster Pro" software provided by Ingersoll-Rand with purchase of
the “Logger” (full package) instrument.

Manual recording of the data can also be done on paper logs, designed by the user to suit the
purpose. Normally, data is taken monthly
for the first three months of operation of a
new machine, then quarterly.
DBM/DBC values are indicators of
bearing condition, and of bearing
deterioration. As a general rule, DBM
values, on new equipment of oil flood/ oil
free compressors, will run in the 20 to 40
range. DBC, about half DBM. Data is
reviewed, and DBM values which rise in
the 45 range and above, particularly when
unit is loaded, are to be noted. DBC will
also rise, coming close to DBM. Two
consecutive DBM readings at or above 55
in 700 hours signal need to consider
bearing overhaul.

IR30 – Snapshot 2
 2001 Ingersoll-Rand Company
Date of Issue: January 2001

IR Confidential: The contents of this publication may not be reproduced, in any form, without the permission of Ingersoll-Rand.
 IR-30 SENTINEL

Sudden changes are to be especially noted, and monitor frequency "doubled up". A cracked or
loosened inner race will result in such drastic changes, and must receive immediate attention.

Oil Free Compressors will display consistent DBM as 10, 15 points higher than DBC in normal
running condition, loaded or unloaded.

Oil flooded single stage units seem to display closer DBM/DBC points than oil free, and when
running unloaded DBM/DBC will be equal to or higher than loaded. When gas load is relieved,
rotors seem to become more unstable and "rattle around" in the bearing clearances more.

Oil flooded two stage units display DBM/DBC loaded points consistent with single stage and oil
free machines. However, unloaded DBM/DBC seem to run at or considerably higher than loaded
figures. Therefore, on oil flooded units, loaded DBM/DBC figures are to be considered dominant
decision points. Drive motor bearings behave in similar manner.

Two stage units have four bearing points per casing. The shock pulse emission from the four
points radiates and overlaps as it is read from the casing flanges. However, trending, and observing
loaded DBM/DBC using these guidelines should yield accurate indications of repair requirements.

IR30 – Snapshot 3
 2001 Ingersoll-Rand Company
Date of Issue: January 2001

IR Confidential: The contents of this publication may not be reproduced, in any form, without the permission of Ingersoll-Rand.
 IR-30 SENTINEL

Key Path

Display 16x Characters

Instrument Type

Light Sensor

Measuring Key

Set Key Select Key

Left/Right Arrow Keys

Up/Down Arrow
Keys

Input Connector SPM

Input Connector Software +
Input Connector Vibration

IR30 – Data Acquisition 4

 2001 Ingersoll-Rand Company
Date of Issue: August 2001

IR Confidential: The contents of this publication may not be reproduced, in any form, without the permission of Ingersoll-Rand.
 IR-30 SENTINEL

Instrument Type
IR30 Sentinel

Measuring Key
Function key used to record IR30 measurements

Set Key
Function key used to set in menu options

Left/Right Arrow Keys

Keys used to scroll around menu options

Input Connector SPM

Connection point for SPM instruments.

Input Connector Software

Data communication to to interface to PC (if applicable)

Display 16x Characters

Text Menu (Available in muli-languages)

Light Sensor
Sensor to detect light level and automatically switches on

background light if selected.

Select Key
Function key used to enter fields from menu

Up/Down Arrow Keys

Keys used to change options highlighted and move up and downloaded rounds.

Input Connector Vibration

Connection point for Vibration instrument.

IR30 – Data Acquisition 5

 2001 Ingersoll-Rand Company
Date of Issue: August 2001

IR Confidential: The contents of this publication may not be reproduced, in any form, without the permission of Ingersoll-Rand.
 IR-30 SENTINEL

DATA ACQUISITION, I-R 30 “SENTINEL” INSTRUMENT

Step1: Press “M” on instrument keypad, Screen should show “SPM”; dbm, dbc lower left, and dbi lower
right. If screen does not show “SPM” press the Left or Right Arrow until it does.

Press “SET”, Screen will appear; see “Bearing Data”

“TLT’ (Transducer Line Test) Off or On. Using the Up or
Down Arrows, Set to “On”. After a reading has been taken,
TLT values above 15 will indicate no signal loss between Bearing data
the instrument and the transducer. TLT on
…. rpm
If BDI is known for a particular reading point (see dbi
tables), press “SET” until the cursor is at dbi ____. Using
…. dmm dBi 26
the Up or Down Arrow adjust field to register desired dbi
value. Press “Ent", see return to SPM screen. You are now ready to take data, using the hand held
probe. (Go to step 2)

If dbi is unknown, then: Press “Set”, see _____rpm. Using the Left or Right Arrow, traverse blank
fields to desired point. Using the Up or Down Arrow, with Left or Right Arrow, adjust field to register
desired shaft speed.
Press “Set”, see _____dmm or inch. This is shaft diameter. Using the Up or Down Arrow, with the Left or
Right Arrow, adjust field to register desired shaft diameter.
Press “Set”, see dbi ____ which is decibel initial. This is the calculated dbi value for this shaft size and
bearing speed.

If shaft size, speed and dbi are unknown, use an arbitrary 25 dbi for any oil flooded single or two stage
compressor. Use an arbitrary 35 dbi for any oil free “Sierra” single or two stage compressor. Once initial
dbi is selected for subject compressor, do not use any other dbi value on subsequent readings for
subject compressor.

Press Ent, see return to SPM screen. You are now ready to take data, using the hand held probe.

Step 2: Attach the hand held probe to the left threaded “SPM” connector on the instrument.

Determine the probe contact point on your subject

machine. See attached Photos for general reference.
Contact point should leave the probe “pointing” at the
outside diameter of the bearing within the housing. The
acoustical path for the shock signal from the bearing SPM
should be as short and direct as possible, with no bolted TLT 18
joints in this path. Bearing housing flange edges make dBm 16
good locations. Take one set of data loaded, a second dBc 8 dBi 25
set unloaded. dbm is Decibel Maximum, dbc is Decibel
Carpet.

With unit running, dbi set in the instrument and SPM Menu on instrument screen, press spring loaded
probe tip to the designated area in the loaded zone of the bearing housing. Holding the tip compressed
to the length of the rubber grommet, press “M” on the keypad and hold for about 1 second. Release “M”,
continue to hold the probe tip in place, approximately 5 seconds, or until dbm and dbc values appear.

Refer to “Snapshot” for further explanations, and upper limit points for Maximum and Carpet values
recorded.
Record data on a log sheet, with any other physical data from the compressor or motor you deem
pertinent.
IR30 – Data Acquisition 6
 2001 Ingersoll-Rand Company
Date of Issue: August 2001

IR Confidential: The contents of this publication may not be reproduced, in any form, without the permission of Ingersoll-Rand.
When Is There a Problem?
What are Good Bearings? *
• Typical dBm less than 40
• Note levels higher than 45 dBm
• One reading greater than 55 dBm*, retest unit within 500-
700 hours
• Two readings higher than than 55 dBm* within 700
hours signals a need for service or replacement.
* Refer to dBi data pages in Section 8 for specific dBm limits

What are Damaged Bearings?

• Large difference between dBm and dBc. This difference
will also increase over time.
• If a damaged motor bearing is greased, the dBm will
decrease, but rise again quickly.

What are Dry Running Bearings?

• Little difference between dBm and dBc.
• When the bearing is greased, these values will drop and
remain low.

From reading to reading, dBm and dBc will

increase and decrease. However, the distance
between them will stay relatively the same.
When the dBm and
dBc start getting
further apart or
closer together,
scheduling of future
replacement or
rebuild should be
considered.

IR Confidential: The contents of this publication may not be reproduced, in any form, without the permission of Ingersoll-Rand.
 Required Documentation, Oil Flood / Oil Free Air End Replacement

Occasionally, it becomes necessary to replace a Rotary Screw Compressor

Air End in a machine that is still in use. This may be caused by High Shock
Pulse Data, Mechanical Vibration, (movement), or High Operating Noise
Level, or a combination of the above.

The following information is required when an air end is removed from a

compressor, and the compressor is still operational, and the air end is
subject for warranty. Include this report with the Air End Return.

Compressor Model_____________ Compressor Serial #______________

Air End Size___________________ Air End Serial #__________________

Hours in Service_______________ Air End Turns ? Yes___ No___

Shock Pulse Data:

MR 1 _____ DBI _____ DBM _____ DBC _____ Loaded

MR 2 _____ DBI _____ DBM _____ DBC _____ Loaded
MR 1 _____ DBI _____ DBM _____ DBC _____ Unloaded (Single Stage Only)
MR 2 _____ DBI _____ DBM _____ DBC _____ Unloaded (Single Stage Only)

Second Stage MR 1 _____ DBI____ DBM____ DBC_____ Loaded

Second Stage MR 2 _____ DBI____ DBM____ DBC_____ Loaded
(If air end is two stage, take both first and second stage male rotor
only. Do not include unloaded 2 Stage.)

Vibration Data: MM/Sec.

Vertical, Loaded____ Unloaded____
Horizontal, Loaded____ Unloaded____
Axial, Loaded____ Unloaded____
Sound Level: Describe____________________________________________

A Copy Of the Oil Analysis Report Must Be Attached to this Form.

If a decision to replace the air end is made, please indicate the individual at
Davidson Technical Service with whom the decision was discussed.
Name_______________________ Date__________________

Your Signature___________________ Organization_____________________

Today’s Date_____________________

Pjm/03/24/03
RequiredAirEnd/pjm/03/24/2003

IR Confidential: The contents of this publication may not be reproduced, in any form, without the permission of Ingersoll-Rand.