Operating and Using the Vibration Data Collector

DCA 31
December 2002

DLI Engineering

Written for:

DCA 31 firmware (ver. 1.06m)

TABLE OF CONTENTS
Data Collector Operations 1

DCA-31 Data Collector ............................................................................................................. 1 Day to Day Operations .............................................................................................................. 2 Instrument Setup........................................................................................................................ 3 Communication between EA and DCA 31................................................................................ 4 Introduction ............................................................................................................................... 4 Loading the data collector ......................................................................................................... 4 Unloading the data collector...................................................................................................... 7 Special functions........................................................................................................................ 9 Set the data collector ................................................................................................... 9 Set the communication options ................................................................................... 9 Common functions ...................................................................................................... 9 Watchman DCA-31 Functions .................................................................................. 10 Using the DCA 31 in the Field ................................................................................................ 11 Navigating Through a Survey ................................................................................... 11 Barcode Entry............................................................................................................ 12 Data Collection Configuration .................................................................................. 13 Off Route Configurations.......................................................................................... 14 Battery and PCMCIA Details .................................................................................................. 15 Battery Level Information ......................................................................................... 16 Battery Basics............................................................................................................ 16 PCMCIA Basics ........................................................................................................ 16 The Vibration Sensor............................................................................................................... 18 Typical Triaxial Accelerometer................................................................................. 19 Care and use of the Triaxial Accelerometer .............................................................. 20 Troubleshooting the DCA-31 .................................................................................................. 20 Soft Boot ................................................................................................................... 21 Hard Boot .................................................................................................................. 21 LCD Backlight On / Off............................................................................................ 21

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Data Collector Operations

DCA-31 Data Collector

The DCA-31 Data Collector is used to collect vibration measurements for processing by the ExpertALERT computer. The DCA-31 is actually an IBM XT-PC clone featuring four dynamic inputs and an external amplitude demodulation circuit. Physically, it consists of a rugged enclosure, large protected display, tactile keypad, weather-tight connectors, detachable accelerometer cable, and a removable battery. All of the buttons shown in the photograph below are labeled with unique names. These terms are used through this chapter.

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Day to Day Operations

Connect the accelerometer to the DCA 31 as shown below.

3 2 1 4 7 2 5 8 0 3 6 9

To power up the instrument, press the red button on the front face (See previous page). The DCA-31 will boot similarly to a computer and the main menu screen will appear as shown below. Note that the four function keys respond to whatever is displayed on the LCD screen above the button. In the sample below, note that the Instrument Setup option is highlighted. To select Data Collection or Review Data simply press either the left or right arrow keys to highlight the appropriate choice.

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Instrument Setup
The instrument setup icon on the main menu provides access to some general setup parameters. You should not need to modify these settings as a routine. To access these items use the arrow keys to highlight the Instrument Setup icon and press the Read OK button. Here is a summary of the options available and the recommended settings. When using the DCA-31 as part of the ExpertALERT program, ensure all the settings are set for Survey Mode. The most common reason for communication failure is a mismatched baud rate between ExpertALERT and the data collector. Both settings must match for successful communication. The Real Time Analyzer mode allows you to see a single axis live display of the vibration signal. Use of this feature is beyond the scope of this manual.

Instrument Setup
Memory

Description
Internal or Card 5, 10, 15, or 20 minutes. Powers unit down due to inactivity. Not active when connected to AC Power source. Disables or enables the infrared serial port. 1200 to 115200. For > 19200 please ensure hardware handshaking has been enabled. English or metric Self explanatory Triax or Single channel Sets the internal clock in data collector. Function allows you to clear / initialize memory

Default
Internal

Survey Mode
Internal

Real Time Analyzer

Internal

Timeout IrDa

5 mins Disabled

20 mins Disabled

20 mins Disabled

Baud Rate Default Units Date Format Transducer Date/Time Memory

19200 English mm/dd/yyyy Triax n/a n/a

115200 English mm/dd/yyyy Triax n/a n/a

115200 English mm/dd/yyyy Triax n/a n/a

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Communication between EA and DCA 31 Introduction

Before a data collector can be used in the field, a survey (or other group of machines) must be loaded into its memory. Once the tests have been completed, the measured data is transferred back to the computer where it is stored for analysis. In addition there are functions required to clear its memory and load the internal software. The steps required to perform all of these functions will be described in this chapter. .

Loading the data collector

To enable measurements to be collected with a data collector, the machines to be tested must be loaded into the data collectors memory. All of the measurement parameters, such as frequency range, number of averages, transducer type must be downloaded to the collector. In addition the barcode number is required as it links the measurement location on the physical machine to the machine in the database.
Click to load the collector

To load the data collector, select Load data collector from the Data collection menu, or click on the Load collector icon. You will see a dialog box that should seem very familiar. Your first task is to specify which machines are to be loaded into the collector.

Specifying which machines are to be loaded into the collector

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In the example above, the survey HVAC SURVEY was selected in the tree before the Load collector option was selected. Regardless of what was selected in the tree before the option was selected, you always have the option to select other collections of machines from the database. While you may normally build a survey and load it into the data collector, you may instead choose to load an entire plant into the collector. Rather than first building the survey with the plant, you can simply select the plant at this tab of the dialog box. At the Options dialog you must specify which data collector is to be loaded, the communication settings (which should not need to be changed once they are initially set), and whether the memory of the collector should be erased first.

Select the collector, communication settings, and the erase options

Select the data collector

Simply click on the name of the data collector you are loading. When you do that the communication settings may change.

Communication options
Ensure that the COM port (the serial port of the computer you are using) and the baud rate are set correctly. If they are not, make the changes required.

Load options
If the data collector has a survey and data in its memory, you may like to erase that information before loading this new survey. Check the Erase collector contents first box to erase this information. You

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will be asked to confirm that the survey and data should be deleted after you click OK

Save as default
If the communication settings you have chosen are the normal settings for the data collector selected, you should click the Save as default button. These settings will be remembered for the next time you communicate with this data collector. Click OK to begin the load process. If you did NOT select a survey to load into the collector, i.e. you selected an area, group of machines, etc., then you will be asked to give this list of machines a name. The name will be used in the data collector, and EAV will create a survey for you with this name. You can delete this survey if you like, and it will not affect the stored data.

Give the list of machines (temporary survey) a name

If you asked to erase the contents of the data collector, you will be asked to confirm this action.

Confirm the deletion of the survey and data from the collector memory

The survey and data will be erased in the data collector, then EAV will gather together all of the information necessary for the data collector. Once this step is complete, this information will be loaded into the data collector. The progress bar will indicate the time it should take to complete the task.

A display of the progress

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Unloading the data collector

Once you have tested the required machines, you must unload the data collector so that the data is available in the database for analysis and report generation. It is not necessary to test all of the machines on the survey before you unload the data collector. You can periodically unload the data so that it may be analyzed before the rest of the machines have been tested. In fact, you can load a huge survey into the collector, even an entire plant if it is not too large, and just leave it in there. When you unload the collector you should erase the measurements from the collector and leave the survey.

Click to unload the collector

To unload the data collector, select Unload data collector from the Data collection menu, or click on the Unload collector icon. The resulting dialog box asks you to first specify which data collector type is to be unloaded. Just click on the tab to make your selection.

Unload the data collector

Select the data collector

Simply click on the tab with the name of the data collector you are unloading.

Communication options
Ensure that the COM port (the serial port of the computer you are using) and the baud rate are set correctly. If they are not, make the changes required.

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Post unload options

Once the data collector has been unloaded, EAV can perform some useful functions for you. First decide what you want to do with the memory of the data collector. You can erase the measured data, leaving the survey; you can erase everything (survey and data); or you can leave the memory alone. !" If you choose Do not erase collector memory, the contents of the data collector will remain unchanged after the unload, however you must erase the stored data before you next unload the collector, otherwise it will be unloaded for a second time. If you choose Erase data but leave survey in collector memory, the survey will be left in the data collector so that it may be used again, but the stored data will be erased. This is a useful option, as the data has been stored in the EAV database, so you dont normally need it in the data collector any longer. If you select the third option, Erase survey and data in collector memory, the survey and stored data will be erased from the collector. It will then be ready to have a new survey loaded.

!"

!"

The check box Automatically run the expert system should be checked if you want to run all of the data unloaded through the expert system. You can then check the master lists Machine Expert List or Machine Unload List to learn of the status of your tested machines.

Save as default
If the communication settings and the post unload settings you have chosen are the normal settings for the data collector selected, you should click the Save as default button. These settings will be remembered for the next time you communicate with this data collector. Click OK to begin the unload process. First the data will be transferred from the data collectors memory to a temporary file on disk, then that data will be stored away in the database. If you chose to erase the survey or data in the collector, this action will then be taken. And finally, if you asked for the expert system to process the collected data, this step will be taken last of all. As mentioned above, the master list Machine Unload List will now only hold the machines that were just unloaded from the collector. If the expert system was also run, all of the machines will also appear in the Machine Expert List. And if the expert system was run, all of the machines found to have faults would appear in the Machine Alarm List. So you should now consult one of those three lists to begin your analysis process.

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Special functions
There are a number of functions you can perform to manage the memory of the data collectors, learn about the contents of their memory, and to load their firmware.

Set the data collector

Your first step is to select the data collector you have connected to the computer. Click on the name of the data collector on the tabs, and the available options will be displayed.

Set the communication options

Your second step is to set the communication options. You must specify which serial port the data collector is connected to, and the baud rate. These options will be set according to your normal preferences. If you make a change and wish these new settings to become the default, click the Save as default button.

Common functions
A number of functions are common between the data collectors, while others are unique. The common functions will be discussed first.

Sample special functions dialog box

All of the data collectors allow you to erase the survey currently loaded in memory (which also erases the stored data), and to erase the stored data in memory leaving the survey.

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Erase survey and data in collector memory

If you select this option and click OK, the memory contents of the connected data collector will be erased. The survey will be removed, taking with it any data stored in the collector. Note: This will not affect the test data stored in the EAV database.

Erase the data, leaving the survey in the collector memory

If you select this option and click OK, any test data stored in the data collector will be erased, however the survey (which describes the machines so that future tests may be performed) will remain in memory. Note: This will not affect the test data stored in the EAV database.

Watchman DCA-31 Functions

.

DCA-31 special functions

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Using the DCA 31 in the Field

Navigating Through a Survey
Once a survey is loaded into the DCA 31, highlight the DATA COLLECTION icon on the main menu, and press the READ OK button. This will place you into a hierarchical menu structure (ship system machine location) similar to the one shown below.

Route Ship

ALL MACHINES USNS PATUXENT HVAC NO 1 A/C COMPRESSOR MOTOR (FE) COMP (FE)

System Machine

Location

Help

Offroute

Config

Esc

In the window above, the data collector is poised to collect data on the compressor free end measurement location on NO. 1 A/C Compressor that is in the HVAC system on the USNS Patuxent. After verifying proper test conditions and connecting the accelerometer to the proper location, simply press either of the two READ OK buttons to start data collection. Highlight an option within a level using the UP/DOWN arrow keys. Drop down to the next lower level in the hierarchy by pressing the RIGHT arrow key. Select appropriate Plant, Area, Machine and Location and then select READ/OK to begin data collection. To move back up the hierarchy, use the LEFT arrow key.

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Barcode Entry
If bar codes are used you can type in a bar code number and the system will automatically advance to the location with that bar code. This can save you plenty of time searching for a machine. The screen below appears when you start typing in a bar code number. Once the bar code is completely entered, press either READ OK button and the hierarchy will align itself to the proper Area, Machine, and Location for that bar code number. After verification, you must press either READ OK button for data collection to begin. Barcode scanner hardware support is planned for a future release of the DCA31.

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Data Collection Configuration

When the data collector is in Data Collection mode, pressing the F3 soft key allows you to modify the data collection configuration. It is very important to have the proper selections to allow the data collector to function properly. Just as in the Instrument Setup discussed earlier, when using the data collector for ExpertALERT all settings should be set for Survey Mode. The table below is provided to help you get all the settings correct.

OPTION
Freq Units Fast Averaging

DESCRIPTION
Display frequency axis in Hz/CPM/Orders. Only used if viewing spectrum during measurement. This feature speeds up the data collection of spectra using the % overlap specified in EA setup file. When set to "Off", no overlap is used for each average. "Off" means you have to manually store data displayed by pressing the READ/OK. "On" means all measurements are automatically accepted based on an algorithm using the settings below. The algorithm is based on a % fluctuation of overall vibration over a period of time, so if the overall stays within X% of the measured level for y seconds, the value is stored. Auto store time in seconds. Only active when auto store is on. Auto store percentage. Only active when auto store is on. "On" meaning no spectrum is displayed. "Off" meaning spectrum is displayed. This only applies for spectrum collection with 1 average in real time mode. "Single shot" means that collection will stop after a spectrum is collected and displayed. "Continuous" means the DCA31 will continuously collect and display successive single average spectra till the user terminates collection by pressing READ/OK. This is the classic real time mode. Options are Conservative and Aggressive. Use the conservative option for most data collection. Use the aggressive option only when you want to minimize the amount of time the data collector takes to determine the bias voltage in the ICP accelerometer. Options are Normal and Slow. Use Slow only for troubleshooting slow speed machinery less than 100 CPM. Use Normal for all other applications. Some accelerometers require more time to allow the ICP power to settle. If you are getting cable fault errors, increase this setting until the errors stop. Typical settings are from 5 to 15 seconds. Choices are (Purge), (Delete tour), (Delete all tours), (Initialize). "Purge" marks all locations on the survey as not taken, and leaves the survey alone. "Delete tour" removes the current survey and data from memory. "Delete all tours" deletes all surveys and data from memory. "Initialize" formats the active memory. THIS WILL DELETE ALL SURVEYS AND DATA IN ACTIVE MEMORY. This feature allows you to choose whether or not to fill the space between spectrum and the X-axis if viewing the data during collection.

DEFAULT
Hz On

SURVEY MODE
Hz On

REAL TIME
Hz On

Auto Store

Off

On

On

Time Percent Auto Advance

2s 30% On

1s 50% On

1s 50% Off

Acquisition

Single Shot

Continuous

Continuous

Auto Range Option

Aggressive Conservative Conservative

Machine Speed

Normal

Normal

Normal

Settling Delay

0,00

As necessary

As necessary

Memory

N/A

N/A

N/A

Fill Signature

Off

Off

Off

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Off Route Configurations

Offroute User Settings Memory Display format Units Coupling Input channel Detection Sensitivity Overall & Signature : Overall only : Signature Only DEFAULT Overall/Sig Spectrum Accel ICP X RMS 100 mv/g ROUTE BASED n/a n/a n/a n/a n/a n/a n/a REAL TIME Sig Only Spectrum A -> V (ips) ICP X RMS 100 MV/G

Spectrum : Time : Phase : Orders Accel(g) : Demod : RPM : A->V(ips) : A->D (mil) AC : DC : ICP X : Y : Z RMS : Peak : Pk-Pk : True Peak : True Pk-Pk xxx mV/EU

Hi pass filter

Fmax Lines/Samples Window Averages Overlap Type Ext trigger slope Level

Off : 0.18Hz / Demod 0.6-1.25 kHz : 0.36Hz / Demod 1.25-2.5 kHz : 2Hz / Demod 2.5-5 kHz : 2.67Hz / Demod 5-10 kHz : 5.3Hz / Demod 10-20 kHz : 10Hz : 23.8Hz : 70Hz 5.3 Hz / Demo 25, 32, 40, 50, 64, 80, 100, 125, 128, 160, 200, 250, 256, 320, 400, 500, 625, 640, 800, 1K, 1250, 1280, 1600, 2K, 2500, 2560, 3125, 3200, 4K, 5K, 6250, 6400, 8K, 10K, 12500, 12800, 16K, 20K, 25K, 32K, 40K 2000 Hz 100/256 : 200/512 : 400/1024 : 800/2048 : 1600/4096 : Hanning : Hamming : Flat Top : Rectangular xxx xx Spectral : Time Synch +ve : -ve xxx 400 / 1024 Hanning 1 50% Spectral +ve 2V

n/a

10 Hz

n/a n/a n/a n/a n/a n/a n/a n/a

10K 400 / 1024 Hanning 1 50% Spectral n/a n/a

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Battery and PCMCIA Details

The DCA-31 can be powered either from its own internal Lithium ION battery or by using the AC/DC adapter plugged into the power connector on the top panel. However, it is not recommended that you collect data while connected to AC power, as power line noise may contaminate low-level signals. !" !" The main battery and internal batteries are recharged in the DCA-31 when the AC/DC connection is being powered. The state of charge can be displayed by pressing the "dot" (decimal point) key in most screens.

!"

Access to the main battery pack is obtained by removing two screws on the plate located on the underside of the Data Collector.

The Main Battery is removed by sliding the cell to the left and lifting from the DCA-31. The battery is refitted to the DCA-31 by following this process in reverse order. NOTE: The DCA-31 has a safety switch positioned under the plate of the battery compartment. By removing this cover the DCA-31 will shut down (as if the Off button were pushed).

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Battery Level Information

The Instrument battery status will be displayed by pressing the "." (dot or decimal point) key. This is available on the majority of screens. The Display reports the status of the removable battery and the condition of the unit's back-up battery. The backup battery will be charged when the unit is connected to the external power input or when the unit is powered on using the internal battery power.

Battery:

100% Backup Battery: Good

Indicates Condition of Internal Backup Battery

Indicates the Instrument is operating under Internal Battery This changes to display a "Plug" When under Mains Power

Main Battery Indicator Bar Gauge

Battery Basics
The specifications for the battery are: Manufacturer: Canon

Model: Battery Pack BP-914 or BP915 Rating: 7.2 V 1350 mAh

This battery is commercially available at most camera stores as it is a standard battery in many cameras. Tests have shown the battery charge will last through about 5 to 8 hours of continuous use. When not in use the battery will slowly drain, so it is best to give the battery a fresh charge once a month. Do not leave the battery off the charger for more than two months or the backup battery will drain. If this happens, you can recharge it by leaving the unit turned on with the external charger attached. It is best to leave the unit plugged in when not using it.

PCMCIA Basics
The size of the databases of some ships may exceed the DCA-31 internal memory capacity (4 Mb). For these ships, a standard SRAM or FLASH memory card must be inserted in the PCMCIA slot on the bottom of the instrument. The compatible card formats are PCMCIA (type I), SRAM, FLASH (linear or ATA), or ATA disk. Here is an example of one manufacturer that has been tested and is know to work well:

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Manufacturer: P/N: Nomen: Type: Barcode SKU:

SimpleTech (www.simpletech.com( STI-ATAFL/32A 32MB FLASH CARD ATA Type I PCMCIA 91000-01012-001

To set up the DCA-31 for use with removable memory, select the Instrument Setup option from the Main Menu. Select Card from the MEMORY option in the Instrument Setup screen.

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The Vibration Sensor

Hand held vibration sensors are widely used, but they invite hidden errors and inaccuracy in the PM program. Hand held sensors might not be reliably held at the same angle or with the same pressure from one test or measurement to the next. This leads to data collection errors and vibration amplitude trend plots that can turn out to be as much a measure of the talent and concern for detail of the data collection personnel as they are of machine condition! Most data collectors use single axis pickups. With a single axis system, data collection in three directions at one location on a machine requires three separate data collection operations. A triaxial data collector can gather more data without extra time. The additional vibration information that tri-axis collection provides can often make the difference between correct and incorrect analysis of machine condition. The triaxial sensor has three accelerometers mounted on a common base. The sensors accelerometers are oriented so that the axis of each coincides with a machine shaft direction, axial, radial, and tangential. Each accelerometer generates an AC signal that is the analog representation of the vibration of the machine bearing housing.

Inside each sensor accelerometer is a piezoelectric crystal with a mass attached to it. When the piezoelectric crystal is compressed, it generates an electrical charge. An amplifier built into the accelerometer converts the small signal to a strong voltage signal that is fed into the data collectors electronics.

ICP Amplifier Pre-loading Spring Seismic Mass Crystal Element

Base

Mounting Stud

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Typical Triaxial Accelerometer

Cable

Cable

Capture Screw Capture Screw

Alignment Key Channel Identification

2 Alignment Key Capture Screw

VdB Usable Range Log Frequency 1 Hz Fr/3 Fr

Accelerometer Frequency Response

The frequency range of the accelerometer is very wide, extending from very low frequencies in some units to several tens of kilohertz. The high frequency response is limited by the resonance of the seismic mass coupled to the springiness of the piezoelectric element. This resonance produces a very high peak in the response at the natural frequency of

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the transducer, and this is usually somewhere near 30 kHz for commonly used accelerometers. A rule of thumb is that an accelerometer signal is valid up to about 1/3 of its natural frequency.

Care and use of the Triaxial Accelerometer

It must be understood that the triaxial accelerometer with its piezoelectric crystal is a sensitive piece of electronic equipment. Though, it is designed to operate in an industrial environment, using the following guidelines is strongly recommended when handling the accelerometer and cables:
" ! " ! !"

Do not drop the accelerometer onto any hard surface from distances greater than three feet. This can result in damage of the crystals and cause erratic spectral data. Do not attach and remove the accelerometer by pulling its cables. Excessive force results in looseness in the connection of the cable, and can result in improper data collection and/or generated cable fault codes. Always ensure the accelerometer is properly aligned, seated, and tightened prior to data collection. Always allow for proper warm-up of the accelerometer due to temperature differences prior to recording data. This will ensure that the data collected will not result in a ski slope spectral plot. Always place the accelerometer in its protective cover when not in use. Understand that a replacement accelerometer costs in the area of $1,800.00.

" ! " ! !"

" ! " ! !"

" ! " ! !"

" ! " ! !"

" ! " ! !"

Troubleshooting the DCA-31

The DCA-31 is a computer and, as such, has an operating system required for successful operation of all the data collector functions. The data collector program that runs under this operating system is often called firmware, internal software, or application software. It is very different than the Survey, which includes all the setup information for your ship. If the operating system indicates errors, you can reset the data collector using either a soft boot or a complete operating system reboot. Here are some specific times when a reset is required: 1. 2. 3. Upon receipt of a new DCA-31 from DLI Engineering Corp. After the battery goes completely dead. When a battery swap is not done quickly enough, allowing the internal battery to run down.

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4.

Standard troubleshooting step anytime the data collector is operating abnormally.

Soft Boot
A soft boot allows the operating system (Windows CE) to remain active while re-starting the Data Collector firmware. To perform a soft boot, first ensure the unit is powered on. Once power is on, simultaneously press and hold down the 2, 7, 8, and 9 keys. Continue to hold these four keys down until you see the progress bar on the screen complete its travel from left to right. Release the four keys and you will see an hour-glass and the reboot will continue. After this, the system will place you at the main menu where you can continue with data collector operations.

Hard Boot
A hard boot forces a shut down and restart of the Windows CE Operating System. To perform a hard boot, first remove the battery cover plate. With a paper clip gently depress the recessed switch on the lower left hand side of the battery compartment. After this, place the cover back on the battery compartment and press the power button. Select option 1 (Run Windows CE) and the unit will power down. Wait about 10 seconds and press the power button to allow the unit to boot. You may have to modify the Instrument Setup and Configuration items mentioned earlier as they may set themselves to the default settings. At a minimum, you will have to reset the internal clock.

LCD Backlight On / Off

The best way to conserve battery charge and prolong the need to put the unit on charge is to turn off the backlight. If using the DCA 31 in a well-lit space you should be able to adequately see the screen without the backlight. To toggle the back light on / off use the following key sequence: +/- 2558 To help remember this, the number 2558 corresponds to the letters BKLT, which is shorthand for the word backlight. Note that each numbered key has three letters just like a phone. The +/- key is the lower right hand key on the keyboard.

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