Instruction Manual

IR30 BEARING MONITOR

Sentinel Model

APDD 766A
MARCH 2003

IR-30 SENTINEL

IR 30 Shock Pulse Instrument

Manual Contents List
Section

Title

IR 30 Sentinel Instrument Parts List

Shock Pulse Monitoring, A Snapshot

Data Acquisition with the IR30

When Is There A Problem?

Required Documentation for Airend Replacement

Measuring Points on Ingersoll-Rand Units

Data Acquisition on a Nirvana

dBi and dBm values for Ingersoll-Rand Units

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

54636519

IR 30 Sentinel Instrument

39262837

TRA 22 Probe

39262928

9022 Batteries (AA Size)

( Installed In Instrument )

54636527

Instruction Manual Package

APDD 766A

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
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
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
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

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

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
the instrument and the transducer.

Bearing data
TLT on
. rpm
. dmm
dBi 26

If BDI is known for a particular reading point (see dbi

tables), press SET until the cursor is at dbi ____. Using
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
should be as short and direct as possible, with no bolted
joints in this path. Bearing housing flange edges make
good locations. Take one set of data loaded, a second
set unloaded. dbm is Decibel Maximum, dbc is Decibel
Carpet.

SPM
TLT 18
dBm 16
dBc 8

dBi 25

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
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 500700 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 _____
MR 2 _____
MR 1 _____
MR 2 _____

DBI _____ DBM _____ DBC _____

DBI _____ DBM _____ DBC _____
DBI _____ DBM _____ DBC _____
DBI _____ DBM _____ DBC _____

Loaded
Loaded
Unloaded (Single Stage Only)
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.)
Vertical,
Loaded____ Unloaded____
Horizontal, Loaded____ Unloaded____
Axial,
Loaded____ Unloaded____
Sound Level: Describe____________________________________________
Vibration Data:

MM/Sec.

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_____________________
Todays 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.