Vibration Monitoring Application Guide v2.0

Background

Industrial facilities have hundreds of critical rotating assets, such as motors, pumps, gearboxes, and compressors. Unexpected failures result in costly down-time. An equipment health monitoring (EHM) preventative maintenance solution uses machine learning to identify when assets exceed pre-defined parameters.

Visual Description: A close-up photograph of a large industrial motor, showing its metallic casing and some internal components.

Value

• Increased Uptime – Eliminate unplanned shut-downs by continuously monitoring up to 40 assets with a single system
• Reduced Maintenance Cost – Repair prior to failure or extensive collateral damage
• Effective Maintenance/Parts Scheduling – Spare parts and labor planning
• Ease of Use – Reduce installation costs and eliminate complexity of traditional data analysis
• Improved Asset Selection – Use data to assist in root cause and reliability analysis
• IIoT – Real-time alerts for better decision making and remote asset management

Banner Solution

Monitors for changes in vibration of rotating assets that are the result of:

• Imbalanced/misaligned components
• Loose or worn components
• Improperly driven or mounted components
• Over-temperature condition
• Early bearing failure

Visual Description: A line graph displaying vibration data over time, with two distinct lines showing fluctuations. The x-axis represents time, and the y-axis represents amplitude.

How Banner Solves

• Banner's Wireless vibration/temperature sensor continually monitors RMS velocity (10-1000 Hz), RMS high frequency acceleration (1000-4000 Hz), and temperature on rotating equipment, but uses vibration data only when the asset is operational.
• DXM Controller uses machine learning algorithm to baseline values and set control limits for alerts with limited end-user interaction. Creates a "check engine light" for each motor!
• DXM Controller collects data for trending and analysis. Script defines acute verses chronic issues.
• Data and alerts can be sent to the host control or to the cloud for IIoT connectivity.

Visual Description: An illustration showing a wireless vibration sensor attached to a piece of equipment, communicating wirelessly to a DXM Controller. The DXM Controller is then shown connecting to a cloud icon, representing IIoT connectivity.

Guide Features and Benefits

Solution Components

Mounting Options

The following mounting options are listed from least effective to most effective. In all mounting options, care must be taken to ensure there is no sensor movement as this could lead to inaccurate information or changes in from the time-trended data.

Step 1: Install the Sensor

Mounting and installing the vibration sensors on a motor are important for getting the most accurate readings. Sensors can be mounted using magnetic brackets, thermal transfer dual-sided tape, standard brackets epoxied directly to the motor, or standard brackets bolted directly to the motor.

The vibration sensors have an X and Z axis indication on the face of the sensor. The Z axis goes in a plane through the sensor while the X goes horizontally.

1. Install the sensor so that the X axis line is aligned with the motor shaft of the motor, or axially.
2. Install the sensor's Z axis into/through the motor. These can be swapped where the X axis is going into/through the motor and the Z axis is in line with the shaft of the motor if you are placing the sensing vertically for easier installation.
3. Install the sensor as close to the bearing of the motor as possible. Using a cover shroud or location far from the bearing may result in reduced accuracy or a reduced ability to detect certain vibration characteristics.

Visual Description: A photograph of a Banner QM30VT1 sensor, showing its model number, certifications (CE), and axis indicators (X, Z, Y). It is shown mounted near a rotating machine part.

Step 2: Configure the System

To customize the system to an actual application, make some basic modifications to the template files. There are two files uploaded to the DXM700 or newer models: the XML file sets the DXM's initial configuration and the ScriptBasic file reads vibration data, performs the machine learning, sets the thresholds for warnings and alarms, and organizes the information in logical and easy to find registers in the DXM.

Loading these files and making adjustments requires using Banner's DXM Configuration Software and the Vibration Monitoring files available from in the links below.

1. Install the Sensor Node pairs after the Nodes are bound to the master radio and a site survey performed. The files automatically begin baselining after they are loaded to the DXM. Avoid any unrelated vibrations from sensor installation.
2. Download the preconfigured files.
3. Extract the ZIP files into a folder on your computer. Note the location where the files were saved.
4. Connect the DXM, via the USB cable supplied with the DXM, to a computer containing the DXM Configuration Software v4 or download the software and install it on a computer.
5. Launch the software and select the DXM700 or newer model.
6. Open the Vibration Monitoring XML file by going to the File > Open menu and choosing the configuration files.
7. Connect the software to the DXM by going to the Device > Connection Settings menu. Select Serial and then select the COM port that the USB cable is plugged into. Click Connect. If unsure which COM port and multiple appear, attempt to connect to each one of them until successful.
8. Upload the Vibration Monitoring script file (.sb) by going to the Settings > Scripting tab. Click Upload file and select the script file.
9. Save the XML file any time the XML has been changed because the tool DOES NOT autosave.

Optional Steps: Customize the XML file

1. Within the DXM Software, go to the Local Registers > Local Registers in Use screen.
2. Rename the Motors by clicking on the register and using the text boxes within the Register Overview Box on the lower half of the screen. Because there are 5 registers per motor being monitored, copy and paste names for efficiency. To display the motor vibration data, warnings and alarms on the website, change the Cloud Settings to Read for each motor' information piece (velocity, acceleration, alert mask, etc.) that you would like to appear on the Banner Cloud Data Service (CDS) website. All recommended registers to send to the cloud are preselected to Read.
3. To change multiple Node's motor vibration data on the website, change the Cloud Settings.
   • On the Modify Multiple Registers screen (lower half), select Set in the drop-down list next to Cloud Settings.
   • Set the Starting Register to 1 and the Ending Register to the value equal to 5 × Number of motors in the system (for example, set the ending register 80 for only using 16 motors).
   • In the drop-down list to the right, select Read for Cloud Permissions. This will push those registers every 5 minutes. (RECOMMENDED for Raw Data registers and alarm masks registers 1-240)
   • Set to Write or Read/Write to be able to update the register value from the Banner CDS website. (RECOMMENDED for Re-baselining registers 321-360)
   • Set to Push UTC 00:00 to only have those registers push once a day (RECOMMENDED for Baseline, Warning and Alarm Registers 5181-5660)
   • Click Modify Registers on the bottom right of the section.

NOTE: If you are using fewer than 40 Nodes, change the Cloud Settings to NONE for registers that aren't being used in the ranges listed in the previous steps to avoid sending unnecessary data.

Warnings and alarms within the system are contained within a register for each Nodes in local registers 201-240. The registers are labeled “NXX VibMask” where XX is the Node number. The number displayed is a decimal form of a 18-bit binary number with a value of 0 or 1 to accommodate up to 18 warnings or alarms for each Node.

The 18-bit binary masks are broken out as follows:

• Bit0 – Warning – X-Axis – Acute Velocity = (0/1) * 2^0
• Bit1 – Warning – X-Axis – Acute Acceleration (Hi Freq) = (0/1) * 2^1
• Bit2 – Warning – Z-Axis – Acute Velocity = (0/1) * 2^2
• Bit3 – Warning – Z-Axis – Acute Acceleration (Hi Freq) = (0/1) * 2^3
• Bit4 – Alarm – X-Axis – Acute Velocity = (0/1) * 2^4
• Bit5 – Alarm – X-Axis – Acute Acceleration (Hi Freq) = (0/1) * 2^5
• Bit6 – Alarm – Z-Axis – Acute Velocity = (0/1) * 2^6
• Bit7 – Alarm – Z-Axis – Acute Acceleration (Hi Freq) = (0/1) * 2^7
• Bit8 – Warning – X-Axis – Chronic Velocity = (0/1) * 2^8
• Bit9 – Warning – X-Axis – Chronic Acceleration (Hi Freq) = (0/1) * 2^9
• Bit10 – Warning – Z-Axis – Chronic Velocity = (0/1) * 2^10
• Bit11 – Warning – Z-Axis – Chronic Acceleration (Hi Freq) = (0/1) * 2^11
• Bit12 – Alarm – X-Axis – Chronic Velocity = (0/1) * 2^12
• Bit13 – Alarm – X-Axis – Chronic Acceleration (Hi Freq) = (0/1) * 2^13
• Bit14 – Alarm – Z-Axis – Chronic Velocity = (0/1) * 2^14
• Bit15 – Alarm – Z-Axis – Chronic Acceleration (Hi Freq) = (0/1) * 2^15
• Bit16 – Warning Temperature (> 158°F or 70°C) = (0/1) * 2^16
• Bit17 – Alarm Temperature (> 176°F or 80°C) = (0/1) * 2^17

The decimal version is the sum of the calculations shown in the right column for each Node's mask register. Note that any value greater than zero in registers 201-240 indicates a warning or alarms for that particular Node. To know the exact warning or alarm, the decimal value will need to be backed out to a binary value, which is done on the Banner CDS cloud site using the automated dashboard icons or can be done with a PLC or HMI. Multiple warnings and alarms may trigger on an event depending on severity.

Visual Description: A screenshot of the DXM Configuration Software interface, showing the "Local Registers in Use" screen with columns for Register Name, Register Group, Units, etc., and the "Modify Multiple Registers" screen for adjusting Cloud Settings.

Step 5: Configure to Receive Email or Text Alerts

An example action rule is when the warning/alarm masks in registers 201-240 are greater than zero, trigger an email or text message. There are six threshold rules that are already configured that trigger on Any Error, Any Acute Warning or Alarm, Any Chronic Warning or Alarm, or Any Radio Connection Error. The steps below can be used for any action rule.

1. Click on the Action Rules tab and expand any rule using the arrow next to the rule OR create a new action rule using the Add Threshold Rule button on the top.
2. Click on the arrow next to Email/SMS on State Transition.
3. Select the recipient of the SMS and/or email upon the action rule becoming true.

In the example shown, both SMS Recipient 1 and 2 and Email Recipient 1 and 2 receive a message when the action rule meets its criteria.

Visual Description: A screenshot of the DXM Configuration Software interface, showing the "Action Rules" tab with options for configuring Email/SMS alerts and recipients.

Set up the Ethernet or Cellular Connection

By default, the XML file configures the DXM700 with an Ethernet Push interface with the ability to send emails and push the data registers to a webserver. The device can also be configured to use a cellular push if the DXM Controller contains a cellular module and data plan. This section is only necessary if the user wants to receive or display information beyond just the DXM Controller's LCD.

1. If the DXM will text, email, or push to the cloud webserver, set up the push interface.
   • On the DXM Configuration Tool, go to the Settings > Cloud Services screen.
   • Select the appropriate Push Interface (Ethernet or Cell) from the drop-down list. Selecting Cell requires a cellular module be installed in the DXM Controller and a wireless plan be set up for sending data.
2. The Cloud Push Interval is set to None for XML because the script associated with this file establishes the five minute push interval internally, so it occurs immediately after the sample of the Nodes. To enable the Script to push, register 844 must be have the Value Type set to Constant and the value of 1 on the Local Register in Use screen.
3. To send emails or text messages, go to the Settings > Notifications screen and enter in the addresses and/or phone numbers in the recipient boxes.
   • To send emails, fill out all SMTP fields for the mail server delivering the email messages.
   • Passwords are not stored in the XML and must be send via the Send SMTP Password button when the DXM software is connected to the DXM.

Visual Description: A screenshot of the DXM Configuration Software interface, showing the "Cloud Services" screen for setting up Ethernet or Cellular connections and SMTP mail server settings.

Step 5: Save and Load the XML File to DXM

When changes are made to the XML file, save the changes. To apply the changes, load the XML file to the DXM.

1. Save the file by going to the File > Save menu.
2. Load the file onto the DXM by going to the Device > Send XML Configuration to DXM menu.

Because of the size of the XML file, the file may take up to three minutes to load. Verify the file is loading by looking at the Application Status indicator in the status bar.

If the Application Status indicator is RED, close and restart the DXM Configuration Software, unplug and re-plug in the USB cable and reconnect the DXM to the software. If the Application Status indicator is GREEN, the file upload is complete. If the Application Status indicator is YELLOW, the file transfer is in progress.

Visual Description: A screenshot of the DXM Configuration Software interface, showing the "Application Status" bar indicating connection and file upload progress.

Step 6: Push Information to the Cloud

The DXM700 can connect to the web via Ethernet or an internal cell module to push data from the site to the cloud and display the data on a website. To enable this capability for remote monitoring and alarms settings, modify the XML file.

The Banner Cloud Data Services (Banner CDS) website can be used for storing, monitoring, and visualizing the system's data at https://bannercds.com/.

1. Connect the DXM to a computer with the DXM Configuration Software.
2. Launch the software and connect to the DXM.
3. Open the saved XML file (File>Open).
4. Go to the Settings > Cloud Services screen.
5. Visit the Banner CDS website (https://bannercds.com/) and log into an existing account or register a new account.
6. Click + New Site, select the company where the site will reside and name your site.
7. Highlight and copy the Site ID and click Save.
8. On the DXM Configuration Software: Return to the Settings > Cloud Services screen and verify the server name is push.bannercds.com.
9. Paste the copied ID into the Site ID field.
10. Save the XML file (File > Save).
11. Upload the file to the DXM (Device > Send XML Configuration to DXM).

Visual Description: A screenshot of the Banner Cloud Data Services (CDS) website, showing a dashboard with various data visualizations and site management options.

Register Glossary and Options for User Interaction

Acute Samples

Non-Volatile Register 853 – Set to a default value of 5 consecutive samples before triggering an acute alert. User adjustable to any value 1 or greater for the number of consecutive samples above a warning or alarm threshold before triggering an acute alert.

Baseline Samples

Non-Volatile Register 852 – Set to a default value of 300 samples for a baseline. User adjustable to any number of five minute samples used to generate a baseline, warning, and alarm thresholds.

Baseline, Warning and Alarm Levels

Local Registers 5181-5660 – Each Node has a baseline, warning, and alarm level for each of the four vibration characteristics stored in these registers. Set to push once per day. Use for graphing with raw vibration data for comparison.

Cloud Push

Local Register 844 – Set to a value of 1 to enable cloud pushing from script.

Load Baseline

Local Register 842 – Users can manually adjust warning and alarm thresholds by entering values into non-volatile registers 7001-7320 for vibration and 7681-7760 for temperature. After the data is entered in those registers, change register 842 to 1 for 10 seconds, then set it back to 0 to load the data and override the automatically generated values

Motor Run Flag On/Off (0/1)

Local Registers 241-280 – The script determines whether or not a motor is running and only uses data from a running motor for trending, alerts, and baselining. These registers could be used to track run time or ON/OFF count with action rules.

Node Connection Status

Local Registers 281-320 – A value of 1 in the 8th bit (decimal 128) indicates a Node is in sync with its master radio. Any other value indicates a Node is no longer in sync with its master radio. This could be due to radio interference or low battery.

OR'd Warnings and Alarms

Local Registers 570-578 – All registers here provide a value of 0 or 1 to indicate if the value is false or true. These indicate a warning or error on any of the 40 Nodes based on the description of the register. Some are for vibration acute or chronic warnings or alarm, some for temperature, and some for the radio connection.

Sensor Vibration and Temperature Data

Local Registers 1-200 – Each Node has five registers, two for RMS velocity, two for RMS High Frequency Acceleration, and one for Temperature. The data is unscaled for easier viewing. In English units (in/s), the velocity = Register value ÷ 10000. For metric (mm/s), the velocity = Register value ÷ 1000. For either units, acceleration (g) = Register value ÷ 1000. For example, a velocity register value of 500 = 0.05 in/s and an acceleration register value of 15 = 0.015 g.

Setup Nodes

Local Register 833 – When the DXM boots up, it attempts to automatically set up Nodes in sync to have the proper vibration characteristics in the correct inputs. When a new Node is bound to the system after initial boot up, the new Node(s) need to be configured. This requires either sending a value of 1 to register 833 or rebooting the DXM.

User Adjustable Temperature Warning and Alarm Levels

Non-Volatile Registers 7681-7760 – Set to a default of 158F(70 deg C) for warning and 176 F(80 C) for alarm. Enter in the required level for each Node. Trigger Load Baseline register to a 1 for 10 seconds after setting user adjusted levels.

User Adjustable Vibration Warning and Alarm Levels

Non-Volatile Registers 7001-7320 – Default level is 0 to use automatically generated values. Users can adjust the level manually by entering a value for any warning or alarm level on any vibration characteristic. In English units (in/s), the velocity = Register value ÷ 10000. For metric (mm/s), the velocity = Register value ÷ 1000. For either units, acceleration (g) = Register value ÷ 1000. For example, 0.05 in/sec = register value of 500. Trigger Load Baseline register to a 1 for 10 seconds after setting user adjusted levels.

Vibration Alerts Mask

Local Registers 201-240 – Each Node has one register in this grouping where all the vibration and temperature alerts are bitpacked into a single register. Any value greater than zero indicates a warning or alarm condition and can be used as a “check engine light" for setting up notifications via email or SMS.

Additional Features

Adjusting Vibration Warning and Alarm Thresholds

After baselining is complete, warning and alarm thresholds are set for each vibration characteristic on each axis automatically. To view those values, check registers 5181-5660 (12 registers per Node). To adjust those thresholds, use registers 7001-7320 (8 registers per Node). These values are stored in non-volatile registers so they will remain through a power loss. Triggering a new baseline zeroes out the user-defined registers.

Adjusting Vibration Thresholds from the DXM tool.

1. Using the DXM Configuration Software, connect to the DXM that is running the Vibration Solutions Kit.
2. Go to Tools -> Register View.
3. The vibration warning and alarm thresholds are in registers 7001 through 7320 and are labeled User_NX_XVel_Warning or User_NX_XVel_Alarm, etc. (where X is the motor ID number).
4. Use the right column and enter in the starting register to change and the value to set it to.
5. Click Write Registers.
6. To change another threshold, follow steps 3 through 5.
7. To modify up to 40 thresholds at a time, adjust the number of registers underneath the starting register and fill in each value next to the register. Click Write Registers when complete.
8. To return to using an original baseline value for a particular Node's vibration characteristic, set the user-defined register (7001 through 7320) back to 0 for that particular vibration characteristic.

Adjusting Vibration Thresholds from a host (PLC or HMI)

1. Write the appropriate value in to registers (X is the Node number 1 through 40):
   • 7000+X for X Velocity Warning
   • 7001+X for X Velocity Alarm
   • 7002+X for Z Velocity Warning
   • 7003+X for Z Velocity Alarm
   • 7004+X for X Acceleration Warning
   • 7005+X for X Acceleration Alarm
   • 7006+X for Z Acceleration Warning
   • 7007+X for Z Acceleration Alarm
2. To return to using an original baseline value for a node's vibration characteristic, set the user-defined register (7001 through 7320) back to 0 for that particular vibration characteristic.

Adjusting Temperature Thresholds

1. Set temperature warning values in registers 7681 through 7720 for sensors 1 through 40.
2. Set temperature alarm values in registers 7721 through 7760 for sensors 1 through 40.

Local Registers

Local Registers (Continued)

Where N represents the Motor Node ID number.