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EasyBalance 2.2 Owners Manual High-end dynamic balancing instrumentation of 51

© 2000 - 2004 BalanceMaster, Inc. 434-993-9182 Doc #: 85EBOM22-63819

Owners Manual

EasyBalance 2.2

High-end dynamic balancing instrumentation with WINDOWS-based EasyBalance software

Version 6.39.1



INDEX: 1 Electrical Connections ...........................................................................................................................4 2 System Requirements............................................................................................................................5 3 Software Installation...............................................................................................................................5 4 Launching the Software .........................................................................................................................6 5 System diagnostics ................................................................................................................................7 6 Rotor Setup Screen ...............................................................................................................................8 7 Instrumentation Setup and Configuration ..............................................................................................9 8 Instrumentation Setup Screen .............................................................................................................10

8.1 Diagnostic mode .......................................................................................................................10 8.2 Vibration display........................................................................................................................10 8.3 Supervisor Lock ........................................................................................................................11 8.4 Automatic cycle .........................................................................................................................11 8.5 Remote Angle Display ..............................................................................................................11 8.6 Gain switching...........................................................................................................................11 8.7 Polar diagram style ...................................................................................................................12 8.8 Display preferences ..................................................................................................................12 8.9 Tooling compensation info ........................................................................................................12 8.10 Key compensation info..............................................................................................................12 8.11 Direction of rotation...................................................................................................................12 8.12 Polar diagram orientation..........................................................................................................12 8.13 Balancing log.............................................................................................................................12 8.14 Print reports...............................................................................................................................13 8.15 Setup and Calibration Report....................................................................................................13

9 Hardware Setup Screen.......................................................................................................................14 9.1 Machine Type............................................................................................................................14 9.2 Instrumentation Speed Range ..................................................................................................15 9.3 Input configuration.....................................................................................................................15 9.4 Hard-bearing machines, hidden dimensions: ...........................................................................15 9.5 Encoder Polarity:.......................................................................................................................16

10 Calibration Screen ...............................................................................................................................17 10.1 Calibration Data ........................................................................................................................19 10.2 Enable RPM Ranges ................................................................................................................19

11 Machine calibration, general: ...............................................................................................................20 12 Setup and calibration backup: .............................................................................................................20 13 Manual calibration:...............................................................................................................................21 14 Automatic Calibration Mode without Equalization ...............................................................................22 15 Automatic Calibration Mode with Equalization ....................................................................................24 16 RPM Calibration Ranges .....................................................................................................................26 17 Rotor Name..........................................................................................................................................27 18 Units of Measure..................................................................................................................................27 19 Rotor Dimensions ................................................................................................................................27 20 Correction Method ...............................................................................................................................27 21 Unbalance Tolerance...........................................................................................................................27



22 Tolerance in journal planes or in correction planes .............................................................................27 23 Tolerance Calculator............................................................................................................................28 24 Tooling Compensation Program..........................................................................................................28 25 Key Compensation Program................................................................................................................29 26 Live Polar Diagram ..............................................................................................................................30 27 Averaging cycle....................................................................................................................................31 28 Soft-bearing mode and Teach-mode (Rotor-specific calibration) ........................................................32 29 Result Display ......................................................................................................................................33 30 Polar Diagram Display .........................................................................................................................33 31 Zoom 5x Tolerance.............................................................................................................................34 32 Zeroing.................................................................................................................................................34 33 Multi-Run Averaging ............................................................................................................................35 34 Amount and Angle Display ..................................................................................................................36 35 Toggle Add/Remove ............................................................................................................................37 36 Recalc ..................................................................................................................................................37 37 Special Correction................................................................................................................................38

37.1 Rotor segments:........................................................................................................................39 37.2 Combine Weights:.....................................................................................................................39 37.3 Drill Correction ..........................................................................................................................40 37.4 Tape Correction ........................................................................................................................41 37.5 Clip bin correction .....................................................................................................................41 37.6 Wire-feed welder .......................................................................................................................41 37.7 Rotor Segments (Vector-Split) ..................................................................................................41 37.8 Combine Weights......................................................................................................................43

38 Print functions ......................................................................................................................................44 39 Balancing Certificate ............................................................................................................................44 40 Next Run ..............................................................................................................................................45 41 Show History........................................................................................................................................46 42 New Rotor ............................................................................................................................................47 43 Static/Couple Separation .....................................................................................................................47 44 Bode-plot..............................................................................................................................................48 45 Balancing Log ......................................................................................................................................49 46 Delete Rotor name...............................................................................................................................50 47 Disclaimer ............................................................................................................................................51 48 Copyright..............................................................................................................................................51



1 Electrical Connections

This rear panel view shows the available connectors. 1. To PC:

RS232 Serial cable, plug into PC serial port (DB9 male) 2. Vibration Pickups Left / Right: Connect to the left and right vibration pickups 3. Reference Pickup: Connect to the phase reference pickup (Photocell or Proximity switch) 4. Encoder Input: Connect to the encoder (if equipped) Warning: Encoder must be designed for 18 Volts supply voltage and have line

driver output (5 Volts signals) 5. Power: Connect to 120 Volts power (230 Volts versions are also available)

1 2 3 4 5



2 System Requirements This software requires a PC with WINDOWS 98, Me, 2000, NT or XP operating system. Windows XP is recommended. Display resolution should to be at least 800x600x16 bit color. 1024x768x16 bit color is recommended. The software automatically adjusts to screen resolutions up to 2048x1536. The PC needs to have a standard RS232 serial port (DB9 male) and a 3-½ floppy drive or a CD ROM drive.

3 Software Installation The EasyBalance software is provided on a CD or in an email attachment and comes with it’s own installation program.

• For new installations, the file name is “EasyBalance_new_CustomerName.exe” • For software updates the file name is “EasyBalance_update_CustomerName.exe”

Double-click the file to start the software installation and follow the screen prompts. Note: If you are updating your existing software to a new version, make sure that the new program file “EasyBalance.exe” has been placed into the existing folder containing your previous EasyBalance program, thereby replacing the old program file with the new one. Your existing calibration and setup data will be preserved.



4 Launching the Software Locate the file EasyBalance.exe and create a shortcut. Move the mouse pointer over the file, right-click, and select “Create shortcut”. A new shortcut for EasyBalance.exe is being created. Drag the shortcut to the desktop. You can rename the shortcut as you like (see your Windows software manual on how to create a shortcut) Double-click the shortcut. The software will launch and show a splash-screen. The splash-screen indicates the software version number, licensed customer, copyright information and an “electronic calibration sticker”.

Software version

Licensed customer

Calibration Sticker



5 System diagnostics Next, the software will perform a self-diagnostic procedure, checking the EasyBalance instrumentation and the proper communication with the PC. If everything is OK, a logon screen will appear:

If you like, enter an operator name. This name will be used as the operator’s name in all print reports. Enter your password (password feature may not be activated in your software version, leave blank). The button “Amplitude-only mode” is only visible in soft-bearing or field-balancing mode and allows to work in a simplified mode showing just amplitude and phase measurements. Click OK and the ROTOR SETUP SCREEN will be next.



6 Rotor Setup Screen

The top of the screen shows a total of 6 pre-programmed rotor configurations: 1. Both correction planes between supports 2. Both correction planes outside of supports 3. Both correction planes outside of RIGHT support 4. Both correction planes outside of LEFT support 5. One correction plane outside of RIGHT support, one between supports 6. One correction plane outside of LEFT support, one between supports In addition to 2-plane mode, you can also select 1-plane mode by clicking the radio button to the left of the rotor setup icons. Click the rotor icon representing your rotor configuration. The selected rotor icon will change to a green background. Please note that when working in Soft-bearing mode, the system will calculate and work with Influence Coefficients. The Influence Coefficient Method does not require rotor setup dimensions, so they are optional. However, rotor setup dimensions are useful for documentation purposes.



7 Instrumentation Setup and Configuration The EasyBalance instrumentation system can be configured for all 3 types of dynamic balancing systems:

• Hard-bearing balancing machines • Soft-bearing balancing machines • Teach-mode (Rotor-specific calibration)

In addition, the EasyBalance system offers manual or automatic calibration modes. For balancing machines where linearity over RPM needs to be improved, a total of 5 RPM calibration ranges are available, with automatic linear interpolation from range to range. All Setup and Configuration options are intuitively organized into 3 screens:

• Instrumentation Setup • Hardware Setup • Calibration Setup

Configuration should only be performed by authorized personnel. Access to the Calibration screen is password protected. All Setup and Configuration options can be accessed by clicking the “M” of the word BalanceMaster, Inc. in the lower right corner of the ROTOR SETUP SCREEN. The SETUP SCREEN can also be accessed by right-clicking the mouse in the following screens:

• Rotor Setup screen • Live Polar Diagram screen • Polar Diagram screen • Amount and Angle screen



8 Instrumentation Setup Screen

The INSTRUMENTATION SETUP SCREEN offers the following features:

8.1 Diagnostic mode The EasyBalance system has a built-in diagnostic feature, which can help pin-pointing system problems. If switched ON, the LIVE POLAR DIAGRAM screen will show a group of 4 numbers in the lower left corner. These numbers provide an insight into the system and are useful for trouble shooting purposes.

8.2 Vibration display If the instrumentation is set to SOFT-BEARING or TEACH-MODE mode, vibration readings in either mil or mm/sec can be displayed in addition to the standard display of unbalance corrections.



8.3 Supervisor Lock Supervisor Lock ACTIVE blocks the operator from editing rotor setup information. Rotor setup information can be recalled from memory, but cannot be changed.

8.4 Automatic cycle If ENABLED, a new measurement cycle will automatically start when the rotor is switched on and stable RPM is recognized by the system. If large and heavy rotors are accelerating extremely slowly, it is best to set AUTOMATIC CYCLE to OFF. In this case click NEXT RUN in the result screen to start a new measure cycle.

8.5 Remote Angle Display If your machine is equipped with an encoder, and the encoder is connected to the EasyBalance Instrumentation, the EasyBalance software will automatically activate the REMOTE ANGLE feature. An encoder generates two independent square wave signals, with a 90° phase offset between each other. The EasyBalance Instrumentation can decode these signals and will generate an on-screen REMOTE ANGLE indication. The REMOTE ANGLE indication will help the operator to locate the exact angular position of the unbalance correction. The Remote Angle Display can be set to two different modes:

• Indicator dot travels with correction location • Indicator dot places correction location at ZERO

INDICATOR TRAVELS WITH CORRECTION LOCATION Using this mode, the Remote Angle Indicator will always indicate the actual angular position of the correction location, for both the left and right plane, independently of each other. For instance, moving the rotor so that the left indicator moves to the 12 o’clock position will place the correction location also at 12 o’clock. Note: In this mode, the indicator has to travel with the direction of the rotor movement. If the direction is not with the rotor movement, go to the HARDWARE SETUP SCREEN and change the setting for ENCODER POLARITY. INDICATOR PLACES CORRECTION LOCATION AT ZERO This remote angle mode is often found on Schenck or Hofmann machines. The operator has to line up both the Remote Angle Indicator and the vector dot (the result dot). Doing so will place the correction location at the ZERO location. If the ZERO is set to be at the 12 o’clock position, lining up the two dots will place the correction location at the 12 o’clock position. Note: In this mode, the indicator dot has to travel against the direction of the rotor movement. If the direction is not against the rotor movement, go to the HARDWARE SETUP SCREEN and change the setting for ENCODER POLARITY.

8.6 Gain switching According to the level of unbalance measured, the EasyBalance Instrumentation will select the appropriate sensitivity range automatically. This is called “Auto-ranging” or gain switching. Gain switching can be set to AUTOMATIC or FIXED. Up to 9 gain ranges are available as default from a drop-down menu. If Gain-switching is set to Fixed, the range selected as default will be used, regardless if the unbalance signal is too small or too large.



8.7 Polar diagram style The Polar Diagram style can be selected with either a 45° or 30° grid. The Polar Diagram background color can be selected to be either BLACK or DARK-BLUE.

8.8 Display preferences SHOW WEIGHT IN LARGE FONT Typically, the required correction weight result is displayed in large font (gram or ounce), with the unbalance being shown in small font. SHOW UNBALANCE IN LARGE FONT If you rather would like to see the unbalance result in large font, and the required correction weight in small font, select this setting. The ANGULAR PRECISION can be set to either 0, 1 or 2 decimal places.

8.9 Tooling compensation info In cases where Tooling compensation is used, the Tooling Error information can be displayed in the Result Screen and be included in the Print Reports. Un-check the check box if you do not want the tooling error values to be displayed. The tooling compensation itself will remain active even if this check box is un-checked.

8.10 Key compensation info In cases where Key compensation is used, the Key compensation information can be displayed in the Result Screen and be included in the Print Reports. Un-check the check box if you do not want the key compensation values to be displayed. The key compensation itself will remain active even if this check box is un-checked.

8.11 Direction of rotation The direction of rotation can be set to either clockwise or counter-clockwise, as seen from the operator position, looking towards the rotor.

8.12 Polar diagram orientation The Polar Diagram orientation can be set to either ZERO at 12 o’clock or ZERO at 6 o’clock. This setting has to correlate with the orientation of your phase reference mark on the rotor.

8.13 Balancing log The EasyBalance system keeps and automatic balancing log and can be set to either LOG ALL RUNS or LOG INITIAL AND FINAL runs or LOG FINAL run only.



8.14 Print reports Print reports can be printed using either PLAIN PAPER or COMPANY LETTERHEAD. If PLAIN PAPER is selected, the customer info will be included in all print reports. If LETTERHEAD is selected, a sufficient margin is added on top of the print reports to allow space for company letterhead. In this case the customer info is suppressed.

8.15 Setup and Calibration Report The complete set of Instrumentation Setup and Calibration Data can easily be documented and stored for future reference. Click PRINT TO PAPER to generate a printed copy af all relevant Setup and Calibration Data. Click PRINT TO FILE to generate an electronic version of this document.



9 Hardware Setup Screen Click the HARDWARE button in the Instrumentation Setup screen to get to the Hardware Setup screen.

The HARDWARE SETUP SCREEN offers the following options:

9.1 Machine Type • Hard-bearing machines • Soft-bearing machines • Teach mode (Rotor-specific calibration)



9.2 Instrumentation Speed Range The EasyBalance software should be set to conform to the actual speed range capability of the EasyBalance instrumentation. In general, the EasyBalance instrumentation system is available in 3 speed ranges:

• Low speed version (50 RPM to 2,000 RPM) • Standard speed version (150 RPM to 6,000 RPM) • High speed version (1,000 RPM to 40,000 RPM) • Ultra-high speed version (2,000 RPM to 200,000 RPM)

9.3 Input configuration The EasyBalance instrumentation is equipped with universal input circuitry. Depending on the actual instrumentation hardware and the selected machine types, the following input configurations are available:

• Linear amplifier • Single-integrator • Dual-integrator

The EasyBalance software will automatically detect the instrumentation hardware version. If the particular instrumentation hardware or the selected machine type does not support certain input configurations, the corresponding option(s) are disabled and grayed out.

9.4 Hard-bearing machines, hidden dimensions: In order to accomplish good plane separation with hard-bearing machines, it is essential that the pedestal planes, roller bearing planes and the virtual sensor planes are identical. Because of certain roller bearing configurations, minute physical differences between virtual sensor points and pedestal assemblies and also due to less than ideal machine foundation, it could be required to correct both the “a” and “b” dimensions by a specific amount. These amounts are sometimes called “hidden dimensions” , because they are invisible to the operator. All the operator has to do is enter the true abc dimensions in the Rotor Setup Screen, as measured. The system will correct these dimensions automatically based on the “a” and “b” values for the hidden dimensions.



9.5 Encoder Polarity: If your machine is equipped with an encoder, and the encoder is connected to the EasyBalance Instrumentation, the EasyBalance software will automatically activate the REMOTE ANGLE feature. An encoder generates two independent square wave signals, with a 90° phase offset between each other. The EasyBalance Instrumentation can decode these signals and will generate an on-screen REMOTE ANGLE indication. The REMOTE ANGLE indication will help the operator to locate the exact angular position of the unbalance correction. The Remote Angle Display can be set to two different modes:

• Indicator dot travels with correction location • Indicator dot places correction location at ZERO

INDICATOR TRAVELS WITH CORRECTION LOCATION Using this mode, the Remote Angle Indicator will always indicate the actual angular position of the correction location, for both the left and right plane, independently of each other. For instance, moving the rotor so that the left indicator moves to the 12 o’clock position will place the correction location also at 12 o’clock. Note: In this mode, the indicator has to travel with the direction of the rotor movement. If the direction is not with the rotor movement, go to the HARDWARE SETUP SCREEN and change the setting for ENCODER POLARITY. INDICATOR PLACES CORRECTION LOCATION AT ZERO This remote angle mode is often found on Schenck or Hofmann machines. The operator has to line up both the Remote Angle Indicator and the vector dot (the result dot). Doing so will place the correction location at the ZERO location. If the ZERO is set to be at the 12 o’clock position, lining up the two dots will place the correction location at the 12 o’clock position. Note: In this mode, the indicator dot has to travel against the direction of the rotor movement. If the direction is not against the rotor movement, go to the HARDWARE SETUP SCREEN and change the setting for ENCODER POLARITY.



10 Calibration Screen Click the CALIBRATION button in the Instrumentation Setup screen to get to the Calibration Setup screen. The CALIBRATION button is only available if Hard-bearing is selected in the Hardware Setup screen. If Soft-bearing or Rotor-specific calibration is selected, the CALIBRATION button is disabled, and the instrumentation will automatically perform Influence Coefficient Calculations. A Calibration Authorization screen will ask for a password.

Enter the password assigned to your system. If you cannot remember your password, call your EasyBalance vendor for assistance.



If the password is correct, the CALIBRATION SCREEN will appear:

The data in the area labeled Calibration Data is used for calibration of the machine. Calibration can be done manually (the operator will calculate the appropriate factors and phase offsets and enter the data into these fields). However, the EasyBalance system offers an AUTOMATIC CALIBRATION mode, which drastically simplifies the calibration procedure and yields a extremely precise calibration. How to use the AUTOMATIC CALIBRATION Mode and is described in the next chapter.



The CALIBRATION SCREEN offers the following features:

10.1 Calibration Data Calibration values for

• Amount Factor LEFT • Angle offset LEFT • Amount Factor RIGHT • Angle offset RIGHT • Amount Equalization Factor • Phase Equalization

In addition, the following calibration factors can be set:

• Vibration Factor LEFT (mm/sec) • Vibration Factor RIGHT (mm/sec) • Displacement Factor LEFT (mils) • Displacement Factor RIGHT (mils)

10.2 Enable RPM Ranges Enabling RPM Ranges provided access to the RPM-RANGE CALIBRATION screen and allows calibration of the machine for various RPM levels. RPM-range calibration is available only in hard-bearing mode, and should be used only if the particular machine does not have sufficient linearity over RPM. The automatic calibration mode, if selected, will also work with the RPM RANGE CALIBRATION feature.



11 Machine calibration, general: There are several ways to calibrate a hard-bearing balancing machine. The EasyBalance system offers 3 different procedures:

• Manual calibration • Automatic calibration without Equalization • Automatic calibration with Equalization

Both the manual and the automatic calibration procedures require a test rotor and a set of known calibration weights. However, the automatic calibration is the recommended procedure, because it takes full advantage of the simplicity and accuracy the EasyBalance system has to offer. It is further recommended to calibrate both planes at the same time, by utilizing the EQUALIZATION feature. When calibrating the machine, use either one of the three calibration methods. Do not mix one calibration method with another. After calibration has been performed, edit the CALIBRATION DATE and CALIBRATION DUE DATE information fields, located in the lower right corner of the MAIN CALIBRATION SCREEN. These dates will be displayed in the INFORMATION SCREEN every time the software is launched.

12 Setup and calibration backup: The EasyBalance software keeps an automatic backup copy of previous calibration data and setups in a special folder. This folder is named BACKUP and is created automatically. If required, a previous setup, including the complete calibration data, can be restored.



13 Manual calibration: Manual calibration is straight forward. Before performing a manual calibration, it is a good idea to go to the CALIBRATION SCREEN and set the Amount Factor to “1.0” and the Angle Offset to “0.0”. The manual calibration procedure is as follows:

1. Measure a known unbalance (using a well-balanced test rotor and a known calibration weight)

2. Record the displayed value for Amount and Angle. 3. Calculate the AMOUNT FACTOR. This is the factor required for the amount to show the

desired value (the calibration weight). 4. Calculate the ANGLE OFFSET. The angle offset is the required angle correction to bring

the angle display in line with the calibration weight location. 5. Enter both the AMOUNT FACTOR and the ANGLE OFFSET into the appropriate fields in

the CALIBRATION SCREEN. Example: Calibration weight: 3 gram

Calibration weight location: 0° Display: 1.5 gram at 45° The display should read 3.0 gram at 0°, but it reads 1.5 gram at 45°.

The Amount Factor and Angle Offset can be calculated as follows: Amount Factor = 3 gram / 1.5 gram = 2.0 Angle Offset = - 45° Calibrate the left channel first. After the left channel has been calibrated successfully, repeat the calibration for the right channel. Calibration is now finished.



14 Automatic Calibration Mode without Equalization To calibrate the machine in automatic calibration mode without using the EQUALIZATION feature, a standard TEST ROTOR and a set of CALIBRATION WEIGHTS are required. The test rotor should be balanced to the lowest unbalance possible, prior to machine calibration. Place the calibration weights on the test rotor, one in the left plane, and one in the right plane. Both calibration weights must be at the same angle. Select AUTOMATIC CALIBRATION MODE by checking the checkbox in the upper left corner of the CALIBRATION SCREEN and click OK. You will be back in the INSTRUMENTATION SETUP SCREEN. Click OK again and you will be back in the ROTOR SETUP SCREEN.

• Enter the rotor data of the test rotor (ABC dimensions, Radius left, Radius right). • Select REMOVE for both planes. • Select POLAR DIAGRAM as the result display.

Click START to go to the LIVE POLAR DIAGRAM and begin the unbalance measuring cycle. Set AVERAGING to a sufficiently long averaging time to accomplish a stable reading (10 seconds averaging time should work in most cases). Adjust rotor speed as desired, within safe operating limits for both balancing machine and rotor. Note: The font color of the RPM display indicates the following:

• Green: System is in calibration mode • Blue: Normal operating mode, machine is calibrated • Red: System is in calibration mode and RPM Range calibration is enabled, but RPM

does not fall within 2% of the defined Speed Points. Adjust RPM to within 2% of speed points and RPM display will turn green.

The progress of the measure cycle is indicated above the RPM display. Once the measure cycle is completed, the system will switch to the POLAR DIAGRAM and display the measured unbalance in a polar graph.



Click the left Polar Diagram, and the calibration window for the left plane will pop up:

Enter the amount and angular location of the calibration weight in the left plane, and click OK. The system will automatically calculate the Amount Calibration Factor and Angle Offset for the left plane, fill this information in the appropriate fields in the Calibration Screen, and re-calculate the unbalance measurement result with the new calibration data. The calibrated result will be displayed in the left polar diagram, instantaneously. Repeat the same for the right plane, by clicking the right polar diagram. A calibration window for the right plane will pop up:

Again, enter the amount and angular location of the calibration weight in the right plane, and click OK. The system will automatically calculate the Amount Calibration Factor and Phase Offset for the right plane, fill this information in the appropriate fields in the Calibration Screen, and re-calculate the unbalance measurement result with the new calibration data. The calibrated result will be displayed in the right polar diagram, instantaneously. Calibration is now finished.



15 Automatic Calibration Mode with Equalization Note: This is the preferred calibration method. In order to increase the accuracy of the calibration and the overall performance of the balancing system, it is recommended to utilize Automatic Calibration and the EQUALIZATION feature. This equalization process will eliminate any amount and phase differences between both measuring channels, taking into account minute structural differences between both pedestals, work supports and sensor signals, as well as instrumentation related differences between both left and right channels. To calibrate the machine in automatic calibration mode by using the EQUALIZATION feature, a symmetrical TEST ROTOR and two equal CALIBRATION WEIGHTS are required. A test rotor is considered symmetrical if both correction planes are between the bearing planes, and the distance between the left bearing plane and the left correction plane is the same as the distance between the right bearing plane and the right correction plane. The test rotor should be balanced to the lowest unbalance possible, prior to machine calibration. Place the calibration weights on the test rotor, one in the left plane, and one in the right plane. Both calibration weights must be at the same angle.

Make sure the system is set to AUTOMATIC CALIBRATION MODE (it will remain in automatic calibration mode until the operator clicks NEW ROTOR in the polar diagram screen or CANCEL in any other screen. When NEXT RUN is clicked, the system remains in automatic calibration mode and a new measurement cycle can be started). As a visual feedback, the RPM display is using a GREEN font if the system is in automatic calibration mode. Start a new measurement cycle. Set AVERAGING to a sufficiently long averaging time to accomplish a stable reading (10 seconds averaging time should work for most cases). Adjust rotor speed as desired, within safe operating limits for both balancing machine and rotor. The progress of the measure cycle is indicated above the RPM display. Once the measure cycle is completed, the system will switch to the POLAR DIAGRAM and display the measured unbalance in a polar graph.



Click the left Polar Diagram, and the calibration window for the left plane will pop up again:

If you are using a test rotor with 2 equal calibration weights, enter the amount and angular location of one of the calibration weights. If you are using a single calibration weight in the CENTER plane of the test rotor, enter ½ of that weight as the amount.. Click EQUALIZE, and an information window will pop up with the newly calculated equalization factor and phase correction for both measurement channels:

NOTE: In general, you should expect the EQUALIZATION FACTOR to be around 1. Values between 0.7 and 1.3 are reasonable. If the EQUALIZATION FACTOR is outside of this range, check your setup. If you are sure that everything is OK, you may accept these factors. If you click NO, the amount equalization factor will default to 1.0, and the phase equalization will default to 0.0. Calibration is not completed. If you click YES, the system will automatically calculate the amount calibration factors, the angle offsets, and the amount and phase equalization factors, and will enter the factors into the appropriate fields in the Calibration Screen. Next, the result will automatically be re-calculated using the new calibration data. The new results will be displayed in the left and the right polar diagram. Both channels are calibrated automatically, at the same time and in one step. Calibration is now finished.



16 RPM Calibration Ranges

When RPM RANGES are enabled, the machine can be calibrated for specific RPM ranges. Each of the 5 available RPM ranges can be defined in the RPM column. Each RPM range should be at least 5% apart from its neighbor. The required Amount Factors and Angle Offsets can be manually calculated and entered here. However, it is much easier to use AUTOMATIC CALIBRATION MODE. Select AUTOMATIC CALIBRATION MODE in the CALIBRATION SCREEN, and perform calibration and channel equalization as described in the following chapters. While in Automatic Calibration Mode, the RPM display is using a GREEN font if the measured RPM is within 2% of the selected RPM range. If the RPM is outside the 2% limits, the RPM display will turn RED. Follow the instructions for AUTOMATIC CALIBRATION above.



17 Rotor Name We are back in the main rotor setup screen. Underneath the rotor configuration icons is the Rotor Name Field. Enter a job number or rotor name to identify your particular rotor. Each rotor is stored with all its relevant rotor setup data. Recalling a rotor name from the Rotor Name field restores all rotor setup data previously saved under this rotor name. Rotor names can be up to 70 characters long. The storage capacity of rotor setups is virtually unlimited and depends only on the available space on the hard drive.

18 Units of Measure Units for linear dimensions can be set to millimeter (mm) or inch. Weight units can be set to gram (g), ounce (oz), milligram (mg) or milliounce (moz) by clicking the radio buttons in the UNITS OF MEASURE area.

19 Rotor Dimensions Enter the rotor dimensions a, b, c, and the correction radius for the left and right correction plane. Refer to the rotor configuration icons for clarification of the a, b, and c dimensions. Note: abc dimensions are not required in Soft-bearing mode, because the Influence Coefficient Method is applied, which will take care of rotor dimensions. It is sometimes easier to measure the diameter of a rotor instead of the radius. The EasyBalance Instrumentation allows entering the correction radius either as actual radius or as diameter. Click the word Radius (or Diameter) for the left plane to toggle between Radius and Diameter. A confirmation window will pop up making sure that this important entry is not changed accidentally.

20 Correction Method Each correction plane can be set independently to either ADD or REMOVE as your preferred method of correction. Click the corresponding radio buttons.

21 Unbalance Tolerance Enter the allowable unbalance for the left and right correction planes. Units will be set automatically based on the selections for UNITS OF MEASURE.

22 Tolerance in journal planes or in correction planes Two radio buttons are provided to allow selection of unbalance tolerance as either “in journal planes” or “in correction planes”. These radio buttons can also be used for conversion between the two.



23 Tolerance Calculator A built-in Tolerance Calculator is a great tool to quickly and accurately determine the allowable unbalance tolerance for a particular rotor, in order to achieve a certain balancing quality grade. To use the Tolerance feature, enter the following data:

• Enter the static bearing load for the left and right bearing (weight of the rotor supported in the left and right bearing).

• Enter the service speed of the rotor. Service speed is the maximum speed this rotor will have in operation.

• Select the desired balancing quality grade • Click Calculate.

The unbalance tolerances for the left and right correction planes will be calculated according to

• API 617 • API 610 • MIL-STD-167-1, or • ISO 1940 • Custom ISO number (user-defined ISO balancing quality grade number)

and transferred into the tolerance fields. If Static/Couple Separation is selected, the unbalance tolerance for both the left and right as well as for the static plane will be calculated and transferred into the Tolerance fields.

24 Tooling Compensation Program Some rotors require special balancing tooling, also called fixtures or mandrels. This tooling can introduce unbalance errors, due to both tooling eccentricity or unbalance in the tooling itself. The TOOLING COMPENSATION program allows to electronically compensate for these tooling errors. This requires 2 tooling compensation runs, with subsequent indexing of the rotor by 180°. Select the desired tooling compensation method. If no tooling is used or tooling compensation is not desired, select NO TOOLING COMPENSATION. Once tooling compensation values have been established, they are stored with the rotor setup data for this particular ROTOR NAME, and can be re-used when the ROTOR NAME is recalled from memory. A Message Box will alert the operator that tooling compensation values are available:

• Click YES to use the existing tooling compensation • Click NO to perform a new tooling compensation



• Click CANCEL to continue without tooling compensation

25 Key Compensation Program Keyways in shafts or fitments will introduce unbalance. Depending on the balancing convention used for the matching part, keyway compensation according to ISO 8821 can use any of these 3 methods:

• Half-height key • Half-length key • Full key.

The key compensation program offers the choice of any of these 3 conventions, for shafts or fitments. To use key compensation, click the field KEY COMPENSATION and select DEFINE AND ACTIVATE. After the Start button is clicked, a KEYWAY COMPENSATION DIALOG will appear and enable you to enter keyway dimensions, as well as to select various key materials.

The weight of the simulated key can be displayed by clicking CALCULATE KEY WEIGHT. Once key compensation values have been entered, they are stored with the rotor setup data for this particular ROTOR NAME, and can be re-used when the ROTOR NAME is recalled from memory.



After all data in the Rotor Setup screen has been entered correctly and the EasyBalance Instrumentation has been setup for your particular balancing application, click START. A live Polar Diagram will appear.

26 Live Polar Diagram

The digital tachometer indicates the rotor speed. Adjust the rotor speed to the desired balancing speed.



27 Averaging cycle The EasyBalance Instrumentation is capable of measuring “live” unbalance, and takes 2 complete unbalance readings per second. AVERAGING allows to mathematically determine the average value of a series of consecutive unbalance measurements. The longer the averaging cycle, the more stable the display becomes. Select an appropriate averaging cycle, between 5 to 30 seconds. You can also select “manual”, which will average results until you click Finish. In addition to the averaging feature, the EasyBalance systems offers a so-called scan-mode. In scan mode, the system measures unbalance at pre-defined intervals and keeps them in a log. This feature is useful for instance to check the unbalance behavior of a rotor or assembly over time (break-in procedure). When AVERAGING is set to ON, and RPM and sensor signals have stabilized sufficiently, the measure cycle will begin automatically. A status indicator will show the progress of the measure cycle. When the end of the averaging cycle is reached, the live polar diagram will switch to the RESULT SCREEN. You can now stop the rotor. The unbalance measurement result will remain on the screen. If you have selected NO AVERAGING, the result screen will be displayed when you click FINISH.



28 Soft-bearing mode and Teach-mode (Rotor-specific calibration) In Soft-bearing mode or Rotor-specific calibration mode (Teach mode), a total of three runs are required to calibrate the system The EasyBalance Instrumentation keeps track of the required runs and prompts the operator throughout the calibration procedure. The first calibration run is called REFERENCE RUN. After the reference run is complete, the ROTOR-SPECIFIC CALIBRATION screen for the TRIAL RUN LEFT appears:

Follow the on-screen prompts. Underneath the trial weight information fields for the left and right planes, a CALIBRATION LOG keeps track of those runs already completed. If you wish to repeat a particular run, click REPEAT REFERENCE RUN or REPEAT TRIAL RUN LEFT or REPEAT TRIAL RUN RIGHT, respectively. Once all calibration runs are complet, the PRINT button becomes enabled. Clicking PRINT will generate a print-out with the complete calibration run information.



29 Result Display Once an unbalance measure cycle has been completed, the result will be displayed in either POLAR DIAGRAM format or AMOUNT AND ANGLE format, depending on your selection for RESULT DISPLAY in the Rotor Setup Screen.

30 Polar Diagram Display

The rotor unbalance is displayed in a polar diagram or vector format. Colored dots indicate the amount and the angular position of the unbalance, individually for each correction plane. The dot color indicates whether or not the measured unbalance is within tolerance limits:

• Green dot: unbalance within 80% of tolerance • Yellow dot: unbalance within tolerance, but above 80% • Red dot: Out of tolerance

The tolerance status is further displayed in the upper right field of each polar diagram, by either OK or REJECT. Each polar diagram also shows a green tolerance circle, indicating the extent of the unbalance tolerance for each correction plane (Tolerance Target).



31 Zoom 5x Tolerance Clicking this button will scale the polar diagrams to 5X TOLERANCE. If the actual unbalance is too large to fall within this zoom range, a status line will appear underneath the scale range saying ”Zoom off scale”. Clicking this button again will toggle back to the optimum zoom factor, providing the best resolution.

32 Zeroing Clicking this button will electronically zero the results for both planes and will activate ELECTRONIC ZEROING. When electronic zeroing is active, a message “Electronic zeroing is active” will be displayed in the result screens.



33 Multi-Run Averaging Clicking this button will display the Multi-Run Dialog. This dialog will show up to 12 previous results, sorted sequentially (youngest result on top).

The calculated average for both planes from these runs is displayed in the upper part of the dialog. Clicking ACCEPT will transfer these results to the Result display. Clicking CONTINUE will bring you back to the result display, without utilizing the calculated average results. Each recorded run has an INCLUDE check-box. Un-checking an individual check-box will exclude this particular run from the calculated average.



34 Amount and Angle Display Clicking this button will switch the result screen to the Amount and Angle screen:

The Amount and Angle screen shows the unbalance result in a digital format. The status line indicates whether or not the unbalance falls within the allowable unbalance tolerance. An out of tolerance status is indicated on a red background, and indicated by the percentage of tolerance.



35 Toggle Add/Remove The EasyBalance Instrumentation offers a convenient way to switch between ADD and REMOVE, without the need to perform a new unbalance measurement run. While in the AMOUNT AND ANGLE screen, click the field above the Amount indication, and the correction method will be toggled between ADD and REMOVE. The correction angle will be automatically calculated based on the new correction method. While in the POLAR DIAGRAM SCREEN, simply point towards the center of a diagram and click. This will toggle between ADD and REMOVE for the particular diagram, and the diagram will show the correct unbalance location based on the correction method. Each correction plane can be set to ADD or REMOVE independently.

36 Recalc Clicking the RECALC button in either AMOUNT AND ANGLE or POLAR DIAGRAM display will bring you back to the ROTOR SETUP SCREEN. Here you can change some or all of the rotor setup data. Clicking START will bring you back to the result screen, which will now show the “re-calculated” unbalance result with the new rotor setup data. The RECALC function is especially useful for finding the optimum a, b, c dimensions that give you the best plane separation (hard-bearing machines only), or for adjusting correction radii and re-calculating the new unbalance correction weight. RECALC can also be used to adjust a correction plane location without the need to perform a new unbalance measurement run.



37 Special Correction Click SPECIAL CORRECTION and new screen will appear allowing to select a variety of special correction features.

In principle, any unbalance display mode other than the standard “weight at angle” is considered “special correction”. For example, showing the result as “number of holes to drill” or “length of bar stock” is a special correction feature. This also includes so-called “vector-split” for rotors allowing unbalance corrections only at pre-defined locations. A good example for such a rotor would be a fan, where unbalance corrections can only be done at a blade, but not at locations between blades.



The SPECIAL CORRECTION SCREEN offers the following options: Preferred correction method

• STANDARD CORRECTION Results are displayed as correction weights (standard method)

• DRILL CORRECTION

Select drill diameter, maximum allowable drill depth, drill point, and material. Result screen will now show the required amount and depth of drill correction holes.

• TAPE CORRECTION

Select from various commercially available weight tapes. The result screen will show the required tape length.

• WIRE-FEED WELDER

Enter the amount of wire weight per second produced by a particular welder setting. The result screen will show the required welding time.

• CLIP BIN

Up to three different clips can be defined. The result screen will show the best possible combination of clips required for balance.

• BAR STOCK

Enter the width and thickness of bar stock, in either mm or inch. The result screen will show the required length of the specified bar stock.

37.1 Rotor segments: Select the numer of rotor segments, individually for each correction plane. The result screen will show the amount of correction for the two segments closest to the actual unbalance location. This feature can also be used in combination with any of the special correction features, like DRILL CORRECTION, TAPE CORRECTION, WIRE-FEED WELDER or CLIP-BIN.

37.2 Combine Weights: The COMBINE WEIGHTS feature is useful for rotors which have been balanced previously and have a cluster of balancing weights which you would like to remove and consolidate into one correction weight per plane.



37.3 Drill Correction Click the radio button DRILL CORRECTION and the fields for entering the required drill setup data will be enabled. You can enter a drill diameter and a maximum drill depth. If a required correction exceeds the maximum drill depth, the software will calculate multiple correction holes. The drill point can be selected from a drop-down menu as 118º, 130º or 135º. A drop-down menu allows the selection of various materials. If you have the need for a material not yet listed in this menu, please let us know and we will be happy to add it. The following screen is an example for a rotor with drill correction:



37.4 Tape Correction Correcting unbalance by adding a certain amount of tape (for instance self-adhesive lead tape) is often used for applications like roll balancing and alike. Click the radio button TAPE CORRECTION and the fields for entering the required tape information will be enabled. If you have the need for a material not yet listed in this menu, please let us know and we will be happy to add it.

37.5 Clip bin correction Adding clips is another correction method which is often used for fans and blower wheels. Pre-fabricated clips in several sizes are being inserted into the rotor. The EasyBalance software has a clip bin feature, allowing the operator to define up to three different clips (clip A, clip B, and clip C, with clip A the heaviest and clip C the lightest). The EasyBalance software will calculate the best possible combination of available clips to balance the rotor.

37.6 Wire-feed welder Enter the amount of wire weight per second produced by a particular welder setting. The result screen will show the required welding time.

37.7 Rotor Segments (Vector-Split) For rotors with pre-defined correction locations, like electric armatures with so called “studs” spaced at 30º intervals or alike, or for bladed rotors where correction weights can only be applied at the actual blade locations, the EasyBalance Instrumentation offers the ability to select between 3 and 99 rotor segments, individually for each correction plane. Click the drop-down menu for SEGMENTS LEFT or SEGMENTS RIGHT and select the desired number of components. If you want to switch components off for a particular plane, click the SOLID button.



The following screen is an example for a rotor with Drill Correction and 9 components on the left side. The right rotor plane is solid.



37.8 Combine Weights

Use this feature if you would like to consolidate existing unbalance correction weights into just one correction weight, per plane. Enter the amount and angular location of those weights you would like to remove and consolidate. Clicking COMBINE will calculate the resulting consolidated correction weight, including the current rotor unbalance. The resulting consolidated correction weight will be displayed in the top of this screen, but the dialog will not close. Clicking ACCEPT will calculate the consolidated correction weight, close this dialog, and transfer the consolidated weight to the RESULT SCREEN. The COMBINE WEIGHT feature can also be used in combination with segmented rotors and with the drill or tape correction feature.



38 Print functions There are various print reports the EasyBalance system can generate. Printing can be done in two modes: Print-to-paper, and Print-to-file. Print-to-file is also called “paperless printing”. Print-to-file will automatically generate an electronic version of the report, saved in a special folder. The folders are automatically created by the EasyBalance software. There are 2 folders for print-to-file reports:

• REPORTS (for Log reports, Trial run reports and Multi-run reports) • CERTIFICATES (for Balancing reports)

These folders are created as sub-folders in the folder containing the EasyBalance software. The file names for the paperless print reports are created with the following convention: REPORTNAME_ROTORNAME_20030101_141015. The first group of numbers is the date in the format YYYYMMDD. The second group of numbers is the time in military format HHMMSS.

39 Balancing Certificate In either Polar Diagram display or Amount and Angle display, the PRINT function can be selected. Clicking PRINT will open a new window where you can enter a Name and Address of a customer, or any other information, such as additional rotor identification, workstation ID and or specific routing information.



A “Include Initial Result” checkbox allows to include the initial unbalance result together with the current result in the same report. Click PRINT TO PAPER and the WINDOWS Print Dialog will appear. Select the printer you would like to use and click OK. A print report will be spooled to the printer. The print report will contain your company information, Job number, date and time, rotor setup data, as well as the unbalance measurement results.

40 Next Run Once the rotor has been stopped and the required unbalance correction has been performed, a new measure cycle will start automatically as soon as the rotor has been started again. This function is called AUTOMATIC CYCLE, because the operator only has to start the rotor, and the EasyBalance Instrumentation will automatically cycle to the next measuring run. You could also Click NEXT RUN if you want to perform another unbalance measurement. The AUTOMATIC CYCLE function can be disabled in the SETUP SCREEN. The LIVE POLAR DIAGRAM screen with the digital tachometer will appear again. Adjust rotor speed and perform a new unbalance measurement. If AVERAGING is switched OFF, click FINISH and the result screen will appear with the new unbalance measurement result. If AVERAGING is switched ON, the measure cycle will automatically finish after the selected averaging cycle time has elapsed.



41 Show History The EasyBalance system can superimpose up to 12 readings in the polar diagram display. When SHOW HISTORY is activated, a window will pop up asking the operator to select how many previous results to be displayed, in addition to the current result.

A round circle identifies the previous results with a number. The number indicates the progress from one measurement to the next. A total of 12 readings can be displayed in each polar diagram. This feature is especially useful when performing unbalance correction by drilling or grinding, where the exact amount of correction cannot be pre-determined. The SHOW HISTORY feature gives a clear indication of the progress of the unbalance correction.



42 New Rotor Click NEW ROTOR to go back to the Rotor Setup Screen for a new unbalance calculation job for a new rotor (different rotor). History information from previous runs are deleted and the SHOW HISTORY feature is reset and available again for the new rotor.

43 Static/Couple Separation Some rotors benefit from a static/couple separation of the measured 2-plane unbalance. Static/Couple separation mathematically separates the dynamic unbalance into a static component and a couple components. Unbalance results in STATIC/COUPLE mode are displayed in 3 side-by-side polar diagrams, one for the left couple component, one for the static component, and one for the right couple component.



44 Bode-plot The Bode-plot feature generates a complete BODE DIAGRAM, showing the rotor unbalance in both AMOUNT and PHASE, over a wide RPM range. The Bode-plot feature is useful, for instance, to determine the linearity of a balancing machine, the quality of the balancing machine foundation, or in general to check the dynamic behavior of a given rotor at different RPM. The Bode-plot can be generated while the rotor RPM is either increased (Bode Diagram, ramp-up), or while the rotor is coasting down (Bode Diagram, ramp-down)

The Bode diagram is generated LIVE, while the rotor RPM is ramped up or coasting down.



45 Balancing Log The EasyBalance automatically keeps logs of all balancing runs. The balancing log can be accessed from the ROTOR SETUP SCREEN by clicking SEE LOG.

Logged balancing runs can be selected either by SELECT BY NAME or by SELECT BY DATE. If the radio button SELECT BY NAME is checked, the ROTOR NAME drop-down list will show all ROTOR NAMES for which balancing logs are available, regardless of the date the individual runs have been performed. If the radio button SELECT BY DATE is checked, the ROTOR NAME drop-down list will show all ROTOR NAMES which have been balanced on the particular date as selected in the DATE-PICKER field. After you have made your selections, click APPLY and the balancing log will be displayed. Click Print to Paper to send the list to a printer. You can also Print to File, using the paperless print feature. CREATE POLAR DIAGRAM Use this feature to re-create a POLAR DIAGRAM from the data displayed in the balancing log.



46 Delete Rotor name Rotor setups longer required to be kept in the rotor setup file can be deleted by clicking DELETE THIS ROTOR NAME. This feature is password-protected. A confirmation dialog will appear to confirm your intention to delete.



47 Disclaimer BalanceMaster Inc. disclaims all other warranties, expressed or implied, including but not limited to, any implied warranties of merchantability, fitness for a particular purpose and non-infringement. BalanceMaster Inc. shall not be liable for any direct, indirect, consequential, exemplary, punitive or incidental damages arising from any cause even if BalanceMaster, Inc. has been advised of the possibility of such damages.

48 Copyright Complying with all applicable copyright laws is the responsibility of the user. This software may be used on a single computer and is licensed to a single user. You are allowed to make one (1) backup copy of this software. Illegal distribution and/or copying of this software will be pursued to the fullest extent of the law.

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