schenck smartbalancer v3

7/27/2019 SCHENCK SmartBalancer V3

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Smartbalancer

SCHENCK RoTec GmbH, Darmstadt BE-49766-ENG-V1 1

SmartBalancer

Contents

1. Safety and operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.1 Type designation plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.2 Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.3 Notes on operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.4 Power supply, charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.5 Memory card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.6 Display and automatic switching-off . . . . . . . . . . . . . . . . . . . . . . 15

2.7 Carrying pouch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.8 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.9 Basic settings - Unit setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.9.1 Date & time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.9.2 Pick-ups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.9.2.1 Available pick-ups in the SmartBalancer . . . . . . . . . . . 19

2.9.2.2 Sensor detection and hardware response . . . . . . . . . . 23

2.9.2.3 Sensor check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.9.2.4 Standard sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.9.3 Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.9.4 Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.9.5 Keyphaser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.9.6 Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.10 Service menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2.11 Memory card (CF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2.12 Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.12.1 Printer setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.13 Data transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2.13.1 USB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2.13.2 Update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3. Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.1 Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.1.1 Safety during balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.1.2 Balancing process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.1.3 Unbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.1.4 Balancing on machines with rotating masses . . . . . . . . . . . . 32

3.1.5 Analysis of the rotor before balancing . . . . . . . . . . . . . . . . . . 33

3.1.6 Preparation for balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.1.6.1 Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.1.7 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36


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Technical documentation

2 BE-49766-ENG-V1 SCHENCK RoTec GmbH, Darmstadt

3.1.7.1 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3.1.7.2 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3.1.7.3 Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3.1.8 Repeat balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3.1.9 Balancing in one plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393.1.9.1 Activating the balancing mode . . . . . . . . . . . . . . . . . . . 39

3.1.9.2 Measuring the initial unbalance . . . . . . . . . . . . . . . . . . 41

3.1.9.3 Test run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

3.1.9.4 Correction run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

3.1.9.5 Undoing balancing runs . . . . . . . . . . . . . . . . . . . . . . . . 44

3.1.9.6 Save result . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3.1.10 Balancing in two planes . . . . . . . . . . . . . . . . . . . . . . . . . . 45

3.1.10.1 Measurement procedure overview . . . . . . . . . . . . . . . 45

3.1.10.2 Definition of measurement and correction plane A . . . 45

3.1.10.3 Test run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

3.1.10.4 Correction run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

3.1.10.5 Evaluation of the data . . . . . . . . . . . . . . . . . . . . . . . . . 47

3.1.11 Combining balancing weights . . . . . . . . . . . . . . . . . . . . . . 48

3.1.12 Options when balancing . . . . . . . . . . . . . . . . . . . . . . . . . . 49

3.1.12.1 Check measurement setting . . . . . . . . . . . . . . . . . . . . 49

3.1.12.2 Changing the correction mode (MENU - Tools) . . . . . 49

Fixed location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Fixed weight (spreading of fixed weights) . . . . . . . . . . . . . . . 49

Tape measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

3.1.12.3 Remove balancing weight . . . . . . . . . . . . . . . . . . . . . . 50

3.1.12.4 Test functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

3.1.13 Balancing with machine setup . . . . . . . . . . . . . . . . . . . . . 51

3.1.13.1 Parameters in the machine setup . . . . . . . . . . . . . . . . 52

3.1.14 Parameters in the measurement setup . . . . . . . . . . . . . . 54

3.1.15 Entering the balancing radius and rotor mass later . . . . . 54

3.2 Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

3.2.1 What is a measuring problem in the Analysis mode? . . . . . . 55

3.2.2 Start measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

3.2.3 Continual measurement (live mode) . . . . . . . . . . . . . . . . . . . 56

3.2.4 Save result . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

3.2.5 Options before, during and after a measurement . . . . . . . . . 57

3.2.6 Create new setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

3.2.6.1 Setup parameters for the measurement . . . . . . . . . . . 61

3.2.6.2 Parameters for pick-ups . . . . . . . . . . . . . . . . . . . . . . . 63

3.2.6.3 Parameters for assessment of a characteristic value / timesignal measurement . . . . . . . . . . . . . . . . . . . . . . . . . . 63

3.2.7 Trend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

3.2.8 Enter event / comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

3.2.9 Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

3.2.9.1 Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

3.2.9.2 Characteristic value trend . . . . . . . . . . . . . . . . . . . . . . 67

3.2.9.3 Time signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68


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3.2.10 Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

3.2.11 3D display of spectra: Waterfall diagram . . . . . . . . . . . . . 74

3.2.12 Setting up the results display in the display setup . . . . . . 76

3.3 Printing out results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

3.3.1 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803.3.2 Printing out the spectrum, trend spectrum . . . . . . . . . . . . . . 80

3.4 Measuring problems in the analysis . . . . . . . . . . . . . . . . . . . . . . 81

3.4.1 Characteristic vibration values . . . . . . . . . . . . . . . . . . . . . . . . 81

3.4.2 Speed measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

3.4.3 Order tracking analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

3.5 Special . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

3.5.1 Phase measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

3.5.2 Recording . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

3.5.3 Envelope analysis, roller bearing condition (optional) . . . . . . 93

3.5.4 User-defined measurement parameters . . . . . . . . . . . . . . . . 94

3.5.5 Impact test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

4. Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

4.1 Numbers Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

4.2 Text Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

4.3 File Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

4.4 SmartBalancer Utility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

4.4.1 Extended Report Software . . . . . . . . . . . . . . . . . . . . . . . . . 102

5. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

6. Problems & solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

7. Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

7.1 Balancing quality stages and groups of rigid rotors (extract from DINISO 1940) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

7.2 Messages during balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . 115


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Foreword

Congratulations, and thank you for deciding on the purchase of theSmartBalancer field balancing unit and signal analyser. With this newlydeveloped measuring unit, you have a reliable aid on the spot when it comes torecording and analysing complex machine signals.

The SmartBalancer detects all forms of machine vibrations, roller bearingconditions (optional) and process and visual inspection data, and saves thisinformation for evaluation, archiving and documentation.

Despite its extensive functional features, the SmartBalancer is easy to operateand effective in use:

! High measurement accuracy and fast data recording

! Two operating modes:

Balancing for detection and correction of rotor unbalances in one or twoplanes (option).

Analysis for individual measurements for machine diagnosis

! Connection of almost any sensor type

! Optionally with one or two analogue measurement channels.

Hardware

! Two synchronous measurement channels

! Adequate storage space (standard: 2 GB CompactFlash).

! Three LEDs (red-yellow-green) signal the exceeding of limit values; a blueLED indicates the completion of the measurement.

! A daylight sensor controls the keyboard lighting

! Dust-proof and protected against spray water (IP65) - ideal for the roughindustrial environment.

! Connection for NiCrNi thermo-element

! Connector technology compatible to SmartBalancer 2 (same cable)

Data recording and analysis

! Characteristic values

Vibration acceleration, speed and deflection

Current and voltage (process figures)

Envelope (roller bearing condition) (optional)

Temperature

Speed! Signals

Frequency and order-based data recording

Amplitude, envelope and order spectrum

Time signal

Phase measurement (synchronous)

Field balancing (1-/2-plane balancing of rigid rotors)

Coast-down curve (natural vibrations, complete machine set)

Impact test (natural vibrations, individual components)


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Ergonomy

! Large backlit colour display ensures clear presentation and otimum legibility(480 x 640 pixels, 116 x 78 mm, 262144 colours)

!Graphic user interface

! Colour-coded connection sockets

! Easy to use keypad

Power supply

! Li-ion rechargeable battery of the latest generation for over 8 operatinghours per charge

! Intelligent charging function in the unit or in external charging station

! Automatic switch-off of the lighting and the measuring unit

Communication! Network-capable

! PC connection via USB

Documentation

! Printout of measurement data and reports, direct onto paper or as PDF-file.

About these instructions

These instructions describe the basic functions, and the operation of the

measuring unit in the operating modes of balancing, analysis and roller bearinganalysis.


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1. Safety and operating instructionsFamiliarise yourself with the safety and operating instructions given in thissection before commissioning the measuring unit.

Symbols used

Warning of faulty operation which can lead to damage to the measuring unit orthe loss of data.

Information and tips on operation of the measuring unit.

Proper use

! Smartbalancer is designed for use as a portable balancing unit for thebalancing of stationary machines with only rotating components (rotors),such as turbine rotors, inductors, circulating pumps, circulatingcompressors, blowers and similar. This does not include machines withoscillating components, such as all piston engines.

! Smartbalancer may be used without restriction for the balancing of rigidrotors. Flexible (soft) rotors may be balanced with Smartbalancer in thearea of the resonance frequency (25%), but only by an experienced user.The measuring unit and the accessories may only be operated by trainedpersonnel.

! The measuring unit may only be used for the measurement of machinesignals in the industrial area, taking into account the technical specification(see Appendix - Technical data).

! Pick-ups and cables may only be used in the specified area defined in thetechnical data sheets.

Any further form of use constitutes improper use, and is not allowed. SchenckRoTec GmbH accepts no liability for damage caused by improper use. Faultyor impermissible use, or failure to observe these operating instructions,invalidates any guarantee on the part of SCHENCK RoTec GmbH.

CE conformitySmartBalancer conforms to the EU directives for electrical operating equipment(2006/95/EG) and electromagnetic compatibility (EMC) (2004/108/EG).

Safety

Users must have carefully read and understood these instructions beforeworking with the SmartBalancer.

! The measuring equipment (cables, holders,...) must be fitted so that theycannot come into contact with exposed, rotating machine componentsduring the measurement. Danger of injury!

!

The measuring units may only be operated when in an undamaged, dry andclean condition.

! The measuring unit may only be operated by trained personnel.


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! Repairs to the measuring unit must be carried out only by authorisedspecialist personnel.

! Only original replacement parts and original accessories must be used.

! The electrical equipment may only be used when in a properly functioningcondition. Faults such as defective plugs or loose connections must be

rectified immediately. Damaged cables must be replaced by a specialist.! Design changes or technical safety modifications to the measuring unit or

accessories are not allowed.

Operation

! Portable radio devices in the immediate vicinity of the measuring unit cancause interference. Check if necessary whether the plug connectionsbetween the pick-up and measuring unit are firmly connected.

! Expose the SmartBalancer, pick-up and cables only to the permissibleenvironmental influences.

! Protect the connections on the measuring unit against soiling with the aid of

the caps provided.


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2. DescriptionThe illustrations below show the interfaces and operating elements of themeasuring unit:

1 Additional button (rear side) 8 Display with starting screen

2 Light sensor (keyboardlighting)

9 Communication

USB for printer or PC

3 LEDs

- Limit value exceeded

- Measurement error

- Charging condition

10 Digital

- Reference pick-up / speed

4 Keyboard and Navigation pad 11 Temperature

5 Memory card (inside the unit) 12 Analogue (A/B)

- Measurement signal

- Charging socket

6 Battery (rear side)


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2.1 Type designation platesThe position and contents of the two designation plates on the measuring unitand the battery are shown in the following illustration.


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2.2 KeyboardThe keys can be comfortably operated with the thumb of the right hand. In adark environment the keyboard illumination automatically turns on.

1

Plus (+) / Minus (-) key

- Zoom for X axis

- Change tab

2

F keyfor special functions such astab, fast key, search

3

Navigation keysand Enter key

4

MENU keyopens the menu withcontext-sensitive functions.

5

On / Off keyfor switching on,switching off and restartingSmartBalancer.

6

HELP keyopens context-sensitivehelp page active language

7

ESC keyis used to cancel anoperation to page back and toswitch off SmartBalancer (only in

start screen)

Status display per LED

Four LED coloured LEDs indicate threshold violations, errors, and systemstatus and show the battery status in the device.

Flashing LEDs have the higher priority, i.e. RED flashes with signal overloadand alarm level exceeded.


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... = further entries available

2.3 Notes on operationIn order to make the operation as easy and intuitive as possible, the userinterface is designed graphically, and is based on the operating concept ofMicrosoft Windows.

Switching on / off

To switch on the measuring unit, press and hold the On/Off button for twoseconds. The switch-on sequence takes about 1 minute. SmartBalancer isready for operation when the starting screen appears (Welcome...). Toswitch off, press and hold the On/Off button for two seconds and confirm thefollowing enquiry on switching off with YES.

Restart (Reset):Press and hold the On/Off button for approx. 5seconds, until the unit switches itself off and thenback on again.

Navigation & editing

Select the screen elements with the cursor which can be moved by thenavigation keys. The selected element is highlighted. To confirm theselection, press the 'Enter' key.

Some examples of navigation and editing are shown below:

Fields

Black frame = The field Measurement channel is selected.

Grey frame => The selection has been confirmed. The settings in the fieldMeasurement channel can be changed (Channel A or Channel B).

Scroll-down menu

Click on the menu in order to open it and display the entries. Click on anentry in order to select it. If the menu contains more entries than can bedisplayed, the entry "..." appears at the end of the menu. Click on this entry inorder to display the further entries.


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Tree view

Plus symbol = there are further entries available.

to open a branch, press 'Enter' or the right navigation key.To close a branch, press 'Enter' or the left navigation key.

Menu

The functions for the current screen can be found in the menu. The menu isopened by pressing the MENU button. To close the menu, press the ESCbutton.

An arrow next to a menu entry indicates a further submenu. To open it, pressthe right navigation key.


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2.4 Power supply, chargingThe SmartBalancer is supplied with power by a lithium-ion battery.The remaining capacity of the battery is shown by the battery symbol at the

top right of the display.

If the battery is almost empty, a message appears in the display, and theblue LED next to the display starts flashing. You then still have a few minutestime to complete the current measurements before changing or rechargingthe battery.

The battery can be charged in the unit with the charger in a maximum of 5hours. Observe the safety instructions provided with the charger.

Use one of the two analog input channels (A/B) as the charging socket. Youcan continue to use the SmartBalancer during the charging process.

Align the charger with the markings when connecting.

You can continue to carry out measurements via the second, free channel,although electrical interference may under certain circumstances lead tofaulty measurements!

To disconnect the charger first unlock it by pushing the plug sleeve to therear. Only then can you disconnect the plug from the unit. Never pull directon the cable itself!


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The charging condition is indicated by the LEDs and the battery symbol in thedisplay:

Connect the SmartBalancer to the mains power supply regularly, if you arenot going to use the measuring unit for any length of time. This will avoid the

battery becoming fully discharged and the date and time setting beingdeleted.

Do not continue to use damaged batteries! Do not open the battery usingforce or throw it into the fire! Do not short-circuit the connection contacts!Maximum charging temperature: 40 C. Dispose of the battery properly at theend of its useful life.

2.5 Memory card

Card formatted, which version?

! The card is new and has not yet been formatted in a SmartBalancer: Youwill be prompted to format the card.

! The card has already been used in another SmartBalancer:

Card version < Firmware version in the unit: the files on the card will beautomatically updated.

Card version > Firmware version in the unit: You will be prompted to resetall settings to Works settings (Reset).

Card version = current firmware version: no action required.

Card fragmented?

! The data on the card is severely fragmented: An instruction will bedisplayed to defragment the card.

! The data on the card is severely fragmented: A message will be displayedthat certain measurements, such as order spectra or time-signalrecording are no longer possible or will take place more slowly. In thiscase, the card must be defragmented!

The formatting and the fragmentation is started in the Service menu.


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2.6 Display and automatic switching-off

Over the display is a scratch-proof, transparent protective film, which caneasily be removed if required.

Since the lighting conditions affect the legibility of the display, you can set thebrightness individually. In order to maintain the battery reserve for as long aspossible, the lighting and measuring unit can be set to switch offautomatically.

Switch on the SmartBalancer.

In the starting screen, click on Unit setup.

In the next screen, click on Display.

Brightness

Press the navigation key right or left until the desired brightness is achieved.Press Enter to accept the setting.

Switch-off time

The lighting / the unit switches itself off automatically if the unit is not usedduring the set time interval (lighting: 10s ... 1m / unit: 6m ... 6h). To switch onthe display press any key.

Background image

A background image (PNG format) can be blended in to the starting screen.Further images can be loaded into the unit with the aid of the PC programmeSmartBalancer utility.

Display battery charging

This displays the remaining capacity of the battery as a percentage.

Then press MENU, and click on OK, in order to save the changes.


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2.7 Carrying pouchThe unit and the measurement equipment can be transported safely andconveniently in the strong and functional carrying pouch. A shoulder strapand a hand loop ensure convenient transport and a secure grip.

Shoulder strap

Attach the strap to two diagonally opposing eyes. Adjust the length of thestrap so that the measuring units can be hung over the shoulders andoperated conveniently.

Hand loop

The hand loop can be fitted to the right or left side. For a firm and stable grip,insert the hand through the loop.

The carrying pouch has an additional compartment on the rear side, whichcan be used to hold pick-ups, cables and small components.

In order to remove the measuring unit from the carrying pouch, open theVelcro fastener on the underside.


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2.8 InterfacesThe connections for the sensor and data cables are located on the front sideof the measuring unit.

For designation and identification of the four multi-pin connections, coloured

circles are printed above the relevant sockets. The corresponding cables arefitted with a coloured sleeve at the plug for the unit. With the aid of themarking point on the plug sleeve and on the socket, the cable can beconnected correctly. To disconnect, first unlock it by pushing the plug sleeveto the rear. Only then can you disconnect the plug from the unit. Never pulldirect on the cable itself!

Analogue

The two connection sockets marked with a blue circle are provided for themeasurement of analogue signals. The setting in the measuring problemdetermines to which of the two channels (A or B) the sensor cable must beconnected.

The analogue channels are not galvanically separated. In 2-channelmeasurements of two machines, check the potential equalisation (VDE0100), or use electrically insulated pick-ups.

The battery can be charged in the unit via one of the two analoguemeasurement channels. The SmartBalancer can be switched on or off duringthe charging process.


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Digital

Digital signals are recorded by the channel marked with the yellow circle(reference pick-up or speed sensor).

The permissible range for reference pick-up signals is: -26V ... 0V (negative)or -5V ... +26V (positive)*. The input signal must not exceed the switchingthresholds of the positive ornegative range, since this could result in faultymeasurements.

Switching thresholds:

positive: max. 2.5V rising

min. 0.6V falling

negative: min. -8V rising

max. -10V falling

Temperature

The QLA socket is intended for the connection of a thermo-element (NiCrNi).

Communication

The connection marked with a green circle is used for data exchange via aUSB port for communication with a PC or printer.

2.9 Basic settings - Unit setup

Before starting to carry out measurements with the SmartBalancer, checkthe basic settings in the unit and change them if necessary.

Switch the SmartBalancer on.

In the starting screen, click on Unit setup.

2.9.1 Date & timeThe time and date are saved along with the measurement result.

Changing the time & date:

Click on the symbol Date & time.

Click in the field Time, and mark the hours, minutes or seconds.

Move the navigation pad upwards or downwards in order to change thevalue - but without clicking! Only click to leave the field after you have setthe time.

Select the time format:

HH:mm:ss = 24 h / hh:mm:ssAP = 12 h

Set the date. Select either the German format (dd.mm.yyyy) or one of theEnglish formats as the date format.

Further parameters:

Time conversion: Yes (summertime) = + 1h

Time zone: Displacement in relation to GMT (Greenwich Mean Time)


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In order to save the settings and leave the menu, press MENU and then clickon OK.

2.9.2 Pick-upsThe Pick-ups menu provides all the functions and pre-settings for the pick-ups. Click on the symbol Pick-ups in order to open the menu. The pick-upsupplied with the standard scope of delivery is saved as the standard sensor.

For standard pick-ups, no settings need to be made. The dialogues on thepick-ups settings are only of interest to the user if other pick-ups are beingused.

2.9.2.1 Available pick-ups in the SmartBalancerThe technically relevant measurement parameters for many pick-ups are

already saved in the SmartBalancer. When compiling a measuring problemtherefore, you need only to select the pick-up which you want to use for themeasurement.

In the menu Available pick-ups you will find a list of pick-ups, which undercertain circumstances may be very comprehensive.

Since you will probably not use all the pick-ups already saved in theSmartBalancer, you can reduce the selection to the pick-ups available to you.When setting up the measuring problems, the SmartBalancer then displaysas standard only the already marked pick-ups:

Click on the relevant pick-ups in the list, so that these are marked with atick.


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Display use of the pick-ups

You can check in which measuring problem the individual pick-ups will beused as follows:

Mark the corresponding pick-up in the list. Press the MENU button.

Click on Use.

A list appears of the measuring problems which will be measured with thepick-up.

The available pick-ups are marked with a .

Pick-up parameters

In order to check or change the parameters, proceed as follows:

Mark the pick-up.

Press the MENU button.

Click on Display* or Edit in order to open the menu with the pick-upparameters.

* Display appears for pick-ups set in the works. Their parameters cannot bechanged.

Measurement parameter

Measurement parameter of the pick-up: acceleration, speed, vibrationdeflection, current, speed, jump, user-defined measurement parameter

Signal type

Signal type of the pick-up: e.g. LineDrive, ICP, voltage, ...


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Input voltage range

3V / 8V1/ 30V2; applies only for pick-ups of the signal type voltage.

Measurement parameter (user-defined)

Designation for user-defined measurement parameters.

AccuracyAccuracy in decimal points.

Coefficients A4, A3, A2

Parameter for linear conversion of a non-linear sensor characteristiccurve

Sensitivity

The sensitivity of the pick-up determines the signal level.

Offset

Offset of the pick-up.

Linear from / to

The linearity range of the vibration pick-up and the filter setting of the

measurement must be matched to each other.

Resonance frequency

The resonance frequency of the pick-up is an important influencingparameter for the surge pulse measurement (roller bearing condition).

Response time

Response time of the speed sensor.


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Filter pick-ups list

The pick-ups list can be filtered according to specific criteria:

Press the MENU button.

Click on Find. Press the right navigation key to open the associated submenu

The following criteria are available for selection:

ALL: all pick-ups

WORKS: pick-ups set up in the works

USER: pick-ups set up by the user

AVAILABLE: pre-marked pick-ups

PARAMETER: pick-ups for a particular parameter

Create new pick-up

In order to create a new pick-up, proceed as follows: In the pick-ups list,press the MENU button.

Click on New, in order to open the Text Editor. Enter the name of thenew pick-up.

Set the pick-up parameters.

Then press the MENU button and click on OK, in order to save the newpick-up.

To leave the menu, press the MENU button and click on OK.

Sort pick-up list Create new pick-up


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2.9.2.2 Sensor detection and hardware responseIn this menu, the sensor detection and response of the amplifier stages inthe SmartBalancer can be switched on or off.

The response of the amplifier stages can only be activated if the sensordetection is switched off. The settings in this menu apply for the operatingmodes Analysis and Machine templates. After switching on the unit, theamplifiers always respond before the first measurement.

2.9.2.3 Sensor checkHere you can manually check the measurement path to the sensor. In thecase of ICP sensors, use the menu ICP Sensor Check, and for all othersensors, the menu Sensor Check.

Select the channel to which the sensor is connected (A, B).

Click on START.

The SmartBalancer then checks the measurement path and displays theresult (LineDrive, open line, short-circuit, etc.).

2.9.2.4 Standard sensorFor all vibration measurements in the operating mode Analysis, a sensorcan be set which will be used as standard for the measurement.

Activate the control box, and select the required sensor. Only vibrationacceleration sensors are available for selection.

If a standard sensor is set up, no other pick-up can be set in the measuringproblem manager. The corresponding field is deactivated (shown in grey),although the originally set pick-up is still displayed.


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2.9.3 LanguageThe SmartBalancer is equipped with 11 dialogue languages. In the deliverycondition, the dialogue language is set to English. In order to change thelanguage to German, proceed as follows:

Click on the symbol Language.

Click on German. Press the MENU button, and click on OK.

Confirm the message to restart the unit.

2.9.4 UnitsIn the works, the units - where applicable - are set to SI units. In order tochange the units of a parameter, proceed as follows:

Click on the symbol Units.

Open the corresponding menu and select the new unit.

In the lower area of the window, the accuracy of the current unit in decimal

places is displayed, together with its conversion factor into the correspondingSI unit.

In order to save the changes, press the MENU button, and click on Save.

2.9.5 KeyphaserHere you can extend the time limit set for rpm measurements and phasemeasurement to enable measurements on very low-speed machines (range:10 ... 30 s, default: 10s). The 'Active edge' option is used to define whetherthe edge of the incoming trigger mark or outgoing trigger mark on the shaft isto be used as the reference signal.


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2.9.6 KeyboardFor some buttons on the SmartBalancer, additional functions are activatedas standard, which facilitate working on the machine or increase datasecurity.

Click on the symbol Keyboard.

In the following screen, the following options can be activated or deactivated.

Additional button on the rear side of the unit

An additional button is located on the rear side of the unit, which is operatedwith the index finger of the left hand. This button can be assigned one of thefollowing functions:

! Entry button (ENTER)

! Start measurement

This button is particularly helpful if enter cannot be pressed with the rightthumb - for example if a mobile measurement probe has to be held against

the machine with the right hand.

Save? enquiry after ESC

If this option is activated, the enquiry Save? appears after pressing the ESCbutton, without having saved the changes / measurement results in thecurrent screen.

Enquiry in case of repeat measurement

A repeat measurement is started automatically if enter is pressed in themeasurement screen. In order to prevent the unintentional start of a repeatmeasurement, this can be used to show a corresponding enquiry in the

measurement screen.In order to save the changes, press the MENU button, and click on OK.


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2.10 Service menuThe functions and settings for service, maintenance and training are found inthis menu.

Click on the symbol Service in order to open the Service menu.

Info

Ishows information on the unit.

Offset compensation

Different factors such as ageing or temperature cause a drift in the analogueelectronics. In this case, you have the facility of maintaining themeasurement accuracy of the unit by regularly calibrating the offset(approximately every 2 months).

Click on the symbol Offset compensation.

Click on Start. This process takes about 3 minutes.

Restoring the works settings

In this menu, you have the facility of resetting various parameters in the unitto the works settings. You can also delete data in the unit which is no longerrequired, such as measurement results (analysis), languages...

Click on the symbol Reset.

Danger of data loss! Make sure once again which setting will be reset, orwhich data will be deleted. This action is irreversible!

Click in the tree view on the relevant entry, and then confirm the followingenquiry by pressing OK. For safety reasons, you must again enter the

word OK in the Text Editor, before the action is carried out.


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LogLevel

In order to simplify fault-finding, the operating steps in the unit can bedocumented in the form of a file (LogFile). Here it can be specified howmuch data can be written to the LogFile.

Click on the symbol LogLevel, and select an option

NONE: No reporting

STANDARD: Only the important operating steps will be reported(standard setting)

RUNTIME / ... / SPECIAL APPLICATION: The volume of the reportedinformation will be increased from step to step.

The higher the LogLevel is set, the greater will be the requirement on thesystem resources (processor / memory). The LogLevel should therefore onlybe increased following consultation with SCHENCK RoTec GmbH.

2.11 Memory card (CF)In this menu, you can format, check and repair the memory card.

FORMATTING: You should only format a card if it is new and has not yetbeen used in SmartBalancer. This process deletes are data stored on thecard!

To format it, click on 'Start' in the top field, confirm the query that is displayedand enter the word 'OK' into the text editor.

CHECKING: The degree of fragmentation is checked automatically atspecific intervals. Here you can start the check function manually by clickingon the 'Start' button.

REPAIRING: If the file system on the memory card is faulty, an errormessage appears. If possible, save the measurement data on the PC beforestarting the repair function.

Start Service menu formatting with OK


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2.12 PrinterWith the SmartBalancer, you can output measurement results and reportsdirect to a printer. All printouts can also be saved as PDF-files andtransferred to a PC. In order to activate the print function, the Linux printerdrivers must first be loaded into the measuring unit, in order to make thenecessary settings.

The printer drivers are already available for some printers from HP andEpson with a USB port.

Further details on the operation of this programme can be found in theAppendix.

Click on the symbol Printer in order to open the Printer menu.

2.12.1 Printer setupIn order to set up a new printer, proceed as follows:

Click on the symbol Printer to open the menu Printer settings.

Mark the uppermost menu, press the MENU button, and click on New.

A tree view of the available printer drivers is displayed.

Open the corresponding folder, and select the required printer driver.

Enter a name in the Text Editor.

Then set the printer parameters:

Resolution, paper format and the paper source.

Printer loop

Print jobs which have not yet been printed out and are being processed in theSmartBalancer can be viewed in the printer loop and deleted if required. Todo this, mark the print job in the list, press the MENU button, and click onDelete job.

Print job being processed

When a print job is being processed, a print symbol appears at the upper

edge of the screen.


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2.13 Data transferData transfer takes place via the USB connection. The following data can betransferred:

Measurement data to the PC (analysis, machine templates)

Software update to the unit

Printer drivers to the unit

Data back-up to the PC

Data restoration to the unit

PDF and screen files to the PC

The data is exchanged via the auxiliary programme SmartBalancer utility,which is located on the SCHENCK RoTec Condition Monitoring CD and mustbe installed locally on the PC.

2.13.1 USBThe USB cable is used to connect the SmartBalancer to a USB port on thePC. The USB cable is provided for the connection to a printer with a USB

port. On the unit side, the cable is connected to the socket marked with agreen circle.

2.13.2 UpdateThe update is in a PTZ-file. The update file is loaded into the unit via USB.

The charger unit must be connected before an update. Otherwise the updateprocess will not start.

Start the update tool on the PC.

Set the communication (Communication type) to USB.

Click on [Continue].

Select the update file on the PC.

The file name contains the version number and the extension ptz.

Click on [Continue]:

Click on [Download]to load the data into the SmartBalancer.

On completion of the data transfer, click on [Close]in order to exit theprogramme.

The unit switches itself on and off repeatedly until the update is completed.This process usually takes a few minutes. Wait until the SmartBalancerstarting screen appears.

The current version number is displayed at the bottom of the starting screen.


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3. MeasurementThe SmartBalancer can be used in the following operating modes for themeasurement of signals and the recording of machine condition data.

! Balancing

! Analysis

Preparation

Before starting a measurement, ensure that

the battery is charged.

the unit settings are correct (date, etc.).

the required measuring problems are set up in the unit.

the required pick-ups and cables are ready and in proper operatingcondition; in the case of speed measurements, you may need a standfor the speed sensor!

the fixed installed measurement points are in order; carry out a visualinspection; if necessary, clean and rectify any damage.

a countersink is fitted at the measurement points for manual probes.

3.1 BalancingThe balancing module is based on the well-known influence coefficientmethod and is characterised by its efficiency and great operatingconvenience. The measurement process used has been optimised by a new,knowledge-based algorithm. The perfectly matched measurement settingssave you time-consuming preparations and automate recurring processsteps. Easy operation is ensured by intuitive, graphic user guidance, whichleads you step-by-step through the balancing procedure. Various methodsfor correction of a rotor unbalance are available for selection: free correction,fixed weight, fixed locations or measuring tape correction. If required, theSmartbalancer will combine all fitted weights into a new, single weight. If youcannot fit any balancing weight to the rotor, the Smartbalancer can calculatefor you the weight which must be removed from the rotor.

3.1.1 Safety during balancingThe safety instructions in the operating instructions and the following safetyinstructions on balancing must be read carefully and understood beforestarting to use the measuring unit.

Check the rotor for damage before balancing and repair or replace anydamaged components.

Remove any material adhesions and loose parts. The applicable safetyregulations must be observed when carrying out measurements onmachines.

When arranging the measurement components, ensure that there are noholders, cables etc. projecting into the vicinity of rotating machine parts.

When fitting the balancing weights, the corresponding instructions of themanufacturer must be observed.

In the case of welded-on balancing weights, care must be taken to ensurethat the attachment points are clean; the earth electrode of the weldingmachine must be connected to the rotor, and not to the machine.

In the case of screw-fitted balancing weights, the maximum permissiblespeed of the rotor must be observed.


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Static unbalance1 Rotation axis2 Mass inertia axis

3 Unbalance

Couple unbalance

When working on the rotor, the machine must be switched off andsecured against switching on again in accordance with the applicableregulations.

Before the first measurement (initial unbalance), it must be ensured thatthe preparations have been carried out properly and completely. Inaddition to the arrangement of the measurement components, care must

be taken to ensure that the parameters have been entered correctly in themachine setup. An incorrectly entered rotor mass will result in thecalculation of too large a trial weight. The consequences for the operatorand the machine may be serious!

During the trial and correction runs, no persons must remain in the radialarea of the rotor. This area must be properly secured againstunauthorised entry. If the trial weight becomes detached from the rotorwhen the machine is running, this can result in fatal danger in this area!

If the rotor is accommodated in a protective housing, any hatches oropenings in the housing must be closed before starting the machine.

The permissible starting frequency of the machine must not be exceeded.Otherwise the motor may be damaged.

3.1.2 Balancing processIncreased vibrations to machines are undesirable occurrences. They impairthe quality of the products, place additional stress on the components andultimately reduce operating safety. The most frequent cause of thesevibrations is the unbalance. The resulting high centrifugal forces lead topremature wear of machine components such as bearings and seals. Theobjective of balancing rotors is therefore to restrict bearing forces and shaftdeformations to acceptable levels.

With Smartbalancer you can reliably detect an unbalance and quickly correctit. Your balancing results will be automatically compared with the assessmentstandards for the balance condition of rotating, rigid bodies of DIN ISO 1940.

3.1.3 UnbalanceIf a rotor is correctly balanced, and if the rotor is placed in roller mountings,the rotor will not turn. If an additional mass is applied, this will immediatelyturn the rotor until it rests at the bottom. This procedure is referred to asrolling. If the additional mass is applied in the plane of the centre of gravity,this will result in a purely static unbalance.

If this rotor is now rotated at the balancing speed, this creates a centrifugalforce perpendicular to the axis of rotation.

If two equal unbalances are applied to a fully balanced rotor so that they aredirectly opposite each other in two separate radial planes, this is referred toas a couple unbalance (or dynamic unbalance). This unbalance cannot beestablished with the aid of roller mountings, since the centre of gravityremains on the rotational axis. When the rotor turns, the unbalances cause amoment due to centrifugal force, which generates equal but opposing forcesin the bearings. Such unbalances can only be detected and correcteddynamically by means of two-plane balancing.

If a single unbalance is applied to a fully balanced rotor in one plane, whichdoes not contain the centre of gravity, this is referred to as quasi-staticunbalance. This corresponds to a combination of a static unbalance and a

couple unbalance, and is usually corrected by means of a correction in twoplanes.


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The decision as to whether a rotor should be balanced in one or two planesdepends essentially on how many correction planes there are available andthe separating distance between them.

Two-plane balancing under operating conditions with an optical referencepick-up and two vibration pick-ups.

1 Vibration pick-up 3 Reference pick-up

2 Reference mark 4 Correction weight

3.1.4 Balancing on machines with rotating massesThe balancing module is based on the well-known influence coefficientmethod:

The Smartbalancer first measures the vibration amplitude and phase angleof the vibration caused by the unbalance. A defined test weight is thenattached, and the amplitude and phase measured once again.Smartbalancer then calculates the influence coefficient from the difference ofboth vibrations and the exact location and amount of the test weight. Theunbalance of the rotor is then calculated with the aid of this influencecoefficient.

In two-plane balancing, the influence of the mass in the other plane is takeninto account in the calculation. All so-called rigid rotors can be balanced

using this balancing method.Rotors which are operated outside the speed range in which they behaverigidly are not the subject of these operating instructions. For the balancing ofthese rotors, further skills and knowledge are necessary, which can beacquired in a seminar by Schenck RoTec.


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3.1.5 Analysis of the rotor before balancingBefore beginning the balancing, you should first ensure that the cause of thereduced running smoothness of the rotor is actually an unbalance. Avibration diagnosis will also show which balancing method is the mostsuitable.

A range of co-ordinated measuring problems are available for the diagnosisof an unbalance:

Click in the starting screen on Analysis,

Vibration speed characteristic value

Detection of the wideband vibration of the machine for documentation of theactual condition before and after balancing. This also identifies themeasurement point with the highest vibration level, which is where thesensors should be fitted.

Speed

Measurement of the rotor speed.

Phase measurement - one / two planes

Registration of the amplitude and phase angle of the speed-synchronousvibration signal. This can be used for example to determine the type of theunbalance (static / dynamic).

Vibration speed - Spectrum & time signal

Measurement of the FFT spectrum and time signal. If the spectrum isdominated by the 1stharmonic, the most probable cause for the poor running

smoothness is an unbalance.


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3.1.6 Preparation for balancing

Before starting any work on the machine, it must be switched off and securedagainst unintentional switching on! The preparations include the arrangement

of the measuring components.

3.1.6.1 Arrangement

1 Drive side 4 Measurement plane 1

2 Reference mark 5 Correction planes A and B

3 Reference pick-up 6 Measurement plane 2


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First try to establish the cause of the vibrations by visual inspection, andrectify this if possible. Example: Remove any material adhering to therotor, or tighten any loose bolts in the foundation.

If the machine is not to be balanced on-site in the installed condition, it mustbe firmly attached to a rigid foundation (direct to the frame or to vibration

insulators).

Determine the measurement and correction plane. Mount the vibrationpick-up on the bearing housing at the measurement point with the highestvibration levels. Note the following:

The measurement plane should be in the centre of the bearing or close tothe correction plane (e.g. rotor side, rotor).

Vibrations are transmitted via the outer race of a bearing in the radialdirection. The pick-up should therefore be attached at the side (horizontal)or at the top of the bearing (vertical). Suitable measurement points can befound by using the test probe to identify the point with the highest vibration

levels.The pick-ups should be attached as close as possible to the bearing. Avoidattenuation of the signal due to excessively long transmission paths, bearingcovers etc. The measurement direction must correspond to the mainvibration direction (usually horizontal). In the case of a horizontalmeasurement direction, attach the pick-up on the lower half of the bearinghousing.

Wherever possible, use pick-ups which can be screwed to the machine,or attach the pick-up using a magnetic adapter. The pick-up must not beattached to components with natural vibrations, such as covers.

Test probes are not suitable for balancing!

For dynamic balancing in two planes: Determine the second plane (B) in

the same way. Assess the running smoothness of the machine.

Measure the vibration speed, and in the event of excessive vibrationlevels, record an FFT spectrum (see DIN ISO 10816-3).

For example, if the speed is 1,500 rpm and high vibration amplitudesoccur in the spectrum at 25 Hz (1stharmonic), these are referred to asrotational frequency vibrations, which indicate an unbalance.

Save the measurement values in order to compare them later with themeasurement values after balancing.

Apply an angle reference mark to the shaft for the reference pick-up. Usereflection film as the reference mark.

Angle convention: The angle reference mark defines the position 0; thefitting angle for the correction weights is counted opposite to the directionof rotation of the shaft.

Tip: In the case of fans, number the blades in accordance with thecounting direction of the fitting angle. Blade No. 1 is at the 0 position.

Fit the reference pick-up with the reference pick-up stand to the machinewhen switched off in accordance with the following illustration. Note thefollowing:

Fit the reference pick-up at a distance of 2 to 50 cm from the shaftsurface. Keep the span length of the stand short, in order to attach thesensor with the lowest possible vibration level.

Ensure that the reference pick-up optic is perpendicular to the shaft

surface (note the arrow direction on the sensor head!). In order not to interfere with the reference pick-up signal, avoid

reflections or other interference with the reference pick-up optic. In


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case of bright, glossy shafts, fit the reference pick-up at a slight angle(approx. 15) to the shaft surface.

Connect the vibration pick-up and the reference pick-up to the measuringunit.

Fitting of the reference pick-up

1 Reference mark 3 Vibration pick-up onmagnetic adapter

2 Reference pick-up 4 Reference pick-up stand

On completion of the preparations:

! The balancing speed should be as low as possible. The higher thebalancing speed, the higher the danger posed by test weights flying offetc.

! Look out for any possible resonance points, and in case of doubt examinethe coast-down curve!

! The speed must remain constant during the measurement! Otherwise thebalancing run must be started again.

! The rotor must be at operating temperature during the measurement (e.g.if the rotor normally operates in a hot air flow).

! Before starting the first balancing run, check the correct installation of allmeasurement components once again.

! Check the set parameters.

3.1.7 Operation


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If you are not yet familiar with the operation in the balancing mode, note thefollowing instructions:

3.1.7.1 SettingsAll settings necessary for the measurement and assessment of a balancing

run are made in setup menus. The individual setups (measurement, pick-up,machine, ...) are combined into a measuring problem. The measuringproblems for balancing are therefore built up in the same way as themeasuring problems in the operating mode Analysis.

Parameters which you can change during balancing are summarised in theMENU under the option Tools:

! Correction mode: free correction / fixed locations / fixed weights / tapemeasure

! Fit balancing weights, i.e. weld or screw weights to the rotor.

! Remove balancing weights, i.e. mill weight from the rotor

! Test functions: activate / deactivate speed, stability of the unbalanceindicator, etc.

3.1.7.2 DisplayIn every balancing run, two main screens are displayed:

The data screen shows the balancing weights and their position on the rotor.The screen also shows the measurement data and balancing weights of allcompleted runs. If a machine setup has been set up, it shows the balancingquality achieved and the resulting centrifugal force at the rotor.

In the measurement screen, the measurement values (amplitude & phaseangle) are displayed numerically and graphically in a polar diagram.

In both screens, the relevant balancing step is shown at the top left:

0. Initial unbalance:

Data screen Measurement screen


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measurement of the initial unbalance; if the vibration values are withinthe tolerance range, the rotor is balanced. Otherwise balancingweights must be fitted to the rotor in accordance with the followingbalancing steps.

1. Test run:

the influence of the fitted test weight is measured, and the required

correction weight calculated.2 to ..n :

Correction runs to reduce the unbalance of the rotor.

Zoom with +/-

The initial unbalance is designated by A or B as the starting point of thebalancing procedure. All following measurements are connected to eachother by a line. In order to enlarge the view, press the + button repeatedly.The Smartbalancer automatically scales the display area with regard to thelast two balancing runs. If the initial unbalance moves out of the display area,the maximum range will also be specified as a percentage of the initialunbalance.

3.1.7.3 Navigation

To scroll forwards and backwards, press the right or the left navigation keyrespectively.

Start / stop measurementPress the Enter key in the measurement screen.

3.1.8 Repeat balancing


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If you want to determine the unbalance of a rotor for a second time:

If the measurement runs were saved the first time, you can use the influencecoefficients obtained during these runs.

Select the saved rotor data in the file manager and click on [Return].

Or

Select the bearing case in the Balancing menu.

Press [Menu]

Click on [Load file]and select the rotor name.

Click on [Return]and select [Restart].

! A message appears:

A restart deletes all previous balancing steps and retains only theinfluence coefficients. Do you really want to restart?

Confirmed by pressing OK and start with the initial unbalance run.

You can also save the influence coefficients under a name in the MENU[Tool][Save coefficients].

You measure the unbalance with the available influence coefficients.

End the measurement run by pressing [Pause]and go to the next page bypressing [Continue].

Load the influence coefficients for this rotor by selecting [MENU][Tool]->[Load coefficient]and confirm by selecting [MENU] [OK].

! The SmartBalancer immediately displays the unbalance for one or bothplanes.

Fit the displayed correction weights.

Carry out a check run. If the rotor is not yet in tolerance, a furthercorrection suggestion will be made.

3.1.9 Balancing in one planeThe next section describes the procedure for balancing in one plane. This isdone without a machine setup; the standard setting under the MENU itemTools is:

! Correction mode: free

! Fit balancing weights

! Test functions all active, except coefficient calculation inactive.

3.1.9.1 Activating the balancing mode Switch the Smartbalancer on, and wait until the starting screen appears

(20-30 seconds).

Click on the screen symbol Balance.

Open the tab 1 plane.

Click on the rotor graphic corresponding to the rotor type, after checkingand if necessary changing the current measuring problem (F button orMENU - Measuring problem manager)


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With the aid of the graphic, allocate the measurement data to the rotor type.


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Selection screenStart initial unbalance run

Before you can load a saved measurement, you must first select the rotortype. Only then can you open the required file by selecting MENU - [Load file].

3.1.9.2 Measuring the initial unbalance Switch the machine on. Wait until the machine has reached the balancing

speed and if applicable the operating temperature.

Press 'Enter' to start the measurement.

The Smartbalancer first registers the speed. The green LED flashes on everyreference pick-up pulse. If the speed fluctuates too much, a warning isdisplayed, which you can acknowledge by pressing enter.

The unit then measures the amplitude and phase of the speed-harmonicvibration. If the values are unstable, the number of values used for averagingwill be increased automatically.

In the case of stable measurement values, press enter in order to stop themeasurement values.

Press enter again in order to repeat the measurement.

Switch the machine off.

3.1.9.3 Test run Press the right navigation key to open the data screen for the trial run.

Enter the weight and fitting angle for the test weight

G Click on the weight or angle field under the rotor graphic.

The active field is highlighted in black. If none of the fields can bemarked, press the F button.

G Enter the relevant value in the Numbers Editor and accept the entry byselecting MENU - OK.

Press the right navigation key until the next screen appears.

Switch the machine on.



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Measurement of the initial unbalance Weight and angle for the test run

In case of stable measurement values, press enter in order to stop themeasurement.


In the test run, the unbalance should change sufficiently. If the unbalanceonly changes slightly, you must increase the test weight. If the unbalance hasmore than doubled, you must use a smaller test weight (see ToolsParameter Check unfavourable influence). If necessary, page back to thedata screen of the test run, change the weight accordingly, and repeat thetest run.

3.1.9.4 Correction run Press the right navigation key in order to close the measurement screen

of the test run and open the data screen of the first correction run.

Depending on whether the test weight has resulted in an improvement ornot, you can leave it on the rotor or remove it. Answer the followingenquiry displayed on the screen accordingly.

Fit the suggested weight at the specified position on the rotor. The valuescan also be changed if required.

Press the right navigation key until the next measurement screenappears.

Switch the machine on.


In case of stable measurement values, press enter in order to stop themeasurement.



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In the correction runs, the Smartbalancer checks whether the unbalance hasbeen reduced sufficiently from one run to the next. If this is not the case, thefollowing message is displayed: No improvement. The corresponding runmust be repeated with a different balancing weight.

A restart is recommended if the vibration values deteriorate, and at the sametime the correction weights are not reduced significantly.

Move the navigation pad to the right, and continue the balancing with thenext correction run.

Before every further correction run, you must specify whether you willleave the balancing weight used on the rotor or remove it.

The balancing is completed as soon as the vibration values have reached anacceptable level. If you are working with Machine setup, the calculatedbalancing quality is the completion criterion. A Smiley symbol appears in

the data screen of the next correction run if the balancing quality has reachedthe tolerance range.


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Balancing quality achieved (balancingin machine setup)

Save result

3.1.9.5 Undoing balancing runs

If the measurement results worsen after a trim run, you can return to a runthat was acceptable and continue balancing with different weights from there.

Navigate to the data screen of the trim run at which you wish to continuethe procedure.

Press the MENU button and click on 'Undo'.

Confirm the next query with 'Yes'. All subsequent trim runs are deleted.

Remove the balancing weights that you attached during the deleted trimruns.

3.1.9.6 Save result In the data screen, press the MENU button.

Click on Save, in order to open the file manager.

Click again onSave, and enter the name in the Text Editor.

Then press the MENU button in the Text Editor, and click on OK in orderto save the result.


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Rotor type selection screen

3.1.10 Balancing in two planesThe procedure in this case corresponds in principle to the previous section.Only the special features of balancing in two planes are therefore describedbelow:

3.1.10.1 Measurement procedure overviewPlane A?: Definition of the measurement and correction plane

A

0. Initial unbalance: Measurement in plane A and plane B

1A. Test run: Suggestion for test weight in plane A;

Measurement in plane A and plane B with testweight in plane A

1B. Test run: Suggestion for test weight in plane B;

Measurement in plane A and plane B with testweight in plane B

2. Correction run: Suggestion for balancing weight in planes A & B;Measurement in plane A and plane B

....

N. Correction run ...

3.1.10.2 Definition of measurement and correction plane A Activate the balancing mode.

Click on the rotor graphic corresponding to the rotor type.

Select plane A:

G Connect the pick-up fitted in measurement plane A to measurementchannel A (see Connection overview).


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3.1.10.3 Test runThe test run is divided into two sections, which are designated 1A and 1Bin the main screens :

1A: The test weight is fitted in plane A and its influence measured in bothplanes.

1B: The test weight is fitted in plane B and its influence measured in bothplanes.

3.1.10.4 Correction runIn the data screen of the correction run, enter the balancing weights for bothplanes. Press the right navigation key, in order to mark the entry fields insequence.

Continue the correction run until the residual unbalance is within thetolerance range.


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3.1.10.5 Evaluation of the dataIn the data screen, the following data is listed for every completed balancingrun:

! Weight of the balancing weight

! Fitting angle

! Effective value of the vibration level

! Phase angle

If you are working with a machine setup, the balancing quality achieved andthe centrifugal force on the rotor will also be calculated. If the balancingquality is within the tolerance range, the Smiley appears, indicating the endof the balancing procedure.

Data View

If you would like to evaluate the completed runs in detail, or combine

individual balance weights into one weight, open the Detailed data view: Press the MENU button in the data screen, and click on Data:

In addition to the individual balancing runs, the data field lists the followinginformation:

! Machine name: Machine setup, if used

! Date & time of the last balancing run

! Speed set in the machine setup

! Balancing quality after the last balancing run

! Residual unbalance after the last balancing run

You can select the individual balancing runs in the list. The marked run ishighlighted in black in the polar diagram. The view of the polar diagram can

be zoomed in and out by pressing the +/- button. An asterisk (*) in the listmarks those balancing runs in which the fitted balancing weight was removedagain after the measurement of the rotor (e.g. test run with weight in plane B:(1BB), see illustration below).


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3.1.11 Combining balancing weightsIf you have already fitted several balancing weights to the rotor, you cancombine these into one single weight. The Smartbalancer adds together theweights of the completed balancing runs vectorially and displays the resultingweight and the fitting angle in the data screen and the detail view.

Press the MENU button in the detail data view.

Click on Combine:

The newly calculated balancing weight appears in the list in the line for thenext correction run. This run is marked with a total symbol (3).

Then press the MENU button, and click on OK, in order to accept thecombination of the balancing weights.

Before continuing with the next correction run, remove the already fittedweights, and fit the newly calculated balancing weight to the rotor.

1 Fitted weights

2 Resulting weight

Combining weights

A: Result in plane A

B: Result in plane B

The weights from runs 1 to 3 havenow been combined:

Run 4 must be carried out with thenewly calculated weights.


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Correctionmode - fixedlocation

3.1.12 Options when balancingDuring the test run and the correction runs, the following options areavailable:

3.1.12.1 Check measurement setting

Press the MENU button, and click on Measuring problem manager. Mark the corresponding setup, press the MENU button, and click on

Display, in order to display the set parameters.

3.1.12.2 Changing the correction mode (MENU - Tools)The correction mode refers to the method by which the balancing weight isfitted to the rotor. The standard setting for the correction mode is Free & fit,i.e. the weight can be of any mass, and can be fitted at any angular position.

Press the MENU button in the data screen, and click on Tools:

The following correction modes are available for selection:! Fixed location

! Fixed weight

! Tape measure

Fixed location

If you can only fit the balancing weight to the rotor at certain positions (e.g.on the blades of a fan), select the correction mode Fixed location. Thenenter the Number of locations on the rotor. The Smartbalancer calculatestwo weights in the balancing runs which must be fitted at two of the specifiedpositions. Position or blade #1 corresponds to the 0 position, and should be

set up as the reference mark for the reference pick-up.

Fixed weight (spreading of fixed weights)

Activate the option Fixed weight, if you only have weights of certain masses(e.g. 2g, 5g, 10g) available for balancing. Then enter the mass of the Fixedweight. The Smartbalancer then calculates two angle positions at which twoequal weights must be fitted.

The option Fit balancing weight must be set.

The fixed weight must be at least and at most 3 times as heavy as thebalancing weight suggested in the Free mode.

Free Fixed weight


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Fixed weight Tape measure

Tape measure

In this correction mode, you can determine the position of the balancingweights with the tape measure, without having to fit a reference system withangular division.

Specify the outer diameter of the rotor in plane A and plane B. The distanceon the rotor surface is calculated from the reference pick-up mark (0position) in millimetres and counted against the direction of rotation. Youmust therefore place a tape measure around the rotor and fit the balancingweight at the specified length.

The distance of the balancing weights from the axis of rotation is thecorrection radius. This is as a rule smaller than the outer radius.

In all three correction modes, you can subsequently change the calculatedspecifications, although the changes should not differ too greatly from thespecifications.

The list in the Data field always displays the correction weights for the freecorrection mode.

3.1.12.3 Remove balancing weightIf you do not attach the balancing weights to the rotor by clamping, welding,screwing etc., you can also correct the unbalance by grinding off some of the

rotor material. To do this, set the option Balancing weight ->remove in theTools menu (see below). The Smartbalancer then re-calculates thebalancing weights as negative masses.

3.1.12.4 Test functionsIn order to ensure that the balancing procedure produces reliable andassessable results, the Smartbalancer is equipped with the following testfunctions in the Tools menu:

! Check speed:

Before every measurement, the Smartbalancer checks whether themeasured speed is stable. If the speed fluctuates too greatly, a

corresponding error message will be displayed.

! Check unfavourable influence:

0 Reference markR Outer radiusr Correction radius


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Remove balancing weight(drilling, milling, grinding...)

The change of the unbalance indicator is checked; if the change is toolarge or too small, a corresponding message will be displayed. You mustthen go back to the preceding balancing run and reduce or increase theweight fitted.

! Re-calculate coefficient:

The coefficient used for the calculation of the correction weight can be

taken from the test run (setting: No) or from the preceding correction run(setting: Yes).

! Check stability:

During the measurement, the stability of the unbalance indicator ischecked. If the fluctuations are too great, the Smartbalancer increasesthe number of values used for averaging automatically. If the maximumnumber of averaging values is reached, a corresponding message isdisplayed.

3.1.13 Balancing with machine setupA machine setup should be carried out if the Smartbalancer is to suggest atest weight before the test run, or if you would like to have the residualunbalance and the balancing quality calculated after every run. This setupcontains the machine data necessary for the calculation and information onthe layout of the measuring arrangement.

Mark a rotor type in the selection screen.

Press the MENU button, and click on Measuring problem manager.

Mark the field Machine setup.

Press the MENU button, and click on New or Edit:

Only user-defined measuring problems can be changed.


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3.1.13.1 Parameters in the machine setupPlanes 1 / 2.

Number of correction planes; cannot be changed, since the selection ofthe rotor type is made in the selection screen.

Correction mode free / fixed location / fixed weight / tape measure

takes into account restrictions on the machine (e.g. fixed location for fanblades) or local circumstances (tape measure. The correction mode canbe changed in any balancing run in the Tools menu. Depending on theselection, the following parameters must be set:

Number of locations: 3-100. As a rule the number of fan blades.

Fixed weight: Mass of the available balancing weight.

Outer diameter:

With the tape measure, you can determine the position of the balancingweights on the rotor without an angle reference.

Fit / remove balancing weight;

The Smartbalancer calculates how much mass has to be fitted to the rotor

or ground off (Negative mass). This parameter can be changed in everybalancing run (MENU - Tools).

Balancing quality

Assessment of the residual unbalance with the aid of quality levels to DINISO 1940. If the calculated balancing quality is lower than the set value,the Smiley appears in the data screen, and the balancing is completed.Select the value 0 if you would like to work without an assessment of theresidual unbalance.

Foundation flexible / rigid;

The balancing weights are smaller for a flexible foundation than for a rigidfoundation.

Radius

Balancing radius; Distance of the balancing weight from the axis ofrotation; the larger the balancing radius, the smaller is the balancingweight at the same speed.

Rotor mass

The mass of the rotor is taken into account in the calculation of the testweights.

Reference pick-up angle (2)

Angle between the pick-up (3) and the reference pick-up (1); thereference pick-up angle (2) is taken into account in the calculation of thetest weight, and is counted against the direction of rotation of the rotor.


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Speed

Balancing speed; this should be as close as possible to the operatingspeed. When balancing using the speed setup entered in the works, onlyone reference pick-up pulse is processed per revolution. You shouldtherefore ensure that only one reference pick-up mark is applied to theshaft.

Check speed*

Yes / No; see Test functions

This parameter can be changed in every balancing run (MENU - Tools)

Automatic averaging

Yes / No; In case of a highly fluctuating unbalance indicator, theSmartbalancer automatically increases the averaging number set in themeasurement setup.

Check most unfavourable influence*

Yes / No; see Test functions.

Re-calculate coefficient*


Automatic test mass

Yes / No; The Smartbalancer calculates a test weight from the machinedata and suggests this in the test run. If this option is deactivated, youmust enter the test weight fitted to the rotor in th data screen of the testrun.

Check stability*



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3.1.14 Parameters in the measurement setupIf you create a new measurement setup, you can set the followingparameters:

Filter

2Hz / 10 Hz; set 10 Hz as the lower frequency if the machine speed is

above 600 rpm, and th machine is located on a flexible foundation.Averaging

1 - 20; in case of a highly fluctuating unbalance indicator, the averagingnumber is automatically increased up to the maximum value.

Order

1 - 5; order filters enable balancing at speed harmonics of a higher order;these special cases can occur in the case of special machinearrangements.

3.1.15 Entering the balancing radius and rotor mass later

You can enter the balancing radius and the rotor mass later in the Toolsmenu to have the achieved balancing quality and the centrifugal forcecalculated. In this way, these values will be available to you if you start thebalancing procedure without the machine setup.

Optionally, you can enter different balancing radii for the trial run and thebalancing runs. To do so, activate the 'Use different radii' option.


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3.2 Analysis

3.2.1 What is a measuring problem in the Analysis mode?In order to perform a measurement, the SmartBalancer needs information on

the measurement parameter, the pick-up used and possibly alsospecifications on the assessment of the result. It also requires information onwhether the speech should also be registered simultaneously with eachmeasurement. This data record is referred to as a measuring problem andforms the basis for every measurement with the SmartBalancer.

In order to simplify the preparations for a measurement in the Analysisoperating mode, and to save you having to enter the required data, theSmartBalancer provides a range of pre-defined, knowledge-based measuringproblems. With these measuring problems, you can simply change the pick-up and then reset the measurement channel. If further changes to themeasuring parameters are required, create a new measuring problem.

An overview of the arrangement of a measuring problem in theSmartBalancer is given below:

Measurementparameter

(symbol)

Measuring problem Overall velocity>600RPM

Overall velocity>120RPM

...

Measurementsetting

velocity / 10-1000 Hz velocity / 2-1000 Hz

Pick-up VIB 6.140 VIB 6.142

Assessment ISO 10816-3 group 2 ISO 10816-3 group 1

Speed Speed measurement No measurement

For a better overview, the measuring problems are sorted according tomeasurement parameter and allocated to a corresponding symbol. Forexample, in the Analysis operating mode, all measuring problems of themeasurement parameter Vibration speed - characteristic value can be foundunder the above symbol. The letters a, v, and d in the symbol stand foracceleration, speed (velocity) and distance.

Measurement - Analysis - Diagnosis

In order to activate the Analysis operating mode, click in the starting screenon [Analysis]in order to open the selection screen of the measuringproblems. The measuring problem for the marked symbol is displayed in thelower half of the screen (Info field).

The measuring problems are grouped under three tabs: Characteristicvalues, Signals, Special (measurements). Certain measuring problems onlyappear if the corresponding module is registered.

The current tab is marked by a black frame. In order to change the tab, pressthe + or button, or use the navigation pad.

Typical measurement procedure


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This section describes how to perform a m

schenck smartbalancer v3

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