SBS AEMS System

User’s Guide
with SB-5500 Series Controls
LL-5200, Rev. 1.6a

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User’s Guide and Specification
For theSBS AEMS System
Covering Operation of SB-5522, SB-5522-6, and SB-5519
with Model 5500 series Control Units

LL- 5200
Manual Revision # 1.6aCovers operation with product firmware rev. 0.41
© 2020 Accretech SBS, Inc.

Corporate Offices
2451 NW 28th Avenue
Portland, OR 97210 USA
sales@accretechSBS.com

Tel: +1 503.595.4270
Fax: +1 503.595.4271
https://accretechsbs.com/

SBS AEMS System

Benefits of SBS AEMS System with SB-5500 Control:

Increases throughput by saving setup timeImproves part quality by providing grind and dress quality monitoring

Gap Elimination - Increases throughput by reducing unproductive grind infeed.

Crash Protection - Quick detection of extreme wheel contact to allow feed shutdown
and prevent dangerous wheel crashes.



Four-channel capability reduces costs by permitting both balancing and AEMS
monitoring of multiple machinesLonger life for grinding wheels, dressing wheels and spindle bearingEnhanced digital electronic design with increased operating life and reliability

Easy to install and operateWorks with existing SBS installations

Profibus, Ethernet and USB 2.0 communication

International adaptability: voltage, frequency, communication, and display languageBacked by world-class SBS customer service

SBS AEMS System

Table of Contents
General Instructions ............................................................................................................................ 1
System Purpose .................................................................................................................................................... 1
Operator Safety Summary .................................................................................................................................... 1
System Theory and Connection ........................................................................................................................... 2
Control Unit Overview ........................................................................................................................................... 3
IVIS Software Interface .................................................................................................................................... 3
Front panel controls ......................................................................................................................................... 3
Power-on display ............................................................................................................................................. 4
SETUP ............................................................................................................................................................. 4
Control unit without front panel connected ...................................................................................................... 4
System Installation ................................................................................................................................................ 5
System Connections ........................................................................................................................................ 5
AEMS card rear panel connections ................................................................................................................. 5
SB5580 ............................................................................................................................................................ 6
Firmware Update and Save or Recall of System Settings .............................................................................. 6
Acoustic Sensor Location ................................................................................................................................ 7
AE Sensor Types ............................................................................................................................................. 7
SB-5522-6 model ............................................................................................................................................. 8
SB-5519 model ................................................................................................................................................ 8Control Unit Instructions........................................................................................................................................ 9
Explanation of M1 and M2 ............................................................................................................................... 9Main Screen Operation .................................................................................................................................... 9
SETUP ........................................................................................................................................................... 10
MENU screen ................................................................................................................................................ 10
CNC Signal Time ........................................................................................................................................ 10
CNC Crash Latch ........................................................................................................................................ 11
CNC Function – Stop/Start ......................................................................................................................... 11
Channel Name ............................................................................................................................................ 11
Menu Entry .................................................................................................................................................. 11
Job Configuration ........................................................................................................................................ 12
Factory Settings .......................................................................................................................................... 12
Job# (Job No.) - Multiple Parameter Sets ................................................................................................... 12
Limit Screen ................................................................................................................................................... 13
Limit Edit ..................................................................................................................................................... 13
Screen .................................................................................................................................................... 14

AEMS Operation................................................................................................................................. 15
M1 and M2 Parameter Menu ......................................................................................................................... 15
Learn Cycle .................................................................................................................................................... 15
Learn AIR ....................................................................................................................................................... 15
Frequency bands defined ........................................................................................................................... 16
Frequency Band Selection and Short Work Cycles .................................................................................... 16
Set Frequency Band 8 ................................................................................................................................ 16
SB-5522-6 Sensor Selection ....................................................................................................................... 16
Learn WORK ................................................................................................................................................. 17
Learn Data screen ......................................................................................................................................... 17
Verify Normal Operation.............................................................................................................................. 17
Graph Time .................................................................................................................................................... 18
Graph Type .................................................................................................................................................... 18
Peak Detect ................................................................................................................................................... 18
Frequency Band ............................................................................................................................................ 18
Plot Scale ....................................................................................................................................................... 18
Hardwire Interface ............................................................................................................................................... 19
Hardwire Control Interface – AEMS Card...................................................................................................... 19
Input Pin Names and Functions .................................................................................................................... 20
Output Pin Names and Functions .................................................................................................................. 20
SBS AEMS System

AE Signal Analog Output ............................................................................................................................... 21
Profibus DP Interface .......................................................................................................................................... 22
Software (USB or Ethernet) Interface ................................................................................................................. 22
Interfacing ...................................................................................................................................................... 22
Software Commands and Responses ........................................................................................................... 22
Displayed Error Messages .................................................................................................................................. 24
Support................................................................................................................................................................ 25
Appendix A: Specifications ................................................................................................................................. 26
Appendix B: Replacement Parts List .................................................................................................................. 27
Appendix C: AEMS Card Installation .................................................................................................................. 28
Appendix D: AEMS System Connection Diagram .............................................................................................. 29

SBS AEMS System

General Instructions
System Purpose
The SBS AEMS System has been developed to provide process control enhancement to grinding machine
operators. “Gap” elimination, Crash Monitoring, and Monitoring of wheel contact in the Grinding and Dressing
processes are all provided, with the following objectives in mind:• Ease and Usefulness of Operation• Maximum Grinding Machine Efficiency• Minimal Installation Requirements• Close Integration with SBS Balance Systems• Attractive Purchase Price

Operator Safety Summary
This summary contains safety information necessary for operation of the SBS Balance System for grinding
machines. Specific warnings and cautions are found throughout the Operation Manual where they apply, but
may not appear in this summary. Before installing and operating the SBS Balance System, it is necessary toread and understand the entirety of this manual. After reading the Operation Manual, contact Accretech SBS,
Inc. for any additional technical assistance required.
Warning: Observe all safety precautions for operation of your grinding machinery. Do not
operate your equipment beyond safe balance limits.
Warning: Failure to properly attach SBS Balance System or AEMS sensor components to
the grinding machine spindle, including the proper use of provided adaptor lockscrews, will result in safety hazard during machine operation.
Warning: Never operate a grinding machine without all proper safety guarding in place.
Caution:To avoid equipment damage, make sure the line voltage is within the range
specified for the system (see specification section).

Caution:Only qualified service technicians should attempt to service the SBS System. To
avoid electric shock, do not remove the cover of the Control Unit, or remove
cables, with power connected.

SBS AEMS System

1System Theory and Connection
The AEMS system consists of an electronic control and either one or two acoustic emission (AE) sensors. This
electronic control is packaged as a separate device card to be inserted in SB-5500 series Control units. The AE
sensors are mounted on the grinding machine and located to detect high frequency acoustic emissions
generated in the machine structure resulting from wheel contact in either the grinding or dressing process. The
level of these signals are monitored and referenced against known background levels at the same frequency,
allowing key events to be automatically and quickly detected on the grinding machine as they occur. These
events include: Initial contact of the grinding wheel to the dresser or work-piece (gap control), abnormal or
severe contact between the wheel and these parts (crash protection), or assurance of either a maximum or
minimum degree of wheel contact throughout the dress or grind cycle (process monitoring). These events arethen reported via both the hardwire and software interfaces, and the Control’s front panel display. Machine
CNC controls can be programmed to use this information to eliminate Gap dwell time, protect against damage
resulting from part crash, and monitor the quality of the grinding and dressing process.

2

SBS AEMS System

Control Unit Overview
The following is an overview of the control and interface features of the SBS SB-5500 Control Unit.
IVIS Software Interface
The standard unit is delivered with an LCD display panel and keypad. This manual describes the hardware
panel user interface for this product. IVIS Software from SBS can also be used as the user interface on somemachine CNC systems. All the basic concepts, data presentation, and parameter settings described are alsopresented in the IVIS interface but organized visually with some differences. Read the IVIS Operations manualin conjunction with this product manual when using the IVIS user interface.
Front panel controls

1

5

2

3

4

The Figure above illustrates the controls and indicators on the front panel of the Balance Control Unit. The
following is a description of these features:
1) ON/OFF. This button turns on the operating power for the system. When the system is turned on the unit
initiates a Power-On Display, and the green LED to the left of the button will be illuminated. When turned
OFF the unit is in the stand-by mode, and the green LED is blinking. This indicates power is connected tothe unit, but the control is inactive.
2) CANCEL BUTTON. Pressing this button will cancel the operation in progress, or the last selection or
entry made. Also clears any displayed error message.
3) LCD DISPLAY. The display is not a touch screen. Do not press on the display screen. The screen isused to display data and assign functions to the function buttons.
4) FUNCTION BUTTONS. Operation of the Control unit is accomplished via the four function buttons to
the right of the display. The menu bar area of the display, to the left of these buttons, assigns the current
function to each button. Use these buttons to make all operational selections.
5) SLOT STATUS LED. A three-color LED on the left side of the display shows the operational status of
the balancer card or other device cards installed in each of the four corresponding card slots.

SBS AEMS System

3

Power-on display
The Front Panel of the control can be removed and remotely mounted using a SB-43xx series cable. Whenswitched on in either configuration the Control Unit performs self-analysis which defines its status, and thesetting of operating parameters. Operator information is then shown on the LCD display following the startup
sequence described below:
1)

The company logo screen is displayed and lights on the front panel are illuminated to verify theiroperation. During this short time, the SETUP button is available. Pressing this button will enter setup
mode for the control.

2)After four seconds, the unit displays information about each balancer or device card installed,
indicating type of device and identifying information. To extend the time that this information isdisplayed, press any one of the function buttons while the slot information is on the screen. Eachbutton press will add six seconds to the display time, giving additional time to read the information.

3)

After two more seconds, the unit displays the initial operational screen for the control unit. The unit
will display either the SHOW ALL monitor screen, or one card slot’s main operating screen, whichever
was selected when the unit was last switched off.

4)

Any error conditions detected by the self-analysis are displayed as “ERROR - code” where code lists
the reference code of the error detected. For detailed description of error codes, see the “Displayed
Error Messages” section of this manual, or additional product instruction addendum manuals.

SETUP
At Power-on, press the SETUP button to enter this mode. The Setup screens allow the user to select:
1. Operational language
2. Ethernet settings
3. Profibus Station ID (if installed)
While in Setup mode:Press ENTER to save current settings on the screen and/or proceed to the next Setup screen
Press CANCEL to cancel unsaved settings on the screen and/or proceed to the next screen
Press START to cancel unsaved settings, exit Setup mode, and start operation.

The first Setup screen selects the language used by the control. Use the arrow buttons to scroll through theavailable languages. The second Setup screen allows Ethernet settings. Manual settings can be made or DHCP
can be enabled for automatic assignment. Use the arrow buttons to scroll through all the available Ethernet
settings and use the up and down arrows to change digits.
If Profibus is installed, the third screen allows selection of Station ID and other items. For more information
see the Profibus manual available at https://accretechsbs.com/.
Control unit without front panel connected
The control unit can be operated without a user interface attached, providing the monitoring functions via the
CNC, Profibus, and Software Interface. The user interface is only required for setting all parameters.
4

SBS AEMS System

System Installation
System Connections
The back panel of the SB-5522 AEMS card is shown installed in slot 1 (S1) of the SB-5500 control below.
The device can be identified by the two 4-pin circular DIN connectors, for connecting the acoustic sensors,
and a female DB-25 for Digital I/O connections. The first sensor position at 9a is SENSOR 1 ( ) and can beused to monitor both M1 and M2 (described in following section). The second sensor connector at 9b is
SENSOR 2 ( ) and can only be used to monitor M2. In cases where only one sensor is to be used, connect
to SENSOR 1.

1)

POWER SUPPLY. Connection for line power input (AC input model shown)
Caution: Before applying power to the Control, make sure the supply voltage is within specified
range.
AC Input Models: 100-120V AC, 200-240V AC, 50-60 Hz
DC Input Models: 21 VDC to 28 VDC. 5.5A max at 21 VDC.
2)FUSE HOLDER. Contains the line fuses. AC Input Controls use (2) 5x20 3A time lag, DC Input
Controls use (1) 5x20 6.3A.
3)
ETHERNET. Provides TCP/IP and UDP Connection to host device, such as CNC Controller or IVIS.
4)USB CONTROLLER. Allows USB flash drive to be connected for Firmware update.
5)
USB DEVICE. Provides connection to another USB 2.0 host, such as a CNC Control.
6)
PROFIBUS. Provides connection to Profibus DP host device, such as CNC Control (option).
7)
REMOTE. This DB-15 connector receptacle is a duplicate of the connector on the font side of the box,
used to connect the optional cable for remote front panel installation.
S1-S4 DEVICE SLOTS. Numbered Slots are available for installation of device cards supplied by SBS.
Unused Slots are covered with blank panels.
AEMS card rear panel connections
The control comes standard with one card, and others can be purchased and added to the control unit asrequired. Each card has three connections on the rear panel of the control.
9a)
9b)
9c)

AEMS SENSOR CONNECTION. Connects to an AEMS Sensor.
AEMS SENSOR CONNECTION. Connects to a 2nd AEMS Sensor (optional).
HARDWIRE INTERFACE. Standard DB-25 connector for connecting the individual AEMS card in
the control to a grinding machine controller. A complete description of this interface is given in the“Hardwire Interface” section.
SBS AEMS System

5SB5580
The SB-5580 is a smaller chassis version of the SB-5500 control series, which has been designed for the spaceconstraints of mounting inside the electrical cabinet of the grinding machine. It supports four device cards ofthe same series (S1-S4), and requires power input of 24 VDC, with the same specification as SB-5500. The
panel connectors are the same and are labeled in the same way as SB-5500 above, except for the USB DEVICE
connector which is located on the bottom of the control instead of the back panel.
A 3-slot version is available and both sizes are also available in a Profinet configuration. For the Profinet,
connection 3 is maintained for the standard Ethernet communications and connection 6 is changed to an
Ethernet connector for the Profinet communication. See the Profibus manual.

SB-5575 – 3 slot version
Profinet configurations:SB-5576 – 3 slots
SB-5581 – 4 slots
SB-5580 – 4 slots
Firmware Update and Save or Recall of System Settings
Insert a USB flash drive into the USB CONTROLLER connection on the rear panel. You will be presented
with an English language menu with icons as described following. If this menu does not display, ensure thatthe control is not in a menu screen, then re-insert the USB drive.
Save Settings
allows user settings for each installed device card in the SB-5500 control to be saved toindividual files on the USB drive. Settings can be backed up for future reference, or to be copied from one
control to another. When this button is pressed, a folder named SAVE is created on the root of the USB drive,and files are saved at that location for each device card in the control. Any existing files for the same devicecard type(s) in the SAVE folder will be overwritten.
Recall Settings
allows the saved files to be used to update settings on the same or another connected
control. This process will overwrite all existing settings on the connected control unit and instead make thesaved settings active. A folder named RECALL must be created by the user at the root of the USB drive.
Device card files must be copied to that location using a separate PC when the user wants to use them in therecall process. When this button is pressed, any files located in the RECALL folder will be written to thecontrol unit. SBS recommends erasing the RECALL folder after use to ensure files are not later accidentallyused.
Firmware Update. The latest firmware for the control unit and all associated device cards is available in a
zip file downloadable from the SBS website: https://accretechsbs.com/. Included in the zip file is a detailed
readme file in English which describes the firmware versions included and covers the update process.
Important - It is important that all installed device cards, the control display PCB (5547Rxxx.sbs) and the6

SBS AEMS Systemmain PCB (5510Rxxx.sbs) are all updated to the latest firmware version included in the zip file to ensure fullfunctionality.
Acoustic Sensor Location
Choose an appropriate sensor location on the grinder for testing. The Sensor must be mounted to the machine
casting or some other rigid machine structure. Do not mount acoustic sensors on thin or loosely attachedmachine components such as wheel guards. The mounting spot should be reasonable flat, and must be free of
foreign matter such as swarf. Paint removal is advisable but not required.
The critical issue to be considered in placing the sensor is acoustic transmission quality. The sensor should belocation on a rigid part of the grinder so that the high frequency noise resulting from contact between the wheel
and work part, or between the wheel and dresser unit, will travel to the sensor with minimal loss of signal.
Signal loss will occur both with distance traveled through the machine structure, and especially with each partto part mating junction in the machine. What is desired is a short path of travel for the acoustic signal, throughas few parts of the machine as possible, with all parts of this travel path being rigid, solid, and closely coupled
and firmly mated portions of the machine structure.
For a Bolt-on sensor, it is recommended to use superglue (Loctite 401 or equiv.) to try some different mounting
locations, until the best location is found.
It may be possible to mount one AEMS sensor on the spindle housing, near where the balancer sensor would
be located, and use this location for monitoring both Dressing and Grinding. If this does not work on aparticular machine structure, the alternative is to mount one sensor on the dresser structure for dressing
monitoring, and another sensor on the tailstock, or other rigid portion of the part holding structure of themachine, for grinding monitoring. Two sensors can be connected, but only one is in use at any time by the
AEMS system.
AE Sensor Types
A variety of Sensor configurations are available to fit your installation requirements. The Main types of sensors
are pictured below. Each sensor type is available in various models and the user should consult the SBS Productcatalog for details on all available models.

Bolt-on Sensor

Non-Contact Sensor
Fluid Sensor

Bolt-On Sensor – The sensor is attached by a screw directly to the machine structure, nearest as possible tothe contact point between the grinding wheel and the work piece or the wheel dresser.
Non-Contact Sensor – The sensor comes in two parts to allow mounting directly to the rotating work spindle
or dresser spindle. A rotating part is mounted to the spindle to pick up the AE signal from wheel contact. A
non-rotating part is mounted directly opposite the rotating part, where the AE signal is detected and transferredto the AE monitor.

SBS AEMS System

7

Fluid sensor – The sensor allows detection of AE signal direct from the work piece or the wheel. A fluid
stream (usually the filtered and pressure regulated machine coolant) is directed to flow onto the target area.
The AE signal transmitted up the fluid stream and is detected by the sensor.
Balancer mounted Sensor – The sensor is integrated into Non-Contact mechanical external or internal SBS
balancers.
SB-5522-6 modelThis is a higher capability model variation of AEMS card. All operations are common to the SB-5522 as
described in this manual, with the exception that instead of a maximum of two AE sensor connections being
supported, up to six sensors can be connected and used. Related key functional changes for this model are
listed in the manual where relevant.
SB-4100 optional cable adapter “Y” can be used to connect two AE sensors to each one of the SB-5522-6 card
input connectors. Using two SB-4100 therefore allows 4 sensors to be attached to the SB-5522-6. The SB4100 has two legs labeled A and B to which AE sensors are connected. The single connector end of SB-4100
must be directly installed to the SB-5522-6 AE input.
SB-4100
See drawing for more details

The SB-5522-E optional slot extension connector panel (not shown) can be used to add 2 additional sensor
inputs (for a total of 6). This expansion panel takes up one slot in the control unit, and it must be installed in
the control unit slot which is one position number lower relative to the slot where the SB5522-6 card isinstalled, e.g SB-5522-6 in S2 and SB5522-E in S1. Using this connector panel allows up to 6 total sensor
connections.
Sensor 1

9a on SB-5522-6 direct

A-leg of SB-4100

Sensor 2

9b on SB-5522-6 direct

A-leg of SB-4100

Sensor 3

B-leg of SB-4100 via 9a on SB-5522-6

Sensor 4

B-leg of SB-4100 via 9b on SB-5522-6

Sensor 5

9a on SB-5522-E direct

Sensor 6

9b on SB-5522-E direct

SB-4100 and SB-5522-E only function with SB-5522-6, not with standard SB-5522 card.
SB-5519 model
1. This is the SBS AEMs Basic product. All operations are the same as described in this manual, with thefollowing limitations and exceptions:2. This model has no hardware front panel interface and can only be operated via IVIS interface software. A
message is displayed on the control panel “User Interface via IVIS Software Only”.
3. Only 2 sensor inputs are supported, designated by M1 and M2.
4. Provides only one evaluation (Limit G), with no other limits available.
5. Does not support multiple Jobs, so only provides 2 saved configurations (M1 and M2). Save/Recall does
function for this one set of saved configurations.
8

SBS AEMS System

6. Does not support user configuration of AE frequency band 8, only fixed bands 1 thru 8 are available for
setup.
7. Only (1) SB-5519 can be supported in any SB-55xx series control unit. Adding a second card of this typewill disable both cards.

Control Unit Instructions
Explanation of M1 and M2
Separate monitoring parameter sets (M1 and M2) are provided for monitoring the results of distinct processeson the grinder. The number of available parameter sets can be extended by use of the JOB# Menu setting whichallows up to 16 different JOBs to be created, each with its own assigned M1 and M2 parameter set. A total of
up to 32 distinct work processes can therefore be learned and monitored by the system. SB-5522-6 note: This
product has a user settable menu option (32 JOBS) to disable the M1/M2 function and instead treat each saved
configuration as a separate job (1-32). A work process is distinct if there is any variation in the contributing
factors that would influence the AE signal intensity generated from wheel contact. This would include a change
in any of the following: AE sensor location, grinding wheel size or type, dressing unit, work piece, feed rates,
wheel RPM, and coolant type or flow. Setup parameters are all stored separately for each parameter set. M1
will always be associated with sensor 1 ( ), and M2 will be associated with sensor 2 ( ) if connected, orwith sensor 1 when only one sensor is installed.
Main Screen Operation
Go to the SHOW ALL menu for the control unit, by pressing the SHOW ALL button from any card main
screen. Select the AEMS card to be displayed.
This is the main screen of the AEMS system. A scrollinggraph of the AE signal is displayed, with the current AE
signal level shown as a numerical value at bottom left. The
current Graph Time (number of seconds of data represented
by the AE graph) is shown at bottom right. The Gap limit
shown in green, limit 1 and limit 2 shown in blue, and the
Crash limit shown in red are all adjusted using the
SETUP\LIMIT menu. Each limit is labeled at the right of thegraph with a corresponding Limit label (G, 1, 2, C). Theselimits can be adjusted to any position and in any order onscreen.
The screen can be formatted to show signal and the limits on either a Log (logarithm) or a Linear vertical scale.
The default setting is Log scale. See Screen Scaling on the M1 or M2 Parameters Menu
When the current AE signal exceeds any of these set limits, the corresponding indicator symbol (G 1 2 C) is
momentarily displayed to the right of the current AE signal level at bottom left of the screen. The bottom of
the graph is set during Learn to a signal value equal to 80% of the learned Air value (see Sensor Learn Process).
With no Learn process, then zero signal is set as the bottom of screen scale.
The Crash limit initially is set at the top of the screen scale after a Learn cycle. The top of the screen scale will
be set just below the usable hardware range of the amplifier. It is possible to adjust any limit higher than the
top of screen by using screen Zoom and Pan settings, or by adjusting the system Gain setting. When any Limit
has been adjusted off screen (higher than top of screen) then a “+” sign is displayed above the highest Limitlabel (G, 1, 2, C) at the upper right of the graph.
SBS AEMS System

9Increasing the Gain setting can raise a Limit setting beyond the functional range of the hardware, and will
result in the signal amplification hardware being maxed. This Error condition is indicated on screen by theindicator symbols (G 1 2 C) next to the signal value at bottom right being replaced by ****. In this condition,
Error D – Limit Relay error will be displayed whenever the user switches to this main screen from a menu
screen.
The SHOW ALL button simply returns the user to the system-wide menu screen, for monitoring all card
channels installed in the SBS control unit, or to select another channel for detailed interface.
M1/M2 button toggles view and operation between these two modes. SB-5522-6 note: When the 32 JOBS
configuration is selected, this button is disabled and not displayed. The two separate monitoring modes “M1”,and “M2” are identified with a corresponding screen label in the blue identification bar at the top of the screen.
The currently selected mode is always shown in the upper screen label, along with the current channel nameassigned to the AEMS card.
The START/STOP toggle button on the bottom right of the screen starts and stops the display from scrolling
real-time acoustical signal levels currently being monitored. It is possible to stop or freeze the display, so thattarget levels can be adjusted against recent signal levels or for review of an event by the operator. Even when
the screen is not scrolling, the unit will continue to monitor for gap and crash events, and provide their status
via the CNC Connector.
SETUP
Pressing the SETUP button from the main screen allows theoperator to access:
MENU screen – Revisable parameters for operation of the
SystemLIMIT screen – On-screen repositioning and editing of theLimit levels, shown relative to the current AE signal.
Screen – Provides for manual adjustment of certain
parameters normally set during the Learn process.
MENU screen
The Menu contains the user selectable operation settings for
the AEMS system. Most parameters are stored independently
for the two separate monitoring modes M1 and M2 and foreach Job. These parameters are accessed under the M1PARAMETERS and M2 PARAMETERS menu. SB-5522-6
note: When the 32 JOBS configuration is selected, this menu
option is renamed “Parameters” These parameters are
discussed in detail under the following AEMS Operation
section of this manual.
The other following menu items listed are general settings orfunctions for the general operation of the AEMS card, and are not specific to a certain M1 or M2 selection. If
Job# selection is enabled (not set to OFF), then the Job# menu item will move to the first position in the menu
list, to better facilitate switching between Jobs.
CNC Signal Time
Sets the minimum hold time, in milliseconds (msec.), that output contacts are opened or closed to indicate an
event signal. Important – The purpose is to make an event's signal last long enough to assure signal
detection by the machine control used. The factory default settings are 1 msec, but PLCs or similar devices
10 SBS AEMS Systemoften will monitor at timed intervals of about 5 msec. In such cases the signal time must be set to exceed thepolling cycle time. Affects Gap, LIM1, LIM2, and (if not latched) Crash signals of the CNC interface.
To change settings, select SETUP from the Main screen. From the Setup screen, select MENU with thecorresponding button, then select CNC SIGNAL TIME from the menu. The two screens that follow control
the ON and OFF contact hold times. Times can be set from 1 to 999 msec.
To set the desired time for the N.O. contact closed time, use the left arrow button to select digits, and the up
and down arrow buttons to change the selected digit. Press ENTER to accept the entry and proceed to the OFFTIME screen. In the same manner, set the time that the N.C. contact will be closed and press ENTER to save
selection and advance to next option.
CNC Crash Latch
OFF Crash not latched, subject to ON/OFF times like Gap,
LIM1, LIM2.
ON

Crash condition closes the Crash N.O. contact until it
is reset by: (1) RESET CNC input (2) HOST error clear(3) CLEAR button when Crash error screen isdisplayed.

This menu option under CNC Signal Time sets how the Crash
output signals will react to crash conditions. Use the up anddown arrow buttons to toggle the cursor between the OFF or
ON selections. Press ENTER to save selection and advance to next option.
CNC Function – Stop/Start
Menu option under CNC Signal Time activates or deactivates
CNC control of the screen STOP and START functions. Thisfunction is always controllable via the front panel screen andmenu buttons (MENU) and by the host port. When this option is
set to MENU+HOST+CNC, the function of two inputs on the
CNC port is modified to allow control of screen STOP and
START. The inputs used for this control are the M1 and M2
inputs (see CNC input section for details). Press ENTER to save
selection.

Channel Name
Selecting the CHANNEL NAME menu item will display an entry screen. Use the right arrow button to selectcursor position, and the up and down arrow buttons to toggle through the alphanumeric list to label the AEMS
card device. Custom labels can be used to identify each card device installed in the SBS control unit with thisfeature. Up to Five characters can be used to label the AEMS card. Press ENTER to save selection

Menu Entry
This selection on the menu list provides for use of a standard access code for menu protection. Setting thechannel to the protected mode denies access to the menu list unless the access code is entered. This setting
ensures that system settings will not be accidentally compromised. The screen displays ENABLED when Menu
access is available, and PROTECTED when menu access is controlled by the access code. Function buttons
are assigned the numbers 1, 2, 3, and ENTER, which are used to input the access code. The standard accesscode is 232123. Once the code has been entered and the ENTER button has been pressed the MENU selection
is protected. Re-entry to the menu list will now require entry of this code. The message MENU ACCESSPROTECTED will be displayed notifying the user that the menu is password protected, and the user will be
SBS AEMS System 11

given the opportunity to enter the code. Entering a code other than the correct number will produce a message
INCORRECT CODE ENTERED
TRY AGAIN/ CANCEL.
To disable menu protection, enter the correct code to access the menu, select the MENU ENTRY item fromthe menu, and enter the code again to turn off the protection. The display for MENU ENTRY will display
ENABLED when protection has been disabled.
Job Configuration
SB-5522-6 note: This menu option exists for this product version only. It allows selection between the default
32 JOBS configuration (M1/M2 is disabled), or the 16 JOBS + M1/M2 configuration. This setting allows
M1/M2 behavior for this product for continuity with the other AEMS card products.
Factory Settings
Allows restore of all general Menu settings to factory defaults. Does not affect M1 or M2 Parameters.
Job# (Job No.) - Multiple Parameter Sets
This menu allows multiple job setups to be stored for futurereference and easy retrieval. This is useful in cases wherechanges in the workpiece, grinding wheels, or other distinct
variables in the grind or dress process might change the
AEMS system settings required to correctly monitor thesedifferent jobs.
The Job# setting is optional, and is by default set to “OFF”.
In this state only two sets of parameters are stored, one eachfor M1 and M2 mode. By Selecting the MENU option JOB#,
the user will be able to setup and save up to 16 separate pairsof parameters, an M1 and M2 pair for each job number, providing total storage of 32 separate setups. When
Jobs are in use, the current selected Job No. (01 to 16) is displayed at top of screen in the blue identification
bar. The JOB# menu item will also move to the top of the MENU list, making selection of various job numbers
more convenient. SB-5522-6 note: When the 32 JOBS configuration is selected, the M1/M2 function isdisabled and instead each saved configuration is treated as a separate job (1-32).
Important – JOB# selection can be made via the Software or Profibus interfaces on the Control but cannot bemade via the Hardwire interface. The Hardwire interface can only select between M1 or M2 for the current
JOB#. Once a user has selected an individual JOB#, it will remain the active Job until changed.
When new Jobs are created for the first time, the current settings from M1 and M2 in Job 1 are used as default
settings for the new Job. Once a Job has been added, it must be setup for proper use by running a Learn Cycle
and making any other needed parameter settings.

M1/M2 normal configuration
SB-5522-6: 32 JOB configurations

12 SBS AEMS System

After selecting the JOB# (Job No.) option from the MENU
screen, the user simply enters the desired reference job
number on the following screen, using the up and downarrows to select the job number desired, and ENTER to makethe selected job No. setup parameters active. Setup for eachjob would proceed normally with a LEARN cycle, and setup
of limits as required for this particular job.
Important – all separate JOB# parameter sets will initially
include factory default settings and must be individually
setup before use.
The ability to switch between JOB# settings is allowed evenwhen system MENU ENTRY is protected. When the user
initially enters the Menu, a default entry of “JOB#” isdisplayed on the menu entry password screen, as shown.
Entry of a number will allow the user to operate the password
screen normally. Entering the access code will enable fullmenu entry. Pressing ENTER to accept the displayed“JOB#” code will grant the user access to the JOB# selection
screen only.
Limit Screen
The LIMIT button displays onscreen Limit editing. From this screen select the limit you want to edit. Pressing
the C, 2, 1, or G button allows the selected limit to be repositioned on the screen.
Limit Edit
This screen allows the limits to be repositioned relative to thedisplayed AE signal level. The limit selected is displayed inyellow and flashes. The corresponding signal level of thecurrent limit position is shown in yellow at bottom right. While
editing the C limit, the corresponding C limit Sensitivity
setting W(x.xx) is also shown at bottom middle of the screen.
This number represents the C limit position as a multiple of the
WORK level recorded during the last sensor Learn cycle.
When editing the 2, 1, or G limit, the corresponding G limit
Sensitivity setting A(x.xx) is also shown at bottom middle ofthe screen. This number represents the G limit position as amultiple of the AIR level recorded during the last sensor Learn
cycle. Sensitivity is the saved value for the G limit, so if a new
Learn cycle is performed and the system gain is changed, thelimit will still be positioned at the same sensitivity level. The
limits can be positioned anywhere onscreen. The bottom of thescreen represents a signal level of 80% of learned Air value.
Limit Signal Level
G Limit Sensitivity

SBS AEMS System 13

Screen
The first three items on this screen are available for use only
when screen Plot Scaling is set to LINEAR mode. When thescreen is set to Log mode, access is only provided to the Zero
Offset function.
screen Zoom – Use up and down arrow keys tochange screen Zoom. Zoom allows the screen
vertical scale and resulting view to be zoomed in(and also adjusted back out) to focus on a particulararea of interest, for instance on low signal levels.
Zoom will allow the top portion of the screen to be
adjusted off screen.
screen Pan – Use up and down arrow keys to change screen Pan. Pan allows the screen to be shiftedin view vertically relative to the current screen zoom setting. If no screen Zoom has been set, thenthe screen is shown full scale, and therefore no Pan is possible.
signal Gain – Use up and down arrow keys to change signal Gain. Allows manual setting of the Gainlevel used to measure signal. Increasing the Gain much beyond the Gain set by the Learn process
will raise the C Limit beyond the usable range of the hardware, resulting in Error D.
Zero Offset – On this screen adjust the Zero offset
which can be used as an offset for the vertical scaleof the signal display. Only when the signal rises
above the offset level is signal displayed. Press SET
button to set the offset value to the current
unadjusted AE signal level. This value is selected at
the moment the SET button is pressed. In the screen
shown at right, 0.000 is displayed as the current
Zero offset setting, which is displayed above the
CLEAR button. Pressing SET would change theoffset value to the current signal level (0.306, assuming the signal is constant). This number would
then be displayed as the current Zero offset above the CLEAR button, and all signal display values
would be shifted by this amount. CLEAR button will eliminate any saved setting and return the Zero
offset value to 0.000. When a zero offset is made the Limits remain unchanged in position relative
to the signal level. This means that the although the vertical scale has been changed, the offset value
is subtracted from each limit for display to ensure that the limits remain relatively in the same position
to the AE signal level. Important – Use of the Zero offset feature can potentially move limit settings
above the usable hardware range, causing an Error D condition. If this occurs, reduce the zero offset,
or reduce the system gain to compensate.

14 SBS AEMS System

AEMS Operation
M1 and M2 Parameter Menu
This menu covers those operating parameters which are saved specific to each M1 and M2 mode, and eachseparate Job.
Learn Cycle
The Learn Cycle is a process to assist with setup for proper
operation. Initiating a learn cycle allows operating
parameters to be determined and properly set for eachdistinct work process to be monitored (M1/M2/Job). The
learn cycle will set the system signal gain and overallmeasurement scale, as well as help determine which of theeight frequency bands should be selected for best results.
During the learn cycle the background AE signal levels foreach of the eight frequency bands will be compared with thesignal levels that occur during normal dressing or grinding
contact, and the frequency band with the best Work/Air signal ratio will be suggested as the frequency to bemonitored. Important - If the results of the Learn process produce Work/Air ratios that are 1.2 or below, thenthe system has been unable to see any significant difference between the AE signal during wheel contact andprior to wheel contact. This is usually a result of either an improperly performed Learn cycle, or a poor AE
sensor location or installation.
A separate learn cycle must be run for both M1 and M2, and resulting parameters are stored separately for eachmode and each Job. The learn cycle will properly set up the gain and other parameters needed for correct
operation in the selected monitoring mode. After pressing SETUP to enter the setup menu, press the MENU
button, followed by selecting either M1 PARAMETERS or M2 PARAMETERS, depending on the currently
selected mode. Next select LEARN CYCLE to activate the learning cycle for the mode selected.
Learn AIR
The first window will show eight bar graphs, representing
the current signal levels for each of the separate frequency
bands covered by the unit. The screen is titled AIR PASS.
The bar graphs will rise and fall as signal levels change. The
VIEW DATA button is only available if a previous Learn
Cycle has been run for the selected parameter set. It allows
the user to view the Data screen results of the previous
learning cycle run, and from there select an alternate
frequency band based on those results.
The first step in performing a learn cycle is to learn the background or AIR signal level. To do this the machine
should be operational, with all systems running, but without wheel contact with the part or dresser. Once thegraph has settled, press START to begin learning. Move the wheel though a mock grind or dress movement,
without wheel contact (the bar graphs may rise a little during this process). When finished, press the ►►button to store the maximum background/AIR levels recorded in each frequency band, and to move to the next
phase of learning.

SBS AEMS System 15

Frequency bands defined
The eight operational frequency bands are defined to cover a wide range of possible applications, while still
covering adequate bandwidth for good signal acquisition.
Band No.

1

2

3

4

5

6

7

8

Center Frequency kHz

110

220

330

440

550

660

770

880

Bandwidth kHz

124

124

124

124

124

124

124

124

Frequency Band Selection and Short Work Cycles
The Learn Process is shown here as it is normally run using all eight frequency bands. When a work or dress
process is very short in duration (3 seconds or less), it may be difficult to capture good signal data for all eightfrequency bands during the Work learn process. Running multiple part or dress cycles while remaining in learn
WORK mode will accumulate Work data across all eight bands. This method should be used for shortpart/dress cycles. The best frequency band to be used for an application is a function of the machine structure,sensor location, and other process factors which often do not change much from one process to the next on thesame grinder. Once the best frequency band for an application is determined, it is no longer necessary to use
this method or running multiple part/dress cycles. The SETUP button from this screen will access a menu
allowing the user to select a single band for the Learn Cycle and subsequent operation.
When a single band is selected for use, only that band will display data on the Learn AIR, Learn WORK, andLearn
Set Frequency Band 8
To provide additional flexibility in operation, when frequency Band 8 is selected it can be customized tooperate with a user defined frequency band. This customization may be helpful in preventing problem noise
sources from being included in the evaluation, or when operation is best focused on a range that does not fit
with one of the 8 predetermined frequency bands. After selecting Band 8 from the Band Selection menu, theuser can enter a desired Center Frequency for the band (13 to 900 kHz), and a desired bandwidth from a list ofavailable options (10, 14.4, 20.5, 29.4, 42.2, 60.4, 86.6, 124.0).
Important – Care should be taken when setting the bandwidth. It is possible to set the band such that part ofthe bandwidth falls below zero and is therefore off scale. This will allow more noise into the measurement.
Also the narrower the bandwidth is set, the lower the total AE signal will be measured. This is because AE
signal generation from wheel contact is very broad in frequency and so narrowing the bandwidth monitored
will likely reduce the total signal power.
SB-5522-6 Sensor Selection
For the SB-5522 card the sensor number assigned to the currently selected parameter set (Job and M1/M2 ) isdisplayed in the upper right corner of the Learn screen as shown. SB-5522-6 note: An additional button isdisplayed at this location, showing the currently assigned sensor (to). Pressing this button will accessa menu allowing the user to select from a list of all currently connected sensors, to select the desired sensor to
be used with the current parameter set.

16 SBS AEMS System

Learn WORKThe screen should now be reversed in color from theprevious screen, and is titled NORMAL WORK PASS. The
operator should now initiate normal wheel contact with the
dresser or part, and complete one or more cycles, until thebar graph is stable. The “-” symbol on each frequency bandbar graph will change to a “+” symbol when significant
signal increase is measured over the AIR level recorded forthat band. This process records the maximum signal levels
during normal grinding or dressing, so the bar graphs will
always show the highest levels recorded during this current
learning cycle. Once the bar graph has stabilized, press the ►► button to store this information and display
the resulting data screen.
Learn Data screen
The data screen will show results of the Learn cycle,
including AE signal WORK and AIR levels recorded for all
eight frequency bands. The resulting ratio between WORK
level and the background AIR level (W/A) is displayed aswell as the signal gain setting, and the Crash Sensitivity(C.S.), which is a factor of how much higher the Crash limit
can be set above the normal WORK signal. The bands arepresented in 1-8 order. Bands with poor results (low C.S.
and/or low W/A) are displayed in red color. Bands with goodresults are displayed in blue. The frequency band selected asby the control unit for optimal monitoring is highlighted. This selection is based on the highest W/A ratio,
within all results with good results (blue). Press ENTER to accept this choice, or override the AEMS systemselection by choosing another frequency band with good results, and then press ENTER. Press EXIT twice toexit the setup menu, and return to the Main Screen.
Verify Normal Operation
The Main Screen can be stopped or started by toggling the lower right-hand button. When running, the screen
will display real time acoustic level information, as it occurs. When stopped, the screen shows the last time
period recorded. Verify that the heading for the screen reads either M1 or M2 and that the mode selected iscorrect. When the wheel is not making contact, the screen should show signal levels below the lowest limit
line, near the bottom of the screen. If the signal level is above the lowest limit set, you should repeat thelearning cycle or move the lowest limit to achieve proper results. The C (Crash) limit level is set
automatically during the learning cycle and can be adjusted from this setting manually using the LIMITS menu
setting.
Initiate wheel contact with the dresser or work-piece, and observe the running display. You should see theacoustic levels falling between the 1 (LIMIT 1) and 2 (LIMIT 2) levels during full contact, and dropping off
below the G level between passes. The 1 and 2 levels usually are set to indicate the normal minimum andmaximum levels for grinding or dressing. These levels can be adjusted by the operator as needed to bracket
the normal operation range. If results are not as described, try the following.
a) Run the Learn process again. Ensure that AIR and WORK signal levels recorded are corresponding
correctly to timing of the grind or dress cycle. AIR must be recorded only when the wheel is not
making contact. WORK must be recorded with normal amount of wheel contact and for a longenough duration to capture good signal. If Work cycles are very short, try limiting the Learn cycle toa selected frequency band for best results.
SBS AEMS System 17b) Verify the AE sensor is well mounted. Try an alternate AE Sensor location, and re-run the LEARN
cycle. Try moving the sensor closer to the point of wheel contact on the machine structure, as
described in Acoustic Sensor Location section of this manual.
Graph Time
Graph Time adjusts the time scale the AEMS system uses to display data on the screen. The Graph time set
represents the number of seconds taken to scroll across the display screen, so the width of the screen thenreflects the data taken in this same time period. The default time is 11.4 seconds and can be set up to 365
seconds. A longer Graph Time will display data over a longer period of time, but at a lower resolution.
Graph TypeGraph Type switches the AE signal graph between a filled graph or an unfilled line graph.

Peak Detect
When this setting is turned ON, peak AE signal levels are
displayed on the Run View screen. Peak values are definedas the highest signal value seen during the period of time thatthe signal rises above the G limit, and then falls again below
the G limit and remains below that limit for a minimum of
10 effective screen pixels of display. The effective screen
pixel size (each discrete displayed signal level) will vary insize based on the screen graph time.
Frequency Band
Allows the manual selection of the currently selected Frequency band used for monitoring AE signal.
Important - when selecting another Frequency band, signal Gain and other the other parameters normally set
via the Learn Cycle must also be set or adjusted for proper system operation.
Plot Scale
Select Log (logarithm) scale or Linear scale for the vertical scale of display signal level and Limit positions.
A log scale shows higher resolution at the lower part of the scale and reduces in resolution as signal increases.
This allows low signal levels to be displayed well, while keeping most high signal level signals onscreen. A
linear scale assigns equal numerical value to all portions of the signal scale. The linear scale setting is needed
to enable manual settings for screen Zoom, screen Pan, and system Gain. The screen scale is set by default toLog.

18 SBS AEMS System

Hardwire Interface
Interfacing the SBS System with a CNC or PLC machine controller is supported via a hardwire interface orsoftware interface. The hardwire interface is provided via a standard DB-25 connector located individually on
the rear panel of the AEMS Card, while the Software interface is supported via either the USB or Ethernet
connections, which are common to the whole control unit. Because of the many possible variations andconfigurations of cabling required for such an interface, it is left to the operator to supply the necessary cable.
When designing an interface for the SBS System, it is important to understand that the grinding
machine's controller must operate the SBS System. It is not possible for the SBS System to control thegrinding machine.
Carefully read this entire manual before attempting to interface the SBS System with any machine controller.
Sections covering the interface of other SBS products installable in the SBS Control are covered separately inthe manual addendum for such products.
Hardwire Control Interface – AEMS Card
The hardwire interface consists of three sections:interface power supply, the inputs, and the outputs.
The interface power supply is provided exclusively
for use with the hardwire interface inputs. It consistsof three common pins and one output pin. The
common pins are internally connected to chassis andearth ground. The output provides a maximum of 30
mA at approximately +15VDC. Any external power
used for interface I/O must be from a SELV (Safety
Extra Low Voltage) source or supply.
The three inputs provide noise immunity androbustness. The inputs are activated by being pulled
high, either by connection to the SB-5500 hardwire
interface power supply output or by connection to acustomer supplied signal. Activating the inputs
requires at least 8 mA at a voltage between 10 and 26
volts, AC or +DC, referenced to the SB-5500
hardwire interface power supply common. The
inputs are deactivated by removing the connection to
the power or signal source.

DB-25 Connector
For SB-5522 AEMS
SUP-COM
A-OUT
M1-R
M1-NO
M2-R
M2-NO
SUP-COM)
CRASH-NC)
LIM1-NC
LIM1-NO
CRASH-NO
GAP-NO

LIM2-NO
LIM2-R
LIM2-NC
FPI
RESET
M1
SUP-OUT
M2
LIM1-R
CRASH-R
GAP-R
GAP-NC

SUP-COM

Shell (Shield)

The four outputs consist of optically isolated, single-pole/double-throw solid state relays. These solid-state
relays may be used to supply an output signal by connection to a voltage source supplied by the customer. The
output contacts are electrically isolated from all other circuits and are rated for 24 Volts DC or AC, 50 mA
maximum. Inductive loads must be protected against flyback to 50VDC.
The three contacts of a single-pole/double-throw solid state relay are referred to as “normally open”, “normallyclosed” and “common”. The term “common” in this sense does not imply connection to power supply
commons. The term “return” is used below to indicate the common contact of the output.

SBS AEMS System 19

Input Pin Names and Functions
Pin#

Name

Description

17

FPI

Front Panel Inhibit- While this input is held active, most operator actions at the front panel
keypad are disallowed. Specifically, the SETUP button, the M1/M2 button, and the
START/STOP Button are disabled. Still enabled are the Power button and the SHOW ALL
button. This affects the operation of this AEMS card only.

18

RESET

Crash Reset. The crash status latch will be reset following the rising edge of a voltage
applied to this input. A crash that occurs while voltage is applied will not be reset. The
voltage must be removed and reapplied. This input is ignored if the CNC Crash latch is set
to OFF.

19

M1

Activate this Input to select M1 mode and initiate AEMS operation using the M1parameters. Selection will be made following the rising edge of a voltage being applied tothis input.
Option: When STOP/START CONTROL SOURCE is set via the menu to allow CNC
control of the screen STOP and START functions, this input will provide control of thisfunction also. When this mode is selected, the screen will continue to scroll (with new data
being displayed) only while this input is held active. Following the removal of voltage fromthis input, the control card will STOP the display, until voltage is applied again.

21

M2

Activate this Input to select M2 mode and initiate AEMS operation using the M2 parameters.
Selection will be made following the rising edge of a voltage being applied to this input.
Option: When STOP/START CONTROL SOURCE is set via the menu to allow CNC controlof the screen STOP and START functions, this input will provide control of this function also.
When this mode is selected, the screen will continue to scroll (with new data being displayed)
only while this input is held active. Following the removal of voltage from this input, thecontrol card will STOP the display, until voltage is applied again.

Output Pin Names and Functions
Pin#

Name

Description

2

A-OUT

Analog signal output (0-10V, 2mA max.) referenced to SUP-COM. See following
section for further details.

4

M1-NO

Closed to indicate the M1 parameters are in use. note: If an error code condition
occurs on the control, both Pins 4 and 6 are closed at the same time. Both pins open at
the same time indicates the control is either OFF, or in a LEARN cycle.

3

M1-R

Common return connection for the M1 output

6

M2-NO

Closed to indicate the M2 parameters are in use. (see note under pin #4).

5

M2-R

Common return connection for the M2 output.

11

CRASHNO

Closed to indicate a crash condition. Latches if the CNC crash latch is on.

8

CRASH-NC

Closed whenever Crash-NO is open (no error condition detected). It is also closed
when power is off and during standby, initialization, self-test, and learn modes.

23

CRASH-R

Common return connection for the Crash output.

12

GAP-NO

Closed whenever the AE signal is at least at the Gap setting (wheel contact detected).

25

GAP-NC

Closed whenever GAP-NO is open indicating that the AE signal is below the Gap
setting. Also closed when power is off, during standby, initialization, self-test, and learn
modes.

20 SBS AEMS System

24

GAP-R

Common return connection for the Gap output.

10

LIM1-NO

Closed whenever the AE signal is at least at the level of the LIM1 setting.

9

LIM1-NC

Closed whenever LIM1-NO is open indicating that the AE signal is below the level ofthe LIM1 setting. It is also closed when power is off and during standby, initialization,
self-test, and learn modes.

22

LIM1-R

Common return connection for the LIM1 output.

14

LIM2-NO

Closed when the AE signal is at least at the level of the LIM2 setting (excessive grindpressure).

16

LIM2-NC

Closed whenever LIM2-NO is open indicating that the AE signal is below the LIM2
setting. Also closed when power is off, during standby, initialization, self-test, and learn
modes.

15

LIM2-R

Common return connection for the LIM2 output.

20

SUP-OUT

A protected supply referenced to the Supply Common connection. It will be adequate tooperate any combination of the CNC inputs on the CNC connector.

1,7,13

SUP-COM

Common reference connection for the CNC input pins on all channels, connected toearth and chassis ground. This connection is for the common of the external supply,
when one is used to activate the CNC input signals.

AE Signal Analog Output
The analog output voltage is presented at pin 2 of the 25 pin CNC connector of the SB-5522 card. Pin 1 is theground reference for this voltage. The analog output on the AEMS system is not calibrated to a fixed level.
The gain of the system is auto scaling, so that the analog signal output always falls in the 0-10 VDC range.
This auto scaling is needed to accommodate the huge variation in signal level, which can be measured on
various types of grinders with different applications and sensor placements. This gain corresponds to the gain
used for the display of AE level on the front panel. This scale will vary with the Gain setup saved for eachparameter set (M1/M2 and Job). It will also potentially change every time a learning cycle is run, if gain isadjusted.
Note that there may be no correlation between the gain settings, and the resulting voltage levels for eachseparate M1 and M2 mode.
Full Scale = 9.7 VDC = near full scale of hardware amplifier

SBS AEMS System 21

Profibus DP Interface
A Profibus Implementation document, along with the required Profibus GSD file, can be downloaded fromthe SBS website at https://accretechsbs.com/.

Software (USB or Ethernet) Interface
The SBS System provides a software interface via either Ethernet TCP/IP or USB. The software interface
allows the same control capability as the hardwire interface plus system status monitoring. The following
description applies to all SB-5500 models.
Interfacing
The software interface provides a serial interface emulation which connects the Control to a Windows
computer over either Ethernet TCP/IP or USB. For TCP/IP, use Telnet at the Windows command prompt
pointed to the IP address of the Control, or use HyperTerminal or similar serial communications software
pointed to port 23 with any baud rate setting. When connecting via USB, Windows will assign a COM port tothe control. If the SB-5500 is not automatically assigned a COM port, a driver for Windows installation of
USB-Serial communication is available on the SBS website at https://accretechsbs.com/. COM port
assignment is controlled by Windows, and a unique COM port will be assigned for each detected SB-5500
control. The port assigned can be determined by viewing Windows Device Manager. Use HyperTerminal orother serial communications software to interact with the Control over USB connection.
Software Commands and Responses
When the Control unit is first powered up, the following message is transmitted via the software interface.
/SB-5500, Copyright (c) 2020, Accretech SBS, Inc.<CR>
V0.85<CR>
Commands - A message preceded with the digit ‘1’ through ‘4’ is a command or response referring to Slot
Cards 1 to 4, respectively. A message starting with any other character refers to the System Control. Examples
following use “1” as the card slot number.

22 SBS AEMS System

The following commands from the Software Interface are available:
Control Unit Commands (Cards are Individually Controlled)
CommandC

Response

Meaning/ Example:
Control Panel Status Inquiry.

<Esc>C<CR>
CI

Control Panel is Inhibited

CI<CR>
CE

Control Panel is Enabled

CE<CR>CX

Control Panel is not installed

CX<CR>
CE

Control Panel Enable.

<Esc>CE<CR>K

Command Acknowledged

K<CR>
CX

Control Panel is not installed

CX<CR>CI

Control Panel Inhibit.

<Esc>CI<CR>
K

Command Acknowledged

Q

Command Not Accepted (Panel in use?)

K<CR>
Q<CR>
CX
V

Control Panel is not installed
Version Request (main board firmware).

<Esc>V<CR>
Vn.nn

Firmware Version

V1.00<CR>
AEMS Card Commands (Cards are Individually Controlled)
CommandX

Response

X3.xxVv.vv[sss]/text

Meaning/ Example:
Type (of slot card) Request.
< Esc >1X<CR> Start Slot 1 Info Request.
Slot info response. 3 is Gap/Crash type. xx is specific model type. v.vv is gap
firmware revision. sss is the user specified name for this card. Text briefly
explains the card type.

1X3.00V1.00[GAP1]/Gap / Crash<CR>
S[C]

S{D|G}aaaa[,CIP][,FPI][,GAP] [,LIM1][,LIM2][,CRASH],
ERR=eeeC[D|G|S|A|nn]

Status Request command. If ‘C’ present then previously reported errors
conditions will be cleared before the status is reported.
<Esc>1S<CR> Report Slot 1 Status.
Status response. D or G indicates current mode (D=M2 or G=M1), aaaa is AE
level. CIP is Cycle In Progress. FPI is Front Panel Inhibit. GAP, LIM1, LIM2, andCrash the corresponding output is closed, eee represent individual error lettersrepresenting error conditions. If the first character is ‘@’ then an error condition
requires clearing (use SC command or press clear on front panel).

1SD2.905,CRASH,ERR=@AB<CR><ESC>1SC<CR> Report Slot 1 Status.
1SD2.912,ERR=B<CR>
Cycle Command: If D or G, will change to the corresponding mode (D=M2 or
G=M1). If nn will change to corresponding Job# parameter set (nn range 0-16,
0 turns Job# OFF). If S or A then will Start or Abort the measurement process,correspondingly. No response to D, G, A or nn.
SBS AEMS System 23

AEMS Card Commands (Cards are Individually Controlled)
Command

Response

Meaning/ Example:<ESC>1C7<CR> Set Job# to 7.
<ESC>1CS<CR> Start Cycle.
{D|G}dddd

L
Lnn{D|G}gggg,
aaaa,bbbb,cccc

Cycle data. D or G indicates M2 or M1 value. dddd is AE signal level. These will
be sent whenever a cycle is running. There will be no response if the command is
not allowed.
1G0.023<CR> M1 Cycle data.
1G0.120<CR> M1 Cycle data.
1G0.134<CR> M1 Cycle data.
<ESC>1CA<CR> Abort Cycle.
(no response)
Level request:<ESC>1L<CR> Request Current Levels.
Level response. nn indicates current Job# parameter set. Nn=0 for OFF, nn=1-16
for current Job#. D or G indicates current mode, M2 or M1. Levels are gggg for
Gap, aaaa for Lim1, bbbb for Lim2, and cccc for Crash. Levels are different foreach mode (D=M2 or G=M1).
1L7G0.023,0.145,1.056,3.112<CR> M1 mode levels.

Displayed Error Messages
Self-diagnostic software has been incorporated into all SB-5500 Control Units. If a problem ever occurs withan SBS system, It is reported on the front panel display as an error code. Below is a listing of these error codes,
a description of when the Control Unit automatically runs each test, how each code is cleared, the definitionof each error message, and prescribed action to be taken by the user.
Press CLEAR or CANCEL to manually clear a displayed error message. Once an error is cleared, it will be
displayed again when the error condition is next detected. To further isolate defective components a series oftest operations accompany some of the error codes.
Please indicate the Error Code (letter) of any displayed Errors when returning equipment for repair. Also pleaseprovide as much detail as possible regarding the conditions when problems were encountered, and thesymptoms experienced.
Error
Code
A

B

Message

Definition

ActionSENSOR 1 DEFECT(SENSOR 2 DEFECT)OPEN – CHECK CABLE
AND CONNECTORSSEE MANUAL

Checkedcontinuously.
Acoustic Sensor 1 (2)presence notdetected. This could
be caused by adefective sensor or by
no sensor being
connected.
Checkedcontinuously.
Acoustic Sensor 1 (2)short circuit detected.

Clears automatically when sensor detected.
Check sensor connections and try Power-On
again. Continued error messages indicate theneed for repairs to the Sensor.

SENSOR 1 DEFECT(SENSOR 2 DEFECT)SHORT – CHECK CABLE
AND CONNECTORS SEE MANUAL

24 SBS AEMS System

Clears automatically. Disconnect the Control Unit
from AC power before checking cables andconnectors, and sensor for shorts. If the problem
cannot be isolated, the sensor, cable, and/or
Control Unit should be returned for repair.

ErrorCode

Message

Definition

ActionC

ANALOG OUTPUT
SIGNAL OUTPUT DACOUT OF RANGE

Checkedcontinuously.
Analog output is out ofrange.

Analog output (0-10V) of AE signal cannot track
the range set by current Gain and Crash settings.
Reduce Crash limit or Gain as needed to resolve.

D

LIMIT RELAY
RELAY SET BEYOND
USABLE RANGE

Checkedcontinuously.
One or more Limits
are set outsideuseable range.

+15V POWER DEFECTSHORT – CHECK CABLE
AND CONNECTORS –SEE MANUAL

Checkedcontinuously.
15V Auxiliary supply
low – fuse open

Crash CONDITION

Checkedcontinuously.
Unit has measured
acoustic signal
exceeding the set
Crash limit.
Checkedcontinuously.
Signal acquisition
circuit failed.
Checked at power on.

Limits are set beyond the functional range of the
hardware.
1. If input AE signal is too high it may overwhelm
the hardware limits of the AEMS card. In thiscondition selecting a different frequency band (onewith normal 3.0 C.S.) should resolve the problem.
2. Remove or reduce the zero offset.
3. Try reduced Gain.
Check for shorts in Sensor and CNC cables andconnectors and re-initialize the system. If the error
persists return Control Unit and cables for repair.
If you have the SBS system cabled to your CNC
controller, verify that the CNC cable is free ofelectrical shorts. The CNC cable is not suppliedwith the SBS system, and repair is the
responsibility of the user.
Cleared manually by pressing “Clear” button or by
CNC RESET.
Check for part crash. Reset Error.

E

F

G

I

J

CIRCUIT FAILURE
UNABLE TO MEASURE
AE SIGNAL
SEE MANUALDISPLAY FIRMWARE
NEEDS TO BE UPDATEDTO SUPPORT FUNCTIONS
SEE MANUALCARD IS DISABLEDREMOVE EXCESS CARDS

Checked at power on.
Only 1 of certain
device card models
can be installed in thecontrol unit.

Clears automatically. No action required otherthan clearing manually from the screen. If the
problem persists, the Control Unit should be
returned for repair.
The firmware on the display PCB must be
updated to the current version to support interfacechanges in the newer device card firmware.
If more than one SB5519 is installed, all cards are
disabled. The error indicates the need to remove
the excess installed cards.

SupportFor support, contact the machine builder or SBS at:

Accretech SBS, Inc.
2451 NW 28th Avenue
Portland, Oregon 97210 USA
Tel.: +1 503.227.7908
Fax: +1 503.223.1258
TechSupport@accretechSBS.com
https://accretechsbs.com/
SBS AEMS System 25

Appendix A: Specifications
SB-5500 Physical Features
Multiple Device Control
Four (4) available slots accept these control cards:
SB-5512 Mechanical wired balancers
SB-5518 Hydro Balancers
SB-5522 Acoustic Emissions Monitoring System
SB-5523 ExactDress™ process monitoring
SB-5560 ExactControl™ process monitoring
SB-5562 Studer AE Control™ process monitoring
SB-5532 Mechanical non-contact balancers
SB-5544 Manual balance control
SB-4500 Compatible
Operates with existing cables and sensors,
CNC/PCL Hardwire Interface
Display
Type: Color TFT LCD
Active area: 480H x 272V pixel
3.74 inch [95mm] x 2.12 inch [53.86mm]
Multi-language Capability
English, Chinese, French, German, Hungarian, Italian,Japanese, Polish, Portuguese, Russian, Spanish,
SwedishCommunication Interfaces
Ethernet TCP/IP, USB 2.0, Profibus DP, CNC/PLC
Hardwire Interface (opto-isolated outputs)
DC or AC Power Options
DC Supply: Input 21 VDC to 28 VDC. 5.5A max at
21 VDC. Reverse voltage protected.
Connector: Molex 50-84-1030 or equiv.
Contacts:
Molex 02-08-1002 or equiv.
AC Supply: 100-120 VAC, 50/60 Hz, 2A max; 200240 VAC, 50/60 Hz, 1A max. Main
supply voltage fluctuations not toexceed +/-10% of nominal supply
voltage.

26 SBS AEMS System

Environmental and Installation
SB-5500
Pollution degree 2
Installation category II
IP54, NEMA 12
Environmental temperature range: 5°C to +55°C
SB-5575/80/76/81
Pollution degree 2
Installation category II
IP20
Environmental temperature range: 5°C to +55°C

CNC Hardwire Interface
Input requirements: 10-26V AC/DC, 8mA min.
Output +15VDC, 30mA max.

Appendix B: Replacement Parts List
Part#

Description

AEMS Sensors
Built in to Non-contact Balancers
SB-42xx
Bolt-on Sensor
SB-41xx
AE-Extension Cable
SB-3208
AE Sensor: Non-contact spindle mounted Mini-Stud Mount – M6x1.0 LH
SB-3209
AE Sensor: Non-contact spindle mounted Mini-Stud Mount – M6x1.0 RH
SB-3225
AE Sensor/ Sender Package: Non-Contact In-Spindle
SB-3210
AE Sensor: Non-Contact In-Spindle w/ slide tube connection
Control Mounting Hardware Options
SK-5000
Rack Panel: SB-5500, Full Wide w/ 1/2 Blank, 3U
SK-5001
Rack Panel: SB-5500, Partial Wide 3U w/ Handles
SK-5002
Rack Panel: SB-5500, 1/2 Rack 3U Bracket
SK-5003
Control Mount: SB-5500, Bottom Flange
SK-5004
Control Mount: SB-5500, 90 Deg. Bracket, Cabinet
SK-5005
Keypad Mount: Flush Panel Frame Kit
Other Parts
EC-5605
EC-5614CA-0009
CA-0009-G
CA-0009-B

A/C Control Fuse, 3 amp time lag 5x20 (2 required)
D/C Control Fuse, 6.3 amp time lag 5x20
Power Cordset
Power Cordset (Germany)
Power Cordset (British)

xx in P/N = cable length in feet
Standard options 11 [3.5m], 20 [6.0m], or 40 [12.0m], e.g. SB-4811 = 11ft [3.5m]

SBS AEMS System 27

28 SBS AEMS System

Unit is shown upside down with the cover removed.

Note: All Service (including card installation) should be
performed by a qualified technician, or the unit returned to
Accretech SBS, Inc. for service.

Safe handling requires that technician have the unit open
or cards out of ESD bags only on an ESD-safe work
surface, and only when the technician is properly
grounded

Slot Screw
4-40x3/16

Card

Inside View of Rear Panel

3. Remove Slot Screw and Blank Slot Cover.
4. Plug Card into Main Circuit Board while sliding Card
metal plate into mating slots on inside of Rear Panel.
5. Install Slot Screw to secure Card.
6. Install Cover and Tighten Cover Screw.

For small chasses (e.g. SB-5575) remove 4 cover screws.

Tools Required:
1. Philips Screw Driver
2. Grounding Wrist Strap
Procedure:
1. Unplug Unit, invert, and lay on an ESD Safe Surface.
2. Remove Cover Screw at Back Panel of Control.

Card metal panel (or Blank Slot
Cover) slide into the matingslots on the inside of Control
rear panel.

Blank Slot Cover

Cover Screw
M4x6

Cover

Appendix C: AEMS Card Installation

DC Input
Option:21-28 VDC

USB
DeviceProfibusDP

M1

SB-5500 Control

Customer CNC / PLC

Use SB-5500 Or
Customer Supplied Power

RESET+15V DC OUTAEMS Card

N/C = Do Not Connect

Customer
Supplied
10-26V
AC or +DC

LIM2

AEMS
EXTENSION
CABLE

LIM1

SENSOR 1

M2

CNC Cable
SB-2411-L 11ft [3.4m]
SB-2420-L 20ft [6.1m]
SB-2440-L 40ft [12.2m]

AC Input
Option:100~120,200-240 VAC

Ethernet
TCP/IP

Standard Cables Customer Supplied

BOLT-ON AEMS SENSOR
SB-4211, SB-4220, SB-4240

Crash

24V AC or DC 50mA Maximum
Inductive Loads Require Protection

GAP

M2

M1

SENSOR 2(OPTIONAL)

NON-CONTACTBALANCER WITH AEMS

Appendix D: AEMS System Connection Diagram
ANALOG OUTFPI INPUTSBS AEMS System 29