OPERATIONSMANUAL
SB-4500 Series Control

The World’s
Best Automatic
Balancer …
Just got better.
L-4100-4

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Operation and Specification Manual
for theSBS Dynamic Balance System
Covering Systems with The Following⎯ Model 4500 series Control Unit
⎯ Model 4400 series Control Unit
⎯ Model 4475 series Control Unit

L- 4100-4
Manual Revision # 4.0© 2007, 2003, 1999 Schmitt Industries, Inc.
2765 NW Nicolai St.
Portland, OR 97210 USA
Phone: (503) 227-7908
Fax: (503) 223-1258
www.schmitt-ind.com

SBS Balance System

Table of Contents
General Instructions ................................................................................................................................................ 1
System Purpose.................................................................................................................................................... 1
Operator Safety Summary .................................................................................................................................... 1
System Theory and Connection ........................................................................................................................... 2
Environmental Considerations.............................................................................................................................. 3
Other Sources of Vibration .............................................................................................................................. 3
Machine Condition ........................................................................................................................................... 4
Balance System Installation.................................................................................................................................. 4External Balancer/ Adaptors............................................................................................................................ 4
Internal Balancer.............................................................................................................................................. 6
SBS Control Unit.............................................................................................................................................. 7
Vibration Sensor Location ............................................................................................................................... 7
Control Unit Operating Instructions....................................................................................................................... 8
Model SB-4500 Front Panel Controls.............................................................................................................. 9Power-On Display for Control Models with Attached front Panel .................................................................... 9
SETUP Option ............................................................................................................................................... 10Power-On Indication for Control Models with no Display .............................................................................. 10
Model SB-4400 Front Panel Controls............................................................................................................ 10
Model SB-4500 Rear Panel Connections...................................................................................................... 10
Model SB-4400 Rear Panel Connections...................................................................................................... 11External/ Internal Balancer Operation.................................................................................................................. 12
Balancer Slot Status LED .............................................................................................................................. 12
Balancer Main Screen Elements ................................................................................................................... 12
MENU Settings and Selections........................................................................................................................... 13
Balance Settings............................................................................................................................................ 13
Vibration Units ............................................................................................................................................... 14
Balance Speed .............................................................................................................................................. 14
Plot Vibration ................................................................................................................................................. 14
Pre-Balance ................................................................................................................................................... 14
Channel Name............................................................................................................................................... 14
Menu Entry .................................................................................................................................................... 14
Factory Settings............................................................................................................................................. 15
Critical RPM................................................................................................................................................... 15
CNC BOT MODE........................................................................................................................................... 15
Balancer Rear Panel Connections ................................................................................................................ 17
Preparing to Set Operating Parameters ............................................................................................................. 17
Background Vibration .................................................................................................................................... 17
Verifying Balancer Sizing............................................................................................................................... 18
Setting Operating Parameters ............................................................................................................................ 18
Auto-Balance LIMIT ....................................................................................................................................... 18
Auto-Balance TOLERANCE .......................................................................................................................... 19
Auto-Balance CRITICAL................................................................................................................................ 19
Vibration Display............................................................................................................................................ 19
Balance Speed Selection............................................................................................................................... 19
Model SB-4400 Control Unit.......................................................................................................................... 19
Automatic Balancing ........................................................................................................................................... 20
Pre-Balancing ..................................................................................................................................................... 20
Prepare for Pre-balance ................................................................................................................................ 20
0-BAL (Zero Balance Weights) ................................................................................................................... 21
Setup.............................................................................................................................................................. 21
Balance Type .............................................................................................................................................. 21
Weight Units................................................................................................................................................ 21
Balance Weights ......................................................................................................................................... 22
Target Level ................................................................................................................................................ 22
Scale Direction and Wheel Rotation ........................................................................................................... 22
Beginning The Pre-Balance Operation.......................................................................................................... 22
SBS Balance System

Position Weight Screen............................................................................................................................... 23
Check Vibration Screen .............................................................................................................................. 24
Manual Balancing ............................................................................................................................................... 25
Manual RPM Filter ......................................................................................................................................... 25
Plotting Vibration................................................................................................................................................. 26
Machine Control Hardwire Interface ................................................................................................................... 27
Hardwire Control Interface Overview............................................................................................................. 27
Input Pin Names and Functions .................................................................................................................... 28
Output Pin Names and Functions.................................................................................................................. 29
Software (RS-232) Interface ............................................................................................................................... 29
Interfacing ...................................................................................................................................................... 29
Setting Baud Rate.......................................................................................................................................... 30
RS-232 Commands and Responses ............................................................................................................. 30
RS-232 Operation Summary ......................................................................................................................... 32
System Maintenance .......................................................................................................................................... 34
Collector Maintenance ................................................................................................................................... 34
SBS Return/Repair Policy.............................................................................................................................. 34
Balancer Cable Schematic ............................................................................................................................ 35
Sensor Cable Schematic ............................................................................................................................... 35
Trouble Shooting Guide ...................................................................................................................................... 36
Display Test Option ....................................................................................................................................... 36
Displayed Error Messages.................................................................................................................................. 37
Appendix A: Electronic Specifications ................................................................................................................ 41
Control Unit.................................................................................................................................................... 41
Vibration Sensor ............................................................................................................................................ 41
Appendix B: Replacement Parts List .................................................................................................................. 42
Appendix C: Balancer Card Installation .............................................................................................................. 43
Appendix D: System Connection Diagram ......................................................................................................... 44
Ordering The SBS Balance System ................................................................................................................... 45

SBS Balance System

General Instructions
System Purpose
A grinding wheel is the cutting tool of a grinding machine. In order for the grinding wheel toaccurately cut, produce smooth surface finishes, and generate correct part geometry, it is necessary to prevent
vibration in the grinding process. One of the primary causes of vibration in an operating grinding machine,is the existence of imbalance in the grinding wheel.
Imbalance is often due to the heterogeneous nature of grinding wheel construction. A wheel contains
great numbers of unevenly distributed grains, which cause an intrinsic imbalance. This imbalance will becompounded by eccentric mounting of the wheel, varying width of the wheel, imbalance in the arbor, andcoolant absorption into the wheel. Even a carefully established wheel balance, considering all these factors,
will not last long. Due to wear and frequent dressing of the wheel periphery, the rotational dynamics of agrinding wheel are always changing. For these reasons, dynamic balancing of grinding wheels has long beenrecognized as an important step in the production process.
The SBS Balance System has been developed to provide dynamic balancing to grinding machine
operators with the following objectives in mind:• Attractive Purchase Price• Ease and Usefulness of Operation• Maximum Grinding Machine Efficiency• Minimal Installation Requirements• Minimal Maintenance Requirements

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 isnecessary to read and understand the entirety of this manual. After reading the Operation Manual, contact
Schmitt Industries 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.
Caution:To avoid equipment damage, do not drop or mistreat.

Warning: Failure to properly attach SBS Balance System components to the grinding
machine spindle, including the proper use of provided adaptor lock screws, will
result in safety hazard during machine operation.
Caution:Only qualified service technicians should attempt to perform service on the SBS
Balance System. To avoid electric shock, do not remove the cover of theControl Unit, or remove cables, with power connected.

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).

SBS Balance System

1System Theory and Connection
The SBS Balance System operates on a principle of mass compensation for a given grinding wheel
imbalance. The Intrinsic Imbalance of a grinding wheel is equal to the product of the wheel’s mass
multiplied by the distance between the wheel’s center of mass and the wheel’s center of rotation (figure 1).

eIntrinsic
Imbalance= e ( Wheel
Mass)
Figure 1r

Measured
Imbalance= r ( Balance
Weight Mass )Figure 2

The imbalance of a grinding wheel is determined in practice by use of the Measured Imbalance of thewheel. The Measured Imbalance is equal to the product of a mass, affixed to the grinding wheel to balance
it, multiplied by the distance between that mass's center and the center of rotation of the grinding wheel(figure 2). In both cases, the imbalance is given in terms of a mass multiplied by a distance, with(grams)(centimeters) being the units used for reference by the system.
In order to correct for various and changing imbalances which occur on a user's grinding machine, the
SBS Balance System uses two movable weighted masses, which can be independently positioned so that
their resulting compensation will counter any imbalance which is within the specifications of the system.
These weights are located in the Balancer, and are driven by high torque electrical motors through a
precision gear train.
Figure 3 is a simplified block diagram of the SBS Balance System. The system consists of the
Balancer, a Balancer Cable, a Vibration Sensor, and the SBS microprocessor based Control Unit. Imbalanceis expressed as spindle movement or vibration and is detected from the grinding machine by the sensor inpeak to peak units of measure. The vibration signal from the sensor is transmitted to the control unit, whichfilters the signal by RPM. The control unit then drives the two balancer masses in the direction that reduces
the amplitude of the incoming vibration signal.

2

SBS Balance System

SensorBalancer

Input
SignalBalance Control Unit

Motor Drive
Signals

Figure 3

When the balance weights are positioned so that minimum vibration is achieved, the balance cycle iscomplete. Figure 4a shows a rotating grinding wheel that is unbalanced, with an SBS Balance Systeminstalled. The imbalance is represented by the white dot located on the circumference of the wheel. The
other two black dots represent the masses located in the balancer. By incrementally repositioning theweights, a triangulation is achieved which cancels out the imbalance, as shown in Figure 4b.
UNBALANCEDBALANCED

Figure 4a

Figure 4b

Environmental Considerations
The SBS Balance System is designed to dynamically correct for grinding wheel imbalance, with its
detrimental effects on quality of surface finish, accuracy of shape production, wheel life, and machine
bearing life. The system cannot correct for other environmental problems, which may also impact theseareas. This section is intended as a discussion of some common environmental problems, which may
influence grinding quality and the ability of the SBS Balance System to fully demonstrate its benefits.
Other Sources of Vibration
A most common source of vibration is adjacent machinery. It is therefore important that a grinding
machine be properly shock mounted or otherwise isolated if vibration-producing machinery is operating
SBS Balance System3nearby. Another source of vibration may be components mounted on the machine, such as pumps, motors,
drives, etc.
The SBS Balance System may not operate as well under the influence of certain external vibrations.
The system filters the vibration signal it detects from the grinding machine by the frequency of the spindle
RPM. This means that vibrations occurring at other frequencies than that of the rotating wheel will beignored by the system. In the case of adjacent machinery operating at the same frequency, or in beat withthat frequency, the system will be unable to distinguish vibrations occurring from wheel imbalance withthose originating in the adjacent machine.
An excellent test for environmental vibration is to monitor the vibration level on the grinding machine
while the spindle is not turning. The vibration level should be checked in various locations on the grinding
machine, but in particular at the location the vibration sensor is to be mounted. All surrounding equipment,
including any auxiliary pumps or attachments on the grinding machine should be operating during this test.
The SBS Balance System can quickly let you accomplish this test (see: Background Vibration section). The
SBS Balance System can not remove these vibrations.
Machine Condition
The grinding machine’s condition is important in determining the balance level, that the SBS Balance
System can achieve. The spindle itself should be balanced, as well as all components in the drive train of thespindle (i.e. belts, pulleys, motor, etc.). The balance system can readily determine if any significant
imbalance exists in the machine itself. Simply use the same method as described above for checking
environmental vibration, except test with the spindle running and with no wheel mounted. The SBS Balance
System does not remove these vibrations.

Balance System Installation
The SBS Balance System is easily installed in a short period of time. This section provides
instructions for mounting of the system hardware on the grinding machine. Included are sections pertaining
to installing the balancer, making system connections, installing the vibration sensor, and selecting theproper line voltage setting.
External Balancer/ Adaptors
The Balancer is mounted with the provided adaptor to the machine spindle (figure 5a). The
mounting adaptor is specifically designed to accommodate the particular machine’s spindle configuration,
and will vary in design. In general, the adaptor will consist of two parts. The Adaptor Nut mounts on the
Grinding machine, usually replacing the spindle nut of the machine, either on the wheel or pulley end of thespindle. The Adaptor Flange will bolt to the Balancer, and then thread onto the installed Adaptor Nut.
Appropriate wrenches are supplied for both parts. Use of a lubricating compound between the Balancer andMounting Adapter is recommended, to ensure ease of future disassembly.
Lock Screws are a feature of many adaptor designs, where required by high machine speeds ormachine spindle braking. These lock screws will consist of M6 socket set screws in the face of the Adaptor
Nut, and M5 socket set screws in the outer diameter of the Adaptor Flange (figure 5a). Warning - All lockscrews must be properly secured each time the Adaptor Nut or Adaptor Flange is installed in place, in orderto prevent the assembly from coming loose during operation of the grinder.

4

SBS Balance System

Mounting
Adaptor
Mounting Flange
Adaptor
Nut

External
Balancer

Secure all Lock Screws at
installation
Figure 5a

Follow this assembly procedure to ensure proper mounting of Adaptor Nuts and Flanges were lockscrews are part of the adaptor design:
1. Loosen all lock screws before assembly. The engagement end of these screws should be below
flush with the face of the adaptor part where they exit.
2. Screw the Adaptor nut onto the machine wrench tight, using the supplied wrench.
hammers or wrench extension bars are not advised.

Use of

3. Tighten all the lock screws in the Adaptor Nut, wrench tight.
4. Thread the Balancer/ adaptor flange assembly onto the mating threads on the Adaptor Nut.
5. Tighten the lock screws in the Adaptor Flange, wrench tight
6. All lock screws must be fully loosened before attempting removal of these parts from the machine.

Modify Machine
Guarding if
Necessary to Clear
Balancer

Figure 5b

The Balancer must be checked for machine clearances upon installation. Make sure there is nointerference between the Balancer or adaptor and any part of the machine (workhead, tailstock, etc.),
especially with the wheel worn to it’s smallest diameter (figure 5b). Modify the machine guarding if needed
to provide clearance from the Balancer.
SBS Balance System

5

The Balancer Cable should be restrained to prevent the cable from being caught up in the rotatingmachine (figure 5c), but should allow for the cable’s removal as necessary during wheel changes. These
components are designed for the harshest environments and the most aggressive coolants. However,common sense dictates that where possible, machine guarding should be modified to allow the rotaryjunction and cable to extend outside the guard. Optimally, the cable should be secured so that the connector
on the Balancer points down, as shown in the diagram. This position will minimize the chance of fluid orswarf entering the connector when the connector is opened during wheel changes. While the connection is
opened, if contamination of the cable connector pins occurs, the pin area must be cleaned prior to reassembly. If heavy wheels are being changed, remove the Balancer from the area during wheel changes.
Most adapters for larger machines are of a two piece design, which simplifies this process.
These installation drawings show the standard balancer version, with the SBS slip ring collector(rotary electric junction) design. Another balancer option is available which includes the SBS non-contact
collector. When this balancer version is used, the installation is similar, except that the balancer comes in
two parts, with the separate collector piece being mounted across an air gap from the balancer, on a
stationary part of the machine. Additional mounting instructions will be provided with this version ofbalancer describing in detail how this is to be accomplished.

Secure Balancer
Cable Firmly to
MachineFigure 5c

Internal Balancer
Internal Balancers are designed for mounting inside or internal to the machine spindle. The machine
manufacturer must provide a precision-machined mounting bore as part of the design of the grinder’s spindle
in order to accept an internal balancer. The method of attachment is the essential difference between aninternal balancer and an external balancer. Once installed, the operation of the two designs is identical andthey are discussed interchangeably throughout this manual. The mounting diagram (figure 6) shows how theinternal balancer is mounted in the wheel end of the machine spindle. The flange style mounting shown istypical, although a taper lock mounting option is available which eliminates the flange mount and allows thewhole internal balancer to fit within the diameter of the mounting bore.
The internal balancer shown is cabled to the SBS collector, which is mounted separately at the rearend of the spindle. With other versions of the balancer, the collector can also be mounted at the wheel end of
the spindle, directly attached to the balancer, eliminating the need for the cable bore down the center of thespindle. Both the standard SBS slip ring collector, and the SBS non-contact collector, are available options
with the internal balancer.
6

SBS Balance System

Balancer
Mounted in
Spindle Bore

Over/ Under
Weight Design
Figure 6

SBS Control Unit
The SBS Control Unit should be mounted in a location that allows observation of the display by themachine operator. Mounting hardware is available for installation on horizontal surfaces or for rack
mounting in standard 19" racks. Cabling connections to the control unit include the Vibration Sensor Cable,
the Balancer Cable, the power cord, and machine controller interface cable if applicable (see: System
Connection diagram). All connections are clearly labeled on the rear of the control unit. Be sure that theproper fuses (Two 3 Amp Time Lag) are installed. (see: Rear Panel Controls section).

Sensor Mounted in
Direction ofWorkpiece Contact

Surface or Creep
Feed Grinders

Workpiece

Cylindrical orCenterless Grinders

Figure 7a

Vibration Sensor Location
The Vibration Sensor can be mounted on the grinding machine either by use of the magnetic mountprovided, or by permanent stud mount. The magnetic mount should be used during initial system start up,
until a good permanent location is found on the grinding machine for the sensor. The sensor can then bepermanently stud mounted at that location. When stud mounting the sensor, a machined flat should be
supplied at the mounting location on the machine.
SBS Balance System

7

The location and installation of the sensor are crucial to successful operation of the SBS Balance
System. Because of differing machine characteristics, Vibration Sensor location is specific to machinemodel. There are some general principles that should assist in finding a proper sensor location for yourgrinding machine.
1.
The first general principle is to locate the Sensor in the same direction as the centerline between
the grinding wheel and the workpiece. The best place to start is a flat machined surface on the spindle
housing over the bearing closest to the wheel, and perpendicular to the spindle’s centerline (figure 7a). A
vertical mounting surface is preferable on most cylindrical grinding machines because the sensor is in linewith the grinding wheel and the workpiece. For this same reason, on surface grinders and creep feed
grinders, a horizontal mounting surface is generally best. Although the balancer itself may be mounted either
on the wheel or pulley end of the machine, the Sensor should always be aligned at the wheel end of themachine (figure 7b).
Pulley Mounting of Balancer
Sensor Location
At Wheel End of
SpindleSecure Any
Lock Screws
Figure 7b2.
The second general principle is to locate the sensor on a rigid part of the machine structure, where
vibration from the spindle will be accurately transmitted. On some machines, the wheel guard can be agood location to mount the sensor, if it is heavy enough and rigidly attached to the spindle housing. Thebalance system relies on vibration signals received from the Vibration Sensor to accurately display thecurrent vibration level, in peak to peak units, and to balance the grinding wheel. The system employs narrow
bandwidth filters that prevent vibration at non-spindle frequencies from being detected. However, inapplications where the motor or other machine components are running at the same speed or frequency as thespindle, interfering vibrations may result. Careful experimentation with the sensor’s location goes a longway in minimizing sources of interference.

Control Unit Operating Instructions
The SBS Balance System, once installed, is easily configured to the particular needs of your grinding
setup. The following section includes an overview of the control and interface features of the SBS Balance
System Control Unit. In the second section of this manual, “External and Internal Balancer Operation”
detailed description is given of the function and operation of the various features of the system which willallow the user to perform auto-balancing, manual balancing, and vibration analysis, as well as machine
controller interface to the system.

8

SBS Balance System

Sections cover the SB-4400 (expandable to two channels), and the SB-4500 (expandable to fourchannels). Both units are capable of being controlled by a CNC or PLC machine controller.
Model SB-4500 Front Panel Controls
Figure 8 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, theunit 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 isconnected to the 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.
3) LUMINESENT DISPLAY. This display is not a touch screen. Do not attempt to operate the control
unit by pressing on the display.
4) FUNCTION BUTTONS. The display is not a touch screen. Operation of the Control unit is primarily
accomplished via. these four multi-function buttons. The Menu Bar area of the display, to the left ofthese buttons, assigns the current function to each button.
5) SLOT STATUS LED. An LED indicator of three colors on the left side of the keypad display theoperational status of the balancer card or other device installed in that card slot.

Figure 8

Power-On Display for Control Models with Attached front Panel
When the ON/OFF button is pressed on the front panel of the Control Unit, and power is applied to theunit, the Control Unit performs a series of self-checks, which define its status, and the setting of various
operating parameters. Operator information regarding these parameters is displayed using the Control Unit’s
graphic display. The sequence follows this order:
1)

The company logo screen will be displayed and lights on the front panel are illuminated to verify
their operation. During this time, a SETUP function button is available. Pressing this button willallow language selection, and RS-232 Baud Rate selection. These setting are common to all installed
card slots.
SBS Balance System

92)After a few seconds, the company identification screen will clear and the unit will display
information related to each slot or slots where card devices are installed, indicating each type ofdevice, and relevant identifying information. To extend the time that this information is displayed,press any one of the function buttons while the slot information is on the screen. Each press will add
six seconds to the display time, providing additional time to read the information.

3)

After a few more seconds, the slot information screen will clear, and the unit will display the initial
operational screen for the control unit. Where one balancer channel is installed, this first screen willbe the main balancer screen. Where more than one device is installed, the unit will display either theSHOW ALL monitor screen, or one channel’s main balancer screen, whichever was selected when
the unit was last turned off.

4)

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

SETUP Option
This option allows the user to select the language used by the control unit for display, and the RS-232
baud rate used by the control for RS-232 communication. During Power-up, while the company logo screen
is displayed, press the SETUP button to change the screen. The next screen displayed allows the selection of
the language used by the control for display. Use the arrow buttons to scroll through the available languages
and press the ENTER button to switch the control unit to the desired language. After pressing the ENTER
button, a screen for changing the baud rate for the RS-232 port is displayed. Use the arrow buttons to scroll
through the available baud rates and press the ENTER button to make the selection. Pressing the START
button at any time during this process will bypass remaining SETUP options and resume normal operation.
Power-On Indication for Control Models with no Display
The only power-on display for this type of unit is the standard RS-232 menu and command prompt.
(see: RS-232 Commands and Responses section)
Model SB-4400 Front Panel Controls
This dedicated remote control model of the Control Unit does not have a front panel, and can be
activated only via. the two interface ports on the Control Unit, or by use of an optional remote front panel.
Operation of the unit via. the remote front panel is identical to that described above for the SB-4500 unit.
Model SB-4500 Rear Panel Connections
Figure 9 illustrates the rear of the control. The following four connections are located on the rear panelof the Balance Control Unit, and are common to any cards installed in the control.
1)

POWER SUPPLY. Connection for line power input. Caution - before applying power tothe Control Unit, make sure the voltage is within specified voltages for the balancer(100-120V AC, 200-240V AC, 50-60 Hz).

2)

FUSE HOLDER. Contains the line fuses. To replace fuses, remove the line plug fromreceptacle and use a small screwdriver to draw out fuse holder from the plug body. An
equivalent of the two supplied 3 Amp Time Lag 5x20 fuses should be used.

10 SBS Balance System

Model SB-4500 Rear Panel
Figure 93)

RS-232 PORT. A DB-9 connector receptacle is used to provide external communication forserial transfer of data.

4)

DEVICE SLOTS. These numbered Slots are available for installation of balancer channelcards or other devices supplied by Schmitt Industries. Factory configuration of the control
unit will include a balancer channel card installed in Slot 1, with unused Slots being sealedwith blank cover panels.

RS-232

Additional capabilities can be added tothe system by installation of separately sold addin card products supplied by SBS. One suchproduct is the SBS AEMS Gap and Crash
monitoring system card. This product allows
automatic acoustic monitoring of the machinefor grinding Gap elimination, and wheel Crash
protection. See your SBS representative fordetails.

REMOTE

Model SB-4400 Rear Panel Connections
Remote Connector
Available
only onS
4400

The SB-4400 is a dedicated machine
contoller or remote controlled version of the
SBS Control Unit. Rear panel control andconnections for this unit are identical to those on
the standard SB-4500 channel unit, except for
the addition of the REMOTE plug, locateddirectly below the RS-232 port (see: figure 10).
This DB-15 connector receptacle is used toconnect the optional remote front panel unit
(SB-4450) to the control, where remote panel
mounting is desired.

Figure 10
SBS Balance System

11External/ Internal Balancer Operation
Balancer Slot Status LED
The status indication for installed Balancer channels is as follow:
BALANCE ABOVE CRITICAL. The LED is lit RED when the measured vibration level is above
the CRITICAL level selected by the user. While the system is performing an auto-balance, the LED
will blink.
BALANCE OUT OF TOLERANCE. The LED is lit YELLOW when the measured vibration levelis above the TOLERANCE level selected by the user. While the system is performing an autobalance, the LED will blink.
BALANCE BELOW LIMIT. The LED is lit GREEN when the vibration level of the grinding
machine is at or below the selected TOLERANCE limit. While the system is performing an autobalance, the LED will blink.
Balancer Main Screen Elements
The following items are elements displayed on the Balancer Card Main Screen (figure 11).
a) MENU BAR. The right side of the display is used to assign current function to the four
corresponding Function Buttons to the right of the display. This includes menu selections anddirection arrows. An animated hourglass appears here during the balance and plotting cycles,
indicating progress.
These Function Buttons are defined as follows for the main screen of each Balancer Channel. See
Function Button Map (figure 12) for an overview of the balancer functions available.
MENU. When this button is pressed, the display shows a menu listing with selectable operating
parameters and other functions for the control unit. The displayed arrow selection buttons are used tomove the highlighted selection bar up and down the listing. Press the ENTER button once the menu
item has been highlighted.
SHOW ALL. This selection will only be displayed on the Menu Bar when more than one balancer
card is installed in the control unit. Pressing the corresponding button will display the monitored
status of all balancer channels, or other devices.
MAN. Manual Balance Menu selection allows movement each of the two weighted masses in the
Balancer, (M1 or M2). Each mass can be moved in both directions using the function buttons
corresponding to the forward and reverse arrows on the display. These arrow buttons are available
only during a Manual Balance operation.
AUTO. Initiates an auto-balance cycle. Pressing the CANCEL button will halt the auto-balancecycle. (see: Automatic Balancing section).
b) IDENTIFICATION TAG. The upper edge of the display is used to identify the name of the channel
currently selected, and the current position in the menu structure.
c) VIBRATION DISPLAY. Indicates the measured vibration level of the grinding machine in either
microns or mils of displacement, or in millimeters/second or mils/second of velocity. The displayed
units are selectable from the Menu.
d) RPM DISPLAY. Displays Spindle RPM measured by the balancer. Display also indicates RPM
frequency during a Manual Filter vibration test.
12 SBS Balance Systeme) BAR GRAPH. The bar graph reflects the monitored vibration level compared to the LIMIT,TOLERANCE, and CRITICAL levels. A bar graph during plot shows the progress of the plot cycle.
f) STATUS. This text label is used to indicate the current status of the selected balancer channel.

Figure 11

MENU Settings and Selections
Note:

All menu items are set independently for each installed balancer card, or other device.

Pressing the MENU button listed on the display will produce a listing of menu items. This menu
provides a means of specifying system settings for individual balancer channels, and for performing certain
optional functions. Use the buttons corresponding to the up and down arrows to move through the menu
items. Press the ENTER button to select an individual menu item for edit or operation. Pressing the EXIT or
CANCEL buttons will exit the Menu screen, and return to the Main Screen for the channel. Description ofeach MENU listing follows:
Balance Settings
Use the button corresponding to the backward arrow to move the cursor from one digit to the next. Use thebuttons corresponding to the up and down arrows to increase or decrease the value of the selected digit.
When finished press the ENTER button to store any change in value, and move to the next balance setting.
Each of the following three balance settings are presented consecutively. Pressing CANCEL will return to
the Menu.
•

LIMIT target level - This is the lower limit that the balancer will try to achieve during an Autobalance cycle (This value should be set 0.2 micros higher than the background vibration level).

•

TOLERANCE level - This level sets the high end of the acceptable operating balance range.
When this level is exceeded a Balance Out of Tolerance (BOT) error condition is reported. Thissignals the operator or machine controller to re-balance the machine. This level needs to be
determined by process considerations. It should rarely be less than 1 micron above the Limit.

•

CRITICAL level - This level can be set at a value that provides a secondary warning of an
extreme out of balance condition that may be damaging to the grinding machine or process.
When this level is exceeded a Critical Balance out of Tolerance (BOT2) error is reported. Thissignals the operator or machine controller to shut down the machine. This same error can also be
triggered by excessive RPM (see: Critical RPM section).

SBS Balance System

13Vibration Units
Press the corresponding button to select from the available vibration units that may be displayed (UM,MIL, MM/S, or MIL/S). The currently selected units are highlighted on the screen. When the unit button
has been pressed, the display will change, giving the opportunity to select the desired display resolution forthat choice. The buttons corresponding to the up and down arrows are used to set the resolution, andpressing the ENTER button stores the selection.
Balance Speed
This setting will affect the time taken to perform an Auto-balance cycle. Normal is the correct setting formost applications.
•

CAUTIOUS balancing – Setting 1. This selection will control the balance weights in a slower
progressive balance mode. This setting is most useful on high speed grinders, or other machines
where slight movement of the balance weights produces dramatic change in vibration level.

•

AGGRESSIVE balancing – Setting 2. The aggressive selection operates the balancer in the fastestbalancing mode. This setting is most useful on machines with slow speeds and large wheels.

•

NORMAL balancing – Setting 3. This selection uses a combination of a fast balancing routine untilthe vibration level reaches 1.0 micron, then switching automatically to a slower routine for accuratebalancing.

Plot Vibration
This function allows the user to perform a vibration spectrum sweep in a selected RPM range. This
operation will take several minutes. It will generate an on-screen graphical representation of the amplitudeof vibration monitored at each RPM range in the form of a bar graph. It will also produce a text listing of the
top twenty vibration peaks encountered during the spectrum sweep. See the Plot Vibration section for
operational details.
Pre-Balance
Allows the user access to the pre-balance function of the control unit. The pre-balance function
provides a step by step process which assists the machine operator in placing manual balancing weights on
the grinding machine in correct position to achieve a rough balance. This feature can be useful upon
installation of new wheels, or whenever the wheel imbalance exceeds the balance capacity of the automaticbalancer. By pre-balancing, the majority of the wheel imbalance is removed, allowing the balance system toperform final trim balancing, and to maintain balance as the wheel wears. See the Pre-Balance section for
operational details.
Channel Name
Select a name or label to identify the balancer channel. This name is used on the various screens to
identify which channel is currently selected. SLOT1 is the factory default name assigned to all channels,
until the user selects a unique name.
Menu Entry
This selection on the menu list provides for use of a standard access code for menu protection. Setting
the channel to the protected mode denies access to the menu list unless the access code is entered. Thissetting 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.
14 SBS Balance System

Function buttons are assigned the numbers 1, 2, 3, and ENTER, which are used to input the access code. The
standard access code 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 ACCESS PROTECTED will be displayed notifying the user that the menu is password protected,
and the user will be 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.
Factory Settings
Returns user selectable parameters under the BALANCE SETTINGS menu to the default factory
defaults, changes BALANCE SPEED to CAUTIOUS, and sets CRITICAL RPM back to 0.
Critical RPM
This setting allows the user to select a maximum RPM level, which when exceeded will cause theBalance Control to indicate an error condition. Toggle the selection cursor with the up and down arrow
buttons to highlight the CRITICAL RPM selection, and press the ENTER button. The screen now displays
the CRITICAL RPM entry screen. Any RPM level set using this screen will act as a maximum limit, and if
this limit is exceeded, the Control will indicate an error in two ways. The SLOT STATUS LED will
illuminate RED. In addition, both the BOT and BOT2 Relay contacts will be tripped. This is an alternatecause of these error conditions. The BOT2 relay can be monitored by the machine controller, and if desired
can be used to set off additional warning systems or interrupt the operation of the grinding machine. To set
the desired RPM for the Critical level, use the left arrow button to select digits, and the up and down arrow
buttons to change the selected digit. Press ENTER to save the setting and return to other screens. To disable
the Critical RPM feature, simply reduce the CRITICAL RPM level to zero.
CNC BOT MODE
This selection controls the behavior of both the BOT (Balance out of Tolerance) and BOT2 (Critical
Tolerance) relays during Auto balance Cycles. When set to “INACTIVE (SB-2500)” both these relays areopen and not active during a balance cycle, except when a Critical RPM error is detected. This inactive
behavior matches the SB-2500/SB-3500 series of controls. When set to “ACTIVE (HK-5000)” both theserelays are active during a balance cycle. Each relay will be closed if the vibration level exceeds its set limits(see CNC/ System Timing Diagram).

SBS Balance System

15

16 SBS Balance System

MENUSHOW ALLMAN.
AUTO

Function Button Map

Initiates Auto-Balance Cycle.
Balance System Will Balance
To Selected Level (Balance
LIMIT)

Allows Manual RPM Setting.
Allows Manual Operation ofBalancer Weights.

Control Monitor Mode:
When More Than One Is
Installed, This Mode Displays
Status of All Balancer
Channels or Other Devices.

BALANCE SETTINGSVIBRATION UNITSBALANCE SPEED
PLOT VIBRATION
PRE-BALANCECHANNEL NAMEMENU ENTRY
FACTORY SETTINGCRITICAL RPM
CNC BOT MODE

Figure 12

Set Operation of BOT/BOT2 CNC Relays
During Auto-balance Cycle

Assign Maximum Normal RPM level, Higher
levels willl Initiate Error

Reset System Settings to Factory Defaults

Protect Access to Menu Screen and System
Settings

Label Each Balancer Channel with Individual
Name/Label

Perform Analysis to Assist With Manual PreBalancing of Machine (Used with Internal
Balancers)

Perform Vibration Spectrum Sweep in
Selected RPM Range

Select Appropriate Choice of Three Balance
Cycle Speed/Performance Settings

Select Preferred Vibration Units for Display

Set Key Vibration Parameters For Operationof Balance System(Limit, Tolerance, Critical)

Balancer Rear Panel Connections

2)

BALANCER CONNECTION. The receptacle with which theBalancer Cable makes connection to the Control Unit.

3)

HARDWIRE INTERFACE. Standard DB-25 connector
receptacle for use in making connection between the Control
Unit and any grinding machine controller. A complete
description of this interface protocol is given in the Machine
Control Hardwire Interface section of this manual.

Preparing to Set Operating Parameters

SENSORSENSOR CONNECTION. The receptacle through which theVibration Sensor cable makes connection to the Control Unit.
CNC INTERFACE

1)

BALANCER

Figure 13 illustrates the rear of the individual balancer card forcontrol of external and internal balancers (part SB-4512) installed in
the control. The control unit comes standard with one such card, andothers can be purchased and added to the control unit as required.
The following three connections are located on the rear panel of the
Balance Control Unit, and are common to any balancer cards installedin the control.

Figure 13

An understanding of the function and operation of the Control Unit’s front panel controls is assumed
in the following section. The following numbered steps provide a quick outline for system set-up.
Background Vibration
A check of the background vibration level must be performed, to correctly set up the system.
1)

Mount the Vibration Sensor in the position to be used during operation (see: Vibration Sensor
Location section). Install the Balancer, Control Unit, and all cables as indicated in the installation
section of the manual before turning on the Control Unit power. Leaving the grinding machine off,press the MAN. Button and use the arrow buttons to manually set the controls vibration filter to theoperational RPM of the machine. Note this measured ambient vibration level with the machine notrunning.

2)

Turn on all secondary machine systems (such as hydraulics, and motors), but leave the machine
spindle turned off. The vibration level displayed without the spindle running is the backgroundvibration level for the machine. Make note of this background vibration level for future reference insetting the operating parameters of the system. Refer to the Environmental Vibration section for
explanation of possible sources of background vibration.

SBS Balance System

17

Verifying Balancer Sizing
3)

Using the manual motor buttons, the left and right arrow buttons marked M1 and M2. Rotate themasses in the Balancer, while the machine is operating at speed. By running each of the two weights
in opposite directions, the operator should be able to introduce more than three microns of vibrationin the grinding machine, but not more than thirty microns. If results do not fall in this range, it may
be a sign that the Balancer needs to be re-sized for your application. Contact your SBS Balance
System provider for consultation. In the interim, do not allow the grinder to operate for extended
periods with high vibration levels.

Setting Operating Parameters
NEW WHEELThe following section details the menu-selectable operating
parameters of the Control Unit, in the order that they appear. For control
units where more than one balancer card is installed, the user should selectthe desired channel, and then enter the MENU list. The menu settings are
independently set for each channel.

MEASUREDVIBRATIONLEVELS

When the MENU button is pressed, a listing will display up anddown arrows, an EXIT, and ENTER selection. Use the up and downarrows to make a selection from the menu list and press ENTER to enter themenu item selected. When all desired changes are made, press the EXIT
button to leave the menu mode.
Auto-Balance LIMITCRITICALTOLERANCEOPERATING
RANGE

LIMIT
The SBS Balance System is designed to balance quickly and
0.1 MICRONS
automatically to a level of vibration specified by the user, with the use of
BACKGROUND
Auto-Balance LIMIT. The Auto-Balance Limit is factory set at 0.4 micronsof displacement. A balance level of 1 micron or less is generally
considered adequate for most applications. If the user wishes, this limit canbe set anywhere from 0.02 microns and up. The lower the Auto-Balance
Limit is set, the more time the system will typically require to achieve balance. Some experience may benecessary to determine the appropriate Auto-Balance Limit for a particular installation.

4)

To set the Auto-Balance Limit, the MENU button is pressed, and BALANCE SETTINGS is selectedfrom the menu. The Auto-Balance Limit is set using the arrow buttons, followed by pressing the
ENTER button. Typically you should set the LIMIT at a level that is 0.2 micron higher than thehighest background vibration level you noted is step #2 above. Press the ENTER button to enter theselected level. Note: While Velocity display modes may be selected for monitoring machine
vibration, the LIMIT setting can only be made in units of displacement.

NO BALANCE SYSTEM IS CAPABLE OF BALANCING THE GRINDING WHEEL TO A
VALUE BELOW THE AMBIENT OR BACKGROUND LEVEL. The results of trying to set thebalance limit below ambient levels will be long or failed balance cycles. Since the background vibrationlevel is often a product of floor transmitted vibrations, these levels may change as adjacent machines are put
into or out of service. Set the balance limit during periods which reflect the maximum floortransmitted vibration the system will receive.

18 SBS Balance System

Auto-Balance TOLERANCE
5)

Related to the Auto-Balance Limit, is the Auto-Balance Tolerance setting. This operator definedsetting establishes the vibration level, which acts as an “upper limit” for the system. When reached,this setting will indicate the need to perform a re-balance operation. This indication is given both by
the yellow color of the SLOT STATUS LED on the front panel, as well as via the hardwire interface.
The Tolerance level is selectable in the same manner as the Auto-Balance Limit. It must be set atleast 0.2 microns above the LIMIT setting. Typically it is set at least 1 micron above LIMIT setting.

Auto-Balance CRITICAL
Related to the Auto-Balance Tolerance, is the Auto-Balance Critical setting. This operator definedsetting establishes the vibration level, which acts as an indicator of the operational upper safety limit for thesystem. When reached, this setting will indicate the critical need to perform a re-balance operation. This
indication is given both by the red color of the SLOT STATUS LED on the front panel, as well as via the
hardwire interface. The Critical level is selectable in the same manner as the Tolerance setting. It must be
set at least 2.0 microns above the TOLERANCE setting.
Vibration Display
The units used by the Control Unit to display machine vibration levels are selectable between metricor English units. Also, the Control Unit can display vibration in terms of velocity or displacement. The
factory setting of displacement most directly reflects the movement of the grinding wheel, and therefore
impact of vibration on the work piece. Use the VIBRATION UNITS Menu item to select the desired option.
Balance Speed Selection
This Menu setting toggles the Control Unit’s response between three automatic ranges. The purposeof this adjustment is to maximize the speed and accuracy of the SBS Balance System when installed on
various sizes and types of grinders.
To determine the correct setting for balance speed, it is necessary to observe the operation of thesystem on its first few balances. With the system installed on the grinding machine, and the machinerunning, initiate an Auto-Balance cycle. Check to see that the system makes steady and timely progress to abalance point. Unbalance the system two or three times, using the buttons located on the Manual screen(MAN.). Each time initiate an Auto-Balance and check the results. Then select each of the other speed
settings and run two or three more tests. An error message “Error I” displayed during this test indicates that
the PULSE setting should be reset to a slower setting” (see: Displayed Error Messages section). This quick
check will give a clear indication of the proper setting. Your SBS Balance System is now “tuned” to yourgrinding machine.
Model SB-4400 Control Unit
LIMIT, TOLERANCE, CRITICAL, and BALANCE SPEED operating parameters are settablethrough the RS-232 port. Other operating parameters can be changed only with the use of the optional
Remote Keypad supplied by Schmitt Industries, Inc.

SBS Balance System

19

Automatic Balancing
Once all operating parameters are set, the SBS Control Unit can perform automatic balance cycles,
which are initiated by pressing the AUTO button, or by a Start Balance command via. the hardwire interface.
It is important to understand that Auto-Balance is an automatic cycle, which is initiated by the user, which
performs according to the operating parameters set, and then ends. Between balance cycles, the system willreport vibration levels, and RPM, but will not self-initiate an Auto-Balance cycle.
The operator (or machine controller) needs to understand when it is appropriate to initiate an AutoBalance cycle. Auto-Balance should be performed with the machine running, and coolant flowing. AutoBalance should not be performed while the wheel is in contact with the workpiece or dresser. The
process of grinding a part, dressing the wheel, moving the wheelhead, etc. can introduce vibrations into themachine which are unrelated to wheel balance. Attempting to balance during such processes will not work,
and will have detrimental effect on the grinding or dressing results. (see: CNC/ System Timing Diagram)

Pre-Balancing
Pre-balancing is used to manually position balance weights on the grinder to achieve an initial roughbalance level. In some applications (especially with internal balancers), an automatic balancer may not haveenough capacity to balance a new wheel with extreme imbalance. In such cases, the SBS Balance system
can aid the user in positioning manual balancing weights to quickly compensate for the major portion of thewheel’s imbalance. Automatic balancing can then be used to provide fine balance control until the next
wheel change.
Begin the pre-balance operation by choosing the“Pre-Balance” option from the MENU. The opening prebalance screen will be displayed. This screen shows thecurrent pre-balance parameters, and allows the user to:•••

EXIT the pre-balance operation.
SETUP pre-balance operation parameters
Go to the NEXT step in the pre-balance process.

Prepare for Pre-balance

Figure 14

Before pre-balancing, it is important to first minimize the Balancer’s effect on machine balance, sothat during the pre-balance operation only the new wheel’s native imbalance will be correctly analyzed andcorrected for. It is suggested that once the old wheel is removed from the machine, and before the newwheel is installed, that the grinder be re-started, and a balance cycle be run. This balance cycle has the
purpose of moving the balance weights inside the balancer to a null balance position, essentially 180 degrees
opposite one another. Once the cycle is complete, stop the machine and install the new wheel, then proceedwith pre-balance. Skipping this step will limit the effective balance range of the system in subsequent autobalance cycles.

20 SBS Balance System

0-BAL (Zero Balance Weights)
This option is only available on special Non-contact Internal Balancers which have the “ZeroWeights” option installed. Instead of running a balance cycle prior to installing a new wheel, the user may
select this option to automatically move the balance weights inside the Balancer 180 degrees opposite one
another, to achieve a null balance effect. When this option is initiated, the first screen displayed looks likefigure 16a. The “Stop Spindle” text will flash, and the “START” button will not be displayed until thegrinding spindle is stopped. After pressing START, the screen in figure 16b is displayed while the rotors arebeing positioned. Once complete, the unit will again display the initial Perform Pre-Balance screen.

Figure 16a

Figure 16b

Setup
After pressing SETUP, the user is presented with a sequential menu of operational parameters or
settings. The first selection is BALANCE TYPE, which describes which of the three available methods ofpre-balance will be used. Upon entering each screen, the current setting is always highlighted. Use theArrow buttons to make changes to the settings as needed, and the ENTER button to save each selection
made. You can abort the sequence of Menus any time by pressing EXIT or CANCEL.
Balance Type1. 2 Spread Weights – Supports pre-balance using two (2) equal fixed mass weights, which can bepositioned at any specific angle on the wheel holder. An angle scale must be provided for locationof the weights relative to some zero point. (0-360 degrees).
2. 3 Spread Weights – Supports pre-balance using three (3) equal fixed mass weights, which can bepositioned at any specific angle on the wheel holder. An angle scale must be provided for locationof the weights relative to some zero point. (0-360 degrees).
3. Variable Weights Fixed Angles – Supports pre-balance using addition of variable weights at
known numbered positions. Following this choice, the user also sets the number of equally spaced
locations (e.g. 6 locations spaced at 60°) where weight can be added to the machine. These
locations can be drilled and tapped screw locations or similar attachment points. This number oflocations can be set from 3 to 99. Each location should be marked with a reference number,starting with zero (e.g. 0-5 for six locations).
Weight Units
The user selects units of weight desired to describe the balance weights to be added. The settings
include Grams, Ounces, or None. The NONE setting can be used to describe any fixed arbitrary unit ofweight. The user can then manipulate weights based on this new “unit”. Such a unit can be used to indicate
the number of any identical objects, such as screws or washers of the same size, or other identical balance
weights of unknown mass.

SBS Balance System

21

Balance Weights
Enter the number of Weight Units assigned to each balance weight. This can be the measured weightin grams or ounces, or any convenient number of arbitrary units to be assigned to each balance weight.
Target Level
Enter the Vibration Level the user wants to achieve. The user can run iterative pre-balance cycles toachieve lower and lower vibration levels, and may quit the pre-balance process at any vibration level. When
this reference Target Level is achieved, the unit will display BELOW TARGET to indicate the pre-balancehas been successful.
Scale Direction and Wheel Rotation
Sets the direction of the weight scale on the machine, used to position the balance weights. This is arelative direction in relation to the rotation direction of the wheel. The weight scale direction is the
direction (clockwise or counterclockwise while facing the scale) in which the angle references (0°, 90°, 180°
etc.) or the weight position location numbers (1,2,3,4, etc.) increase. The system must know if this directionis the same or opposite the direction of the wheel’s rotation. The system can determine this automatically,
but to do so requires one extra trial-run cycle at the beginning of the pre-balance cycle, which may not bedesired in situations where this direction relationship remains constant. The following four settings areavailable.
1. Automatic Always – Every pre-balance operation, thedirection will be determined automatically by having theoperator run the extra trial-run cycles. This can be useful
where the spindle swivels or otherwise changes
directions.
2. Automatic Once – On the first pre-balance cycle ran after
selecting this option, the system will automaticallydetermine the direction by having the operator run theextra trial-run cycles, but will then store the result, andnot run the auto-determination cycle again.
3. Same – This setting allows the operator to manually input
the direction as SAME, without running the autodetermination cycle.
4. Opposite – This setting allows the operator to manually
input the direction as OPPOSITE, without running theauto-determination cycle.

Wheel
Rotation
Clockwise

0

270

90

180

Scale direction shown OPPOSITE
Figure 15

Beginning The Pre-Balance Operation
The user must provide for the following before attempting to pre-balance. The machine must be fitted
to allow the user to manually position balancing weights on the machine conveniently, without machine
disassembly. This can be accomplished in any of the method described under the Balance Type setting
description. Fixed mass weights to be used should be labeled A, B, or C, to identify them individually. On
the opening pre-balance screen, press the NEXT button to initiate the pre-balance operation, using thecurrently selected parameters. The pre-balance operation is an iterative or repetitive process of manually
positioning balance weight(s) according to the system’s directions, and then checking the vibration level
results of each move.
22 SBS Balance System

Position Weight Screen
A1

A5
A6

A2

A7
A3
A8
Figure 17

A4

The first screen in this progression, the “Position Weight” screen, will look something like figure 16, withsome variation, depending on the type of pre-balance operation being performed. The elements of the screen
are described below.
A1) Instruction Section – This part of the screen tells the user what to do next. The “STOP SPINDLE” text
will flash until the unit detects no incoming RPM signal. The NEXT button will also not be available
until this condition is met. The user is instructed to stop the machine spindle, position balance
weights as shown in the location detail, then press the NEXT button.
A2) Run Identification Bar – The highlighted bar shows the run reference number, followed by a descriptive
label for the run. A list of typical labels follows:
01: REMOVE WEIGHTS – On the first run the user must remove all balance weights
02: TRIAL RUN – On the Second run, the user will add a balance weight at the zero position.
03: DIRECTION RUN – This run is optional and only occurs when the control is set to auto-determine
the Scale Direction setting.
04: (Balance Vector) – A Balance Run. This and any subsequent cycles are called balance runs, andattempt to balance the machine. Each of the balance runs will be identified by it’s balance vector (seescreen example). This vector always shows the calculated additional amount and location of weightneeded to achieve balance, assuming any installed weights on the machine were left as is. The user canchoose to place a single weight of this mass at this location, to achieve balance if this method is desired.
A3) Location Detail – For two or three spread weight balancing, this area will look like the screen above,with each weight (A, B, etc,) listed, along with the mass of the weight expected, and the location eachweight should be positioned at. For any balance runs beyond the initial one, a plus (+) or minus (-) will
indicate relative angle movements from the current position.
For variable weight fixed angle balancing, a list will be shown of the amount of weight to be added at
specific location numbers. Angles are also referenced for each location number. For any balance runs
beyond the initial one, a plus (+) or minus (-) will indicate relative changes in weight placement fromthe current positions.
A4) Direction Setting – This area will show the current Scale direction setting, or “AUTOMATIC
DIRECTION” if the unit is in the process of automatically determining the direction.
A5) EXIT – will always exit the pre-balance process, back to the Main Menu. The CANCEL button willaccomplish the same.

SBS Balance System

23A6) SETUP – Pressing setup from one of these screens allows the user to change balance settings midcourse, and then continue from that point forward with the pre-balance process.
A7) BACK – Pressing this button will display a history screen, which allows the user to use arrow buttons toscroll back though each of the balance runs conducted, and even allows the user to choose one of theseearlier reference points as their current start point to continue the pre-balance process from. This allows
the User to “go back” to an earlier point in the pre-balance process, if desired, without having to startfrom the beginning again. All references to weight amount and location shown are absolute references,in this mode.
A8) NEXT – This button will only be available when the spindle has stopped. Pressing this button will
display the Check Vibration screen, so the unit may determine the balance level achieved.
Check Vibration Screen
Figure 18 shows the elements of the second pre-balance screen, the “Check Vibration” screen. This
screen will be displayed after each Position Weight screen, and has the purpose of showing the balance orvibration level which has resulted from the prior placement of weights. Many of the screen elements are thesame as on the Position Weight screen, with the critical differences described below.
B1

B2
B5

B3
Figure 18

B4B1) Instruction Section – This part of the screen tells the user what to do next. The “RUN SPINDLE” text
will flash until the unit detects a stable incoming RPM signal. The NEXT button will also not be
available until this condition is met. The user is instructed to start the machine spindle, check thevibration level to determine if the balance level is adequate, then press the NEXT button tocontinue with the next step in the process.
B2) Below the run identification bar, the screen now shows the measured vibration level, in the units
selected by the user. To the right of the vibration level, the measured phase angle is also displayed tointerested users.
B3) BELOW TARGET – This text is displayed whenever the measured vibration level is at or below thePre-Balance Target Level set by the user in the Setup section. Once this Level is reached, the prebalance is considered complete by the system, so the NEXT button will no longer be available.
B4) Reference – The bottom line of the screen displays the current Target Level set, and to the right of theTarget level, the current measured RPM level.
B5) NEXT – This button will only be available when the spindle is running, and the Target level has notbeen achieved. Pressing this button will display the next Position Weight screen, so the user may makefurther weight adjustments.

24 SBS Balance System

Manual Balancing
The SBS Balance System is fully automatic, but also provides the capability for manual operation.
The ability to move the weighted balance masses in the Balancer by hand can be utilized in various
situations. Purposefully unbalancing the system to a given vibration level can be useful for performing
diagnostic tests of the grinding machine. Occasionally operator preference may dictate that the balancing
procedure be performed manually.
Manual Balance buttons are accessed by pressing the MAN. button. A manual RPM can be specified
when no RPM signal is being received from the balancer, by using the arrow buttons to set the level andpressing the ENTER button. The buttons are divided into two groups, each controlling one of the twomasses in the balancer (M1 and M2). Each mass can be moved in either the forward or backward direction,with reference to the rotation of the grinding wheel. Only one button may be operated at a time. To
manually balance, the operator must move the two masses in the direction which reduces the vibration
reading on the Vibration Display. This should be accomplished in three stages.

Figure 19a

Figure 19b

First move each of the two masses equally in the same direction, either forward or backward. If
moving them forward increases the vibration, then choose the opposite direction. Continue this way until thevibration level can no longer be reduced. This movement has the purpose of positioning the two masses
equally about the line through the center of the wheel and the center of the imbalance (figure 19a).
The next stage is to find the correct angle for position of the masses in relation to the “center line”(figure 19b). Do this by moving the masses equally in different directions (one forward and one backward).
Again, if the vibration level is increased, the opposite movement should be tried. This stage is complete
when the vibration level can no longer be reduced. Finally the balance level can be fine-tuned by moving themasses individually in small increments, in order to minimize the vibration reading.
It should be realized that any change in vibration level of the machine would lag behind the
movements of the masses by one or two seconds. This is due to a “settling effect” of the machine. For thisreason, when the correct direction of movement is not yet clear, or the vibration level itself is small (2.0
microns or less), any movement of the masses should be performed in small increments, with a delay of two
seconds between movements to evaluate the movement’s effect.
Manual RPM Filter
The system has application as a vibration measurement and analysis tool, aside from its purpose as adynamic balancing system. To facilitate this function, the Control Unit has the capability of manualadjustment of the vibration frequency filter. Any filter RPM from 300 to 30,000, incremented in units of one
SBS Balance System

25RPM, can be manually implemented. This function allows the Control Unit to operate independently of the
Balancer, and to measure vibration levels occurring at different frequencies.
To set the Manual Filter, the 12-pin Balancer Cable can be detached from the Control Unit toeliminate an incoming RPM signal. The MAN. Button on the balancer Main Screen should be pressed toenter manual mode. Set the desired RPM frequency for the manual filter, using the left arrow button to selectdigits, and the up and down arrow buttons to change the selected digit. Press ENTER to view the vibrationlevel at this selected RPM. If desired, the Manual Filter level can be adjusted again to display the vibrationlevels at another frequency. In this way many different frequencies of vibration can be analyzed. A
complete analysis of all frequencies from 300 to 30,000 RPM is also available using the RS-232 Interface
port (see: command “G” under RS-232 Interface section).

Plotting Vibration
This function will perform an automated vibration sweep of a specified RPM (frequency) range, anddisplay the results as a graph on screen. This function can be very useful in diagnosing machine condition
induced vibration or discovering environmental problems, which may have adverse effects on the grinding
process. The RPM range to be evaluated will vary by machine and process. On constant surface speed
machines, the minimum and maximum RPM should be determined. The suggested range to evaluate is from
0.4 x (minimum RPM) up to 2.0 x (maximum RPM). This range is important because it includes all thelikely frequencies, which will have harmonic influence on the operating RPM range.
RPM RANGE – After selecting the PLOT
VIBRATION menu item, the first screen displayed allows
the user to press this button to select the RPM range. The
RPM Range is the frequency range that will be evaluatedduring the spectrum sweep for vibration amplitudes. Once
this selection is made, use the arrow buttons to first set thelow end of the RPM range, press ENTER to store thevalue, and then select the high end of the range in the samemanner. When setting the RPM range, use the up anddown arrow buttons to increase or decrease values, and theleft arrow button to move the cursor to the desired digit.
While the RPM RANGE screens are shown, the number
preceded by T= indicates the amount of time in seconds
estimated to perform the sweep, given the current RPM
settings.

Figure 20

START – This button begins a vibration sweep forthe selected RPM Range. The rotating hour glass figureon the right hand side of the display signifies that theControl is sweeping through the RPM range and recording
the maximum value in each monitored RPM range.
During this process, all recorded RPM, Vibration levelpairs are sent out the serial RS-232 port, in ASCII format..
When the RPM sweep is complete, the display willchange to the screen shown (figure 20). The area
necessary to display the incremented RPM range isdependent on the RPM range selected, divided by the

26 SBS Balance System

Figure 21

number of available pixels across the horizontal axis. The vertical scale is based on the peak value,
displayed at the top of the plot. The vertical scale is logarithmic.
1)

VIEW DATA. Pressing this button will change the display to a listing of peak vibration values (figure21). These are the top 20, or less, values recorded in the selected range. The VIB./RPM button on thisscreen switches the order of these values, allowing them to be ordered either by vibration level or
RPM. The arrow buttons are used to scroll up or down through the peak values. The VIEW PLOT
button returns to the screen showing the last recorded graph.

2)

SEND DATA. Pressing this button will export the vibration peak values, and corresponding RPM
levels out the serial RS-232 port, in ASCII format. This information can then be captured and used asneeded by the user.

3)

PLOT SETUP. This button returns the user to the setup screen for performing a vibration plot, where
alternate RPM settings can be input for plotting, or the plot process can be exited, by pressing the
EXIT button.

Machine Control Hardwire Interface
There are two different options available for interfacing the SBS Balance System Card with a CNC
or PLC machine controller. Either a hardwire interface or software interface is supported. The hardwire
interface is supported via a standard DB-25 connector located on the rear panel of the Balancer Card, while
the Software interface is supported via the DB-9 connector located on the rear panel of the SBS Control
Unit’s Main Card, which is 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 it isintended that the grinding machine's controller operate the SBS System. It is not possible, or advisable,
for the SBS System to control the grinding machine. The following interface is provided as a means toconnecting with the SBS control, using information provided by the system, to maintain the desired balanceparameters. The whole of this manual should be read before attempting to interface the SBS System withany machine controller. Sections covering the interface of other SBS products installable in the SBS
Control, are covered separately in the manual addendum for such products.
Hardwire Control Interface Overview
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 inputs of the hardwire interface. It
consists of three common pins and an output pin. The common pins are internally connected to chassis andearth ground, while the output is intended to provide a maximum of 30 mA at approximately +15VDC. Any
external power used for interface I/O must be from a SELV source or supply.
The three inputs provide optical isolation between input signals and the rest of the Control circuitry.
The inputs are activated by being pulled high, either by connection to the SB-4500/4400 hardwire interface
power supply output or by connection to a customer supplied signal. Activating the inputs requires at least 8mA at a voltage between 10 and 26 volts, AC or +DC, referenced to the SB-4500/4400 hardwire interface
power supply common. The common pins are internally connected to chassis and earth ground. The inputs
are deactivated by removing the connection to the power or signal source.
The four primary outputs consist of optically isolated, solid state, single-pole/double-throw relays.
These relays may be used to supply an output signal by connection to a voltage source supplied by thecustomer. The relay 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.
SBS Balance System

27

The three contacts of a single-pole/double-throw relay are often referred to as “normally open”,“normally closed” and “common”. The term “common” in this sense does not imply connection to power
supply commons. The term “return” will be used below to indicate the common contact of the relay.

Hardwire Interface Connector
Standard for SB-4400, and SB-4500

Common

1

N/C

2

N/C

3

N/C

4

RPM Return5

RPM Output

6

Common7

FBSI Relay Contact - NC

8

BOT Relay Contact – NC

9

BOT Relay Contact – NO

10

FBSI Relay Contact – NO

11

BIP Relay Contact - NO

12

Common13

14

BOT2 Relay Contact - NO

15

BOT2 Return16

BOT2 Relay Contact - NC

17

FPI Input

18

SBC Input

19

SPB (Stop Balance) Input

20

Supply Output

21

N/C

22

BOT Return

23

FBSI Return

24

BIP Return

25

BIP Relay Contact - NC

Shell (Shield Gound)Figure 22

Input Pin Names and Functions
Pin# Name Description
18
SBC
Start Balance Command- This input is momentarily activated to initiate an automatic balance
operation. The rising edge of this signal starts the operation.
19

SPB

Stop Balance Command- While active, this input stops an automatic balance operation inprogress and inhibits the start of an automatic balance operation.

17

FPI

Front Panel Inhibit- While this input is active, most operator actions at the front panel keypad
are disallowed. Specifically, the Menu button, the Manual button, and the Auto Button are
disabled. Still enabled are the Power button and the Cancel button, which can be used to stop
an automatic balance operation.

28 SBS Balance System

Output Pin Names and Functions
Pin#
22
10
9

Name
BOT-R,
BOT-NO
BOT-NC

Description
Balance Out of Tolerance: Return, Normally Open, and Normally Closed contacts.
This relay is energized when the sensed vibration level exceeds the operator definedTolerance. Function of this relay during an automatic balance cycle is determined by
the CNC BOT MODE setting.

15
14
16

BOT2-R
BOT2-NOBOT2-NC

Balance Out of Tolerance Two: Return, Normally Open, and Normally Closed
contacts. This relay is energized when the sensed vibration level exceeds the operator
defined Critical Tolerance, or when the spindle RPM exceeds the operator defined
Critical RPM. Function of this relay during an automatic balance cycle is determinedby the CNC BOT MODE setting.

24
12
25

BIPR
BIP-NO
BIP-NC

Balance In Progress: Return, Normally Open, and Normally Closed contacts. This
relay is energized while an automatic balance operation is in progress.

23
11
8

/FBSI-R/FBSI-NO/FBSI-NC

Failed Balance/ System Inoperative: Return, Normally Open, and Normally Closed
contacts. This relay is energized after a successful Power On Self Test. It is deenergized if a fault condition arises.

6
5

RPM
RPM-R

This relay closes once per revolution. This is a buffered output of the RPM signal
generated by the balancer. It is not available if the RPM has been entered manually.

Software (RS-232) Interface
The SBS Balance System provides an alternate interface using the RS-232 signal lines on the DB-9
connector. The RS-232 interface allows the same control capability as the hardwire interface with theadditional capability of monitoring the system status, setting of the Auto-Balance Limit, and performing avibration spectrum analysis. The following description applies to all models of SBS Control Units. Theinterface is identical for the SB-4500 and SB-4400 units.
Interfacing
The RS-232 interface is a subset of the complete RS-232 specification, and uses only three wires forcommunication. When connecting to this interface, some systems will require additional jumper wires on
the control unit end of the cable for successful operation with this three-wire interface. The following pinson the DB-25 connector are used for the RS-232 interface.
Pin #Pin Name

Description

5
2
3

COM
TXD
RXD

Signal/Common
Transmitted Data RS-232-C
Received Data RS-232-C

SBS Balance System

29Setting Baud Rate
The baud rate of the RS-232 interface is set at unit power-up, by selecting the SETUP option. The
factory setting for baud rate is 9600 baud, which should be adequate for most applications. To change thebaud rate, turn the Control on by pressing the button marked ON/OFF in the upper right corner of themembrane keypad, and immediately after the unit is powered up, press the SETUP button. When thelanguage setting screen appears press the ENTER button again to change to the Baud Rate screen. To selectthe Baud rate, use the up and down arrow buttons, to select from the displayed list. Once the correct baudrate is highlighted press the ENTER button, to choose the new setting. The baud rate can be set from 300 to
19200 baud. Use of the optional Remote Keypad is necessary to change the baud setting for a SB-4400
Control Unit.
RS-232 Commands and Responses
When the Control unit is first powered up, the following messages are transmitted out the RS232 Port.
The first two lines are from the System Control, the first is identifying text and the second is the firmware
version. The remaining lines identify the functions plugged into the Slot Card positions and the firmware
revision associated with each. The last five messages may be transmitted in any order:/SB-4500, Copyright (c) 1998, Schmitt Industries, Inc.<CR>
V0.02<CR>
2X1.00V0.09[GR1]/Standard Balancer<CR>
1X0/No Card<CR>
3X0/No Card<CR>
4X0/No Card<CR>
Commands - A message preceded with the digit ‘1’ through ‘4’ will be a command or responsereferring to Slot Cards 1 through 4, respectively. A message starting with any other character refers to the
System Control.
The following commands from the RS232 Port are available:
Control Unit Commands
CommandC

Response

Meaning/ Example:
Control Panel Status Inquiry.

<Esc>C<CR>
CI

Control Panel is Inhibited

CI<CR>
CE

Control Panel is Enabled

CX

Control Panel is not installed

CE<CR>CX<CR>
CE

Control Panel Enable.

<Esc>CE<CR>K

Command Acknowledged

K<CR>

30 SBS Balance System

CX

Control Panel is not installed

CX<CR>CI

Control Panel Inhibit.

<Esc>CI<CR>
K

Command Acknowledged

K<CR>
Q

Command Not Accepted (Panel in use?)

CX

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

Q<CR>
V

<Esc>V<CR>
Vn.nn

Firmware Version

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

Response

Xz.xxVv.vv[sss]/text

Meaning/ Example:
Type (of slot card) Request.
< Esc >1X<CR> Start Slot 1 Info Request.
Slot info response. z indicates Slot Card type: 1 is Mechanical Balancer; 2 isHydro Balancer. 4 is EM Ring Balancer. xx is specific hardware or balancer
category. v.vv is balancer firmware revision. sss is the user specified name forthis card. The slash delineates a text comment that briefly explains the card
type.

X0/No Card

No card is installed in the slot.

XX/NotResponding

A card is installed in the slot, but is not responding to the system.

1X1.00V1.00[GR1]/Std Balancer<CR>
1X0/No Card<CR>
BA

1XX/Not Responding<CR>
Balancer Abort Command.

<Esc>2BA<CR> Abort Slot 2 Balance Cycle.
BT

Balance cycle terminated (if running)

2BT<CR>
BS

BS

Balance Start Command. This command will start the auto balance cycle if thesystem resources can be acquired. Once it starts, the front panel Cancel button
will stop the cycle.
<Esc>1BS<CR> Start Slot 1 Balance Cycle.
Balance Cycle started

1BS<CR>
BT

Balance Cycle terminated

1BT<CR>
G[sss][,[eee]]

U=units

Graph Vibration Spectrum. This takes vibration readings as a function of the
rpm of the vibration. Optionally specify sss as starting rpm and eee as endingrpm.
<Esc>1G500,2000<CR> Start Slot 1 Vibration Spectrum Program. Scanfrom 500 to 2000 RPM.
Spectrum program started (units given)

1U=UM<CR>
Grrr,vv.vvv

Graphic Vibration Point. One line is generated for each RPM measured. rrr isthe current rpm. vv.vvv is the measured vibration at the specified RPM.

1G500,0.04<CR>
1G550,0.05<CR>
SBS Balance System

31

Balancer Card Commands (Cards are Individually Controlled)
Command

Response
GE

Meaning/ Example:
Graphic Spectrum End. The graphics vibration spectrum routine is finished.

1GE<CR>
GX
GE
L[x.xx[,[y.yy][,[z.zz]]]]

Lx.xx,y.yy,z.zz

Cancel Vibration Spectrum.
<Esc>1GX<CR> Stop Slot 1 Vibration Spectrum Program.
Graphic Spectrum End
Limits Command. x.xx is Limit, y.yy is Tolerance, z.zz is Critical Vibration level,
all in microns. If x.xx is not present then the Limit level will not be changed. If
y.yy is not present then the Tolerance level will not be changed. If z.zz is notpresent then the Critical Vibration level will not be changed.
<Esc>1L<CR> Get Slot 1 Balance Limits.
Balance limit response (new values). x.xx is Limit, y.yy is Tolerance, z.zz is
Critical Vibration level, all in microns.

1L0.40,1.20,20.00<CR><Esc>1L0.08,,15<CR> Set Slot 1 Limit to .08, Critical level to 15.00, don’tchange Tolerance.

1L0.08,1.20,15.00<CR>
P[1|2|3]

P1

Balance Speed setting. 1 sets cautious balance. 2 sets aggressive balance.
3 sets normal balance.
<Esc>1P<CR> Get Slot 1 Balance Speed setting.
Current Balance Speed setting is cautious.

1P1<CR><Esc>1P2<CR> Set Slot 1 Balance Speed setting aggressive.
1P2<CR>R[rrr]Rrrr
S[C]S rrr,v.vv,[FBSI,][BIP,][FPI,]ERR=eeeSet critical RPM level. rrr is new Critical RPM level 300 to 30000. Use 0 (zero)for rrr to turn Critical RPM Off.
<Esc>1R3500<CR> Set Slot 1 Critical RPM to 3500 RPM.
<Esc>1R0<CR> Turn Slot 1 Critical RPM check Off.
<Esc>1R<CR> Get Slot 1 Critical RPM
1R3500<CR> Slot 1 Critical RPM is 3500 RPM.
Status Request command. If ‘C’ present then previously reported errors
condition will be cleared before the status is reported.
<Esc>1S<CR> Report Slot 1 Status.
Status response. rrr is RPM, v.vv is vibration level in microns, FBSI indicatesbalance failed/system inoperative, BIP indicates balance in progress, FPI
indicates front panel is inhibited. eee represent individual error lettersrepresenting error conditions. If the first letter is ‘@’ then an error condition
requires clearing (use SC command or press clear on front panel).

1S 1590,0.23,ERR=@GI<CR><Esc>1SC<CR> Report Slot 1 Status.
1S 1590,0.24,ERR=G<CR>
RS-232 Operation Summary
The RS-232 capability of the SBS Balance System, when used in conjunction with a capable hostcomputer can provide a completely automated testing and balancing capability for a grinding machine. If thevibration spectrum is recorded at a point in time (perhaps when the machine is new), that record can thenbecome a reference for gauging bearing condition, spindle balance, and overall machine condition. The
RPM and vibration level readouts from the status line can be used to provide a remote indication of themachine operating speed, and characteristics. On some machines this data may be interpreted to indicate
when a grinding wheel needs to be changed or other maintenance performed.
32 SBS Balance System

SBS Balance System

33

BALANCE LIMIT

BOT LEVEL

BOT2 LEVELGRINDING OR
DRESSINGCYCLEVIBRATION
EXCEEDSTOLERANCEBEWEENGRINDING
CYCLES= RELAY CLOSED= RELAY OPENWHEEL BALANCED

0.2 MICRONS (minimum recommended)

ALLOW 2 SEC.
FOR RELAY TO OPEN

BOT SET “ACTIVE” 1

BOT SET “INACTIVE” 1

BALANCECYCLE IN
PROGRESSSTARTBALANCE
COMMANDISSUED

VIBRATION PLOT AT
SPINDLE FREQUENCYGRINDING OR
DRESSING
CYCLE

SBC ALTERNATESBC SIGNAL

BIP RELAY

BOT2 RELAY1

BOT RELAYBEWEENGRINDING
CYCLES

CNC/ System Timing Diagram

BACKGROUND VIBRATION LEVELGRINDER ON

POWER UP
(ALLOW 5MS FOR RELAY TO OPEN)

Figure 23

ACTIVE SETTING – RELAY OPENS AFTERVIBRATION LEVEL IS BELOW SET LIMIT (HK-5000).

INACTIVE SETTING - RELAY OPENS WHEN
BALANCE CYCLE STARTS (SB-2500).

BOT /BOT2 RELAYS BEHAVIOR DURING BALANCECYCLE ARE BOTH SET BY CNC BOT MODE MENU
SELECTION.

1

System MaintenanceCollector MaintenanceOperator maintenance of the SBS Balance System consists of replacement of the line fuse in theControl Unit, and replacement of Balancer slip ring assembly as necessary. Instructions are available withthe replacement parts below. Cable schematics for the Balancer Cable and Sensor Cable follow (see: figure
25 and 26), in order to assist with minor repair or wiring connection work. If further service is required,contact your SBS Balance System source, or Schmitt Industries Inc.

Balancer Slip Ring Replacement
RPM Sensor(SB-8520) Slip Ring Block
Guide Slot
Slip Ring Post
Slip Ring Connector
Plastic Retaining Clamps
Main Connector
Cover
Cover Screws (M3)Cap

SBS Collector Diagram (SB-8510)

Post Screws (M3)
(SB-8530) Slip Ring Post
Bearing
Ring
Post Connector
Balancer

Figure 24

An optional non-contact version of the SBS collector is shipped with some balancers. This version isrecognizable in that the collector with cable attachment point is a separate part from the balancer, and ismounted independently on the grinder. The non-contact version contains no serviceable parts.
SBS Return/Repair Policy
Schmitt Industries’ policy is to give highest priority to the service needs of our customers. We
recognize the cost of machine downtime, and strive to deliver same day repair of items arriving at ourfacility, whenever possible. Because of the complication and delays involved with international shipments,
customers outside the continental U.S. should contact their local SBS source for service support. Before
return of any equipment for repair, it is necessary for you to contact Schmitt Industries, Inc. for a Return
Materials Authorization (RMA) number. Without this tracking number, Schmitt Industries can not ensure
prompt and accurate completion of your repair needs. Failure to obtain an RMA number may result in
substantial delay.
34 SBS Balance System

Balancer Cable Schematic
Balancer Cable
For Cable Part Numbers SB-48xx

OUTER BRAIDED SHIELDDRAIN 24 AWG (7/32)
BLACK 24 AWG (7/32)

CONNECTOR AT
CONTROL END

CONNECTOR AT
BALANCER END

WHITE 24 AWG (7/32)
GREEN 24 AWG (7/32)
INNER FOIL SHIELDBLUE 24 AWG (7/32)
VIOLET 24 AWG (7/32)
BROWN 24 AWG (7/32)
RED 24 AWG (7/32)

12p CIRCULAR MALE
DIN PIN VIEW

ORANGE 24 AWG (7/32)

7p BAYONET FEMALEPIN VIEWYELLOW 24 AWG (7/32)

Figure 25

Sensor Cable Schematic
Sensor Part Number SB-14xx
BACKSHELL

1
2

3
4

2
5

OUTER SHIELD

1

3
4

BLACK 20 AWG (19/32)
RED 20 AWG (19/32)

5
CIRCULAR MALE DINPIN VIEW

Figure 26

SBS Balance System

35

Trouble Shooting Guide
If you experience trouble with the operation of the SBS Balance System, the following guide isdesigned to help in determining the source of the problem.
Step 1
If the balance Control Unit is displaying any error messages, refer to the Displayed Error
Messages section of this manual for explanation of the message(s) displayed. Contact Schmitt Industries forassistance as required.
Step 2
If you are experiencing problems, with no displayed error messages, then check the Vibration
Sensor, and verify that the Sensor is firmly seated on the machine, its magnet firmly tightened in place, and it
is properly connected to the Control Unit. Also check that the Sensor's position on the grinding machineaccurately reflects machine balance (see: Vibration Sensor Location section).
As a final check, set the RPM manually on the Control Unit to the operating speed of the grinder,
and verify that there is an incoming vibration signal. If you receive a zero reading from the Sensor during
this test, the Vibration Sensor and Control Unit should be returned for repair. Contact Schmitt Industries fora return materials authorization (RMA) number.
Step 3Once the Vibration Sensor's function is verified, the next step is to perform an integrity check of
the rest of the system. This test should be performed with the machine running, but not in a grinding or
dressing cycle. Press the MAN. button to enter the manual control mode, and simply press each of the four
manual buttons, one at a time, for a period of about 5 seconds. With each movement of the Balancer
weights, the system should register a change in the displayed vibration level on the Control Unit. If this does
not happen for any of the four buttons, there is a service problem with the system. The Balancer, Control
Unit, Vibration Sensor, and Balancer Cable should all be returned as a unit. Contact Schmitt Industries for a
return materials authorization (RMA) number.
Step 4
If the integrity check shows no service problem with the SBS System, then the final area toinvestigate is environmental/application issues. The background vibration level on the machine should bemonitored under operation, and the Balance Limit setting checked against this level. (see: Environmental
Considerations section) (see: Setting Operating Parameters section) Also, the sizing of the Balancer to theapplication should be checked. (see: Verifying Balancer Sizing section)
If you continue to have problems after following these four steps, contact Schmitt Industries, or your
SBS Balance System source for assistance.
Display Test Option
During control power-up, while the company logo screen is displayed, a functional test of the display
can be initiated by pressing one of the function buttons above the SETUP button followed by the SETUP
button. The screen will display a DISPLAY TEST message and list buttons for TEST, START, and SETUP.
Pressing TEST will reverse the light and dark text areas. Pressing TEST again will display a full screen withall pixels lit. Pressing again will turn all screen pixels off. Pressing again returns the screen to DISPLAY
TEST. Also displayed are the revision reference numbers for the system main board and display board. The
LED status indicators on the left side of the display will sequence through the three colors to check
operation. Press the START button to bypass SETUP and resume normal operation. Press the SETUP
button to continue to system setup.

36 SBS Balance System

Displayed Error Messages
New self-diagnostic software has been incorporated into all SBS Balance Control Units. If a problem
ever occurs with an SBS system, It is quickly reported on the front panel display in the form of an error code.
Below is a listing of these codes, a description of when the Control Unit automatically runs each test, howeach code is cleared, the definition of each error message, as well as the prescribed action to be taken by theuser of the system. To further isolate defective components a series of test operations accompany some ofthe error codes.
A—

Checked continuously .........................................................

message:

RPM OUT OF RANGEOPERATION RANGE IS
300-30000
CHECK RPM SENSOR

Clears automatically.
definition: Displayed if the RPM signal coming from the Balancer is below 300 RPM or exceeds 30,000
RPM and the RPM number cannot be displayed.
action: Verify operating speed of the grinding machine. If the machine is running above 30,000 RPM,
contact your SBS Balance System source for application consultation. If the machine is runningwithin the operating speed limits, and this error message persists, this indicates a failure of the
RPM sensor in the Balancer. The Balancer should be returned for service.
B—

Checked Continuously ........................................................

message:

VIB SENSOR DEFECTSHORT – CHECK CABLE
AND CONNECTORS SEE MANUAL

Clears automatically.
definition: Vibration Sensor presence not detected. This could be caused by a defective sensor or by nosensor being connected.
action: Check sensor connections and try Power-On again. Continued error messages indicate the needfor repairs to the Sensor.
C—

Checked Continuously ........................................................

message:

VIB SENSOR DEFECTSHORT – CHECK CABLE
AND CONNECTORS –SEE MANUAL

Clears automatically.
definition: Vibration sensor short circuit detected.
action: Disconnect the balancer from AC power before checking cables and connectors, and sensor for
shorts. If the problem can not be isolated, the sensor, cable, and/or Control Unit should be
returned for repair.

SBS Balance System

37

D—

Checked at the end of a motor pulse...................................

message:

MOTOR DRIVER FAULTSHORT – CHECK CABLE
AND CONNECTORS –SEE MANUAL

Cleared manually.
definition: Motor – short circuit detected.
action: Determine which is the defective component by swapping with another system, or by using thefollowing diagnostic test. Return defective component for repairs. If in doubt, return all items.
test: Shut off the grinding spindle, and disconnect the Balancer Cable from the Balancer, but not fromthe Control Unit. Press MAN. Button on control to enter manual control mode. Press and holddown the first of the four manual motor buttons for 15 seconds. Repeat with each of the manualmotor buttons (only one button can be actuated at a time).
If error E is displayed, clear this error, as it is expected. If no other error occurs during this test,
then the problem is with the Balancer. If error D or F is displayed, then continue on and perform
part two of this test.
Disconnect the cable from the Control Unit, and repeat the above test, using all four manualmotor buttons. If error E is displayed, clear this error, as it is expected. If no other error occurs
during this test, then the problem is with the Balancer Cable. If error D or F is displayed, theproblem is with the Control Unit.
E—

Checked at the end of a motor pulse...................................

message:

MOTOR DRIVER FAULT
OPEN – CHECK CABLE
AND CONNECTORS –SEE MANUAL

Cleared manually.
definition: Motor – open circuit detected.
action: Determine which is the defective component by swapping with another system.
defective component for repairs. If in doubt, return all items.
F—

Checked at the end of a motor pulse...................................

message:

MOTOR DRIVER FAULTEXCESS CURRENT PERFORM MANUALFUNCTION TEST

ReturnCleared manually.
Cleared by pressing Auto button.
definition: Motor – excessive current detected (short or stall).
action: Verify that both ends of the Balancer Cable are properly attached. If connector pins arecontaminated, clean with electrical contact cleaner. If problem persists, determine if the Balancer
Cable is the defective component by swapping with another system, or by using a voltmeter, andthe enclosed Balancer Cable Schematic. Return the defective cable or Balancer for repairs. If in
doubt, return both items.
38 SBS Balance System

G—

Checked continuously .........................................................

message:

AUX POWER DEFECTSHORT – CHECK CABLE
AND CONNECTORS SEE MANUAL

Clears automatically.
definition: 24V Auxiliary Supply low – fuse open.
action: Determine which is the defective component by swapping with another system, or by using thefollowing diagnostic test. Return defective component for repairs. If in doubt, return all items.
test: Check for shorts in cables and connectors and re-initiate system check. If the error persists return
Control Unit and cables for repair.
H—

Checked Continuously ........................................................

message:

RPM/CNC POWER DEFECTSHORT – CHECK CABLE
AND CONNECTORS SEE MANUAL

Clears automatically.
Cleared by pressing Auto button.
definition: 15V Auxiliary supply low – fuse open.
action: Check for shorts in Balancer and machine controller interface cables and connectors and reinitiate system check. If the error persists return Control Unit and cables for repair. If you have
the SBS system cabled to your machine controller, verify that the interface cable is free ofelectrical shorts. The interface cable is not supplied with the SBS system, and repair is the
responsibility of the user.
I—
Checked during Auto Balance cycle ...................................
message:

AUTO-BALANCE FAILEDLIMIT NOT REACHABLE
BEST BALANCEACHIEVED AT

Cleared manually.
Cleared by pressing Auto button.
definition: Auto Balance Failed – unable to reach limit.
action: Reset the PULSE setting to “CAUTIOUS”, and verify system integrity as OK (see: Trouble
shooting Guide section). If this error continues, there are two possible causes of this error.
1) LIMIT set too Low - The LIMIT must be set 0.2 higher than the Measured background vibration(see: Other Sources of Vibration section).
2) It is a signal that the Balancer supplied is sized incorrectly for the application. Conduct the test
described in the Verifying Balancer Size section. If test results are outside suggested levels,
contact your SBS Balance System source to discuss replacement.

SBS Balance System

39

J—

Checked Continuously........................................................

message:

NO RPM SIGNALCHECK CABLESCHECK SPINDLE

Cleared automatically.
Cleared by pressing Auto button.
definition: No incoming RPM signal, possible open in RPM sensor circuit.
action: Ensure that spindle is running, with balancer cable attached at both balancer and control ends.
Determine which is the defective component by swapping with another system. Return defective
component for repairs. If in doubt, return all items.
K—

Checked when Auto Balance Cycle Completed .................

message:

ABNORMAL CONDITIONBAL CYCLE COMPLETEDAFTER ERROR DETECTEDSEE MANUAL

Checked when Auto Balance Cycle Completed.
definition: Balance cycle completed after error detected and cancelled, clears automatically.
action: No action required other than clearing manually from the Balancing screen.
L—

Checked Continuously........................................................

message: CIRCUIT FAILURE
UNABLE TO MEASUREVIBRATION
SEE MANUAL
definition: Signal acquisition circuit failed.
action: Clears automatically, no action required other than clearing manually from the Balancing screen.
If the problem persists, the Control Unit should be returned for repair.

40 SBS Balance System

Appendix A: Electronic Specifications
Control Unit
Installation: Pollution degree 2, Installation category II
RPM Reporting: 300 to 30,000 RPM
Vibration Range: 120 µG to 25 G
Vibration Display Resolution:
One of three options are
selectable by the userover the operational range
Vibration Display Repeatability:
6,000 RPM
300 – 30,000 RPM
Vibration Display Accuracy:
6000 RPM
300 – 30,000 RPM

0.1 µm0.01 µm0.001 µm

0.01 mil
0.001 mil
0.001 mil

0.01 mm/s
0.001 mm/s
0.001 mm/s

1 mil/s
0.1 mil/s
0.01 mil/s±1% @ 5.0 µm±2% @ 50:1 signal to noise±2% @ 5.0 µm±4% @ 50:1 signal to noise

Vibration Filter
3% width
60 dB per decade drop-off
modified Butterworth (SBS proprietary)
Auto-Balance accuracy+ /- 0. 1 microns displacement.
Power Requirements:
Supply: 100-120 VAC, 50/60 Hz, 2A max; 200-240 VAC, 50/60 Hz, 1A max
Mains supply voltage fluctuations not to exceed +/- 10% of nominal supply voltage.
Environmental Conditions:
Intended for indoor use only.
Temperature: 5°C to + 55°C
Humidity: 0 to 95% relative humidity (non-condensing) throughout temperature range.
Altitude: <= 2000 m
Cleaning Instructions:Wipe unit off with clean cloth. May use mild detergent or water. Do not spray or immerse unit.
Vibration Sensor
Sensitivity Range+ /- 25g
Sensitivity Resolution 0.0001g
Voltage Sensitivity
100 mv/g
Excitation Current
2 to 8 ma
Frequency Response 0.5 to 5000 Hz
Operating Temperature 0 to +70 C

SBS Balance System

41

Appendix B: Replacement Parts List
Part#

Description

Balancer Cables1
SB-48xx
SB-48xx-V
SB-46xx

Balancer Cable /SB-4500 series
Balancer Cable /SB-4500 series – Heavy Duty
Balancer Extension Cable /SB-4500 series

Controls/ Options
SB-43xx
SB-24xx-L
SB-4500
SB-4400
SB-4450
SB-43xx
SB-4475
SB-4512SB-4518
SB-4522

Remote Keypad Cable for SB-4400
Hardwire Interface cable (standard lengths)
CONTROL UNIT (Expandable to 4 Channels)
CONTROL UNIT (Expandable to 2 Channels)
Remote Keypad (option for SB-4400)
Remote Keypad connection cable (option for SB-4400)
CONTROL UNIT (w/ optional installed front panel)(Expandable to 2 Channels)
Additional Mechanical Balancer Channel Card
Additional Hydrokompenser (water balancer) Channel Card
AEMS Gap/Crash Monitoring System Card

Vibration Sensors1
SB-14xx
SB-16xx

Sensor Cable (standard lengths)
Sensor Ext. Cable (standard lengths)

Control Mounting Hardware Options
SB-0451
Rack Mount Panel: SB-4500 – 19”
SB-0441
Rack Mount Panel: SB-4400 ½ Rack DIN 3U
MC-0400
Control Mount Bracket: SB-4500
SB-0442
Control Mount Bracket: SB-4400
Other Parts
EC-5605
CA-0009
CA-0009-G
CA-0009-B
SB-8510SB-8520
SB-8530
MC-8516
MC-8515
CA-0114CA-0121CA-0125
CA-0105
SB-0020
SB-1300
SB-1311
SB-1321

Control Unit Fuse, 3 amp time lag 5x20 (2 required)Power Cordset
Power Cordset (Germany)
Power Cordset (British)
Complete SBS Balancer Low Profile Collector replacement
Collector Slip Ring Block Replacement—L/P
Collector Slip Ring Post Replacement—L/P
Collector RPM Sensor Replacement—L/P
Collector 7-Pin Connector w/ Wire Harness
7-Pin Male DIN (control end plug of Balancer Cable for 25xx series cables)
12-pin Male DIN (control end plug of Balancer Cable for 48xx series cables)
Standard 7-Pin Female Bayonet Connector (Balancer end of Balancer Cable)
Heavy-Duty 7-Pin Female Bayonet Connector (Balancer end of Balancer Cable)
1" Hex Wrench (Large Adapter Nuts)
Adjustable Hook Pin Spanner (Adapter Flanges)
Adjustable Face Pin Spanner 1/4” pins (Small Adapter Nuts)
Adjustable Face Pin Spanner 3/8” pins (Large Adapter Nuts)
1)

42 SBS Balance System

xx = cable length in feet - standard options 11, 20, or 40 at standard priceNote: All Service (including card installation) shouldbe performed by a qualified technician, or the unit
returned to Schmitt Industries Inc. for service.
(Unit is shown upside down with the cover removed.)

Figure 27

1. Unplug Unit, Invert, and Lay on a Non-Marring Surface.
2. Remove Back Cover Screws (1).
3. Loosen Front Cover Screws (2) A Few Turns.
4. Remove Bottom Cover (3) and Attach Grounding Wrist
Strap (4) To Rear Lip Of Panel
5. Remove Slot Cover Screws (5) And Slot Cover (6).
6. Plug Balancer Card (7) Into Back Plane Board (8).
7. Install Slot Cover Screws (5) Into Balancer Card (7).
8. Remove Grounding Wrist Strap (4)9. Install Cover (3) And Tighten Cover Screws (1 & 2).

Procedure:

1. 1/16" Allen Wrench
2. Grounding Wrist Strap

Tools Required:

Appendix C: Balancer Card Installation

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43

44 SBS Balance System

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

Power Cord 10ft [3m]CA-0009
American
CA-0009-B
BritishCA-0009-G
GermanAC 90~260 volts

Control
SB-4500,
SB-4400, or
SB-4475

RS-232 Serial Cable
Commercial ProductNot Supplied by SBS

Sensor Extension Cable
SB-1611 11ft [3.4m]
SB-1620 20ft [6.1m]
SB-1640 40ft [12.2m]

Sensor w/ Attached Cable
SB-1411 11ft [3.4m]
SB-1420 20ft [6.1m]
SB-1440 40ft [12.2m]

Customer
Supplied
8mA, 10-26V
AV or +DC

SB-4512,
Balancer CardSPB INPUT
SBC INPUTFPI INPUT

Use Either SB-4500 Or
Customer Supplied Power

BOT
RELAY

HALL EFFECT
RPM SENSOR

BOT2
RELAY

FBSI
RELAY

RPM
RELAY

Customer CNC / PLC

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

BIP
RELAY

N/C = Do Not Connect

Balancer Cable Extension
SB-4611 11ft [3.4m]
SB-4620 20ft [6.1m]
SB-4640 40ft [12.2m]

Balancer Cable
SB-4811 11ft [3.4m]
SB-4820 20ft [6.1m]
SB-4840 40ft [12.2m]

External /Internal
Balancer

Figure 27

Appendix D: System Connection Diagram+15V DC OUT

Ordering The SBS Balance System
The SBS Balance System is sold as a set, matched to the requirements of the users grinding machine.
The system includes a Balancer, a microprocessor based Balance Control Unit, a Balancer Cable, a Vibration
Sensor, and all necessary attachments and tools for installation on the grinding machine.
Selection of your balance system requires only a few moments of your time:1)

Complete the Application Questionnaire provided by your SBS Balance System dealer.

2)

Based upon response to the questionnaire, your dealer selects the appropriate mounting adapter anddetermines the mass compensation required by your application.

3)Your SBS Balance System is delivered, matched to your exact needs. The system comes withcomplete operating instructions, which makes operator training and system use simple, and helps bring
immediate return to your investment.

SBS Balance System

45