SBS ExactDress™ System
User’s Guide
with SB-5500 Series Controls
LL-5400, Rev. 2.5

SBS ExactDress™ System

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SBS ExactDress™ System

User’s Guide and Specifications
For theSBS ExactDress™ System
Covering Operation of SB-5523
with Model 5500 series Control Units

LL- 5400
Manual Revision # 2.5
Covers operation with rev. 0.24 firmware© 2020 Accretech SBS, Inc.

In partnership with:
Dr. Zinngrebe GmbH

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

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

SBS ExactDress™ System

Benefits of SBS ExactDress™ System with SB-5500 Control:

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

Gap Elimination - Increases throughput by reducing unproductive dress infeed.

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



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

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

Profibus, Ethernet and USB 2.0 communication

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

SBS ExactDress™ System

Table of Contents
General Instructions ............................................................................................................................ 1
System Purpose .................................................................................................................................................... 1
Operator Safety Summary .................................................................................................................................... 1
System Theory and Connection ........................................................................................................................... 2
System Installation ................................................................................................................................................ 3
Acoustic Sensor Location ................................................................................................................................ 3
AE Sensor Types ............................................................................................................................................. 4
Control Unit Operating Instructions ....................................................................................................................... 5
Front Panel Controls ........................................................................................................................................ 5
Power-On Display ............................................................................................................................................ 5
SETUP ............................................................................................................................................................. 6
Control Unit without Front Panel Connected ................................................................................................... 6
Rear Panel Connections .................................................................................................................................. 7
ExactDress card rear panel connections ......................................................................................................... 7
SB5580 ............................................................................................................................................................ 8

ExactDress™ Operation ...................................................................................................................... 9Main Screen .......................................................................................................................................................... 9
Error H ........................................................................................................................................................... 9Run View ......................................................................................................................................................... 9
Process View ................................................................................................................................................... 9
EDIT button ................................................................................................................................................. 10
Process Parameters ...................................................................................................................................... 10
Maximum Limit (MAX) ................................................................................................................................. 10
Zone Minimum (MIN) .................................................................................................................................. 10
Ignore Level (IGN LEVEL) .......................................................................................................................... 10
Zone Edit (ZONE) ....................................................................................................................................... 11
Setup ................................................................................................................................................................... 11
Limit Screen ................................................................................................................................................... 11
G Limit Edit .................................................................................................................................................. 11
Menu ................................................................................................................................................................... 12
Job Defined ................................................................................................................................................. 12
Job# ............................................................................................................................................................... 12
Sensor Parameters ........................................................................................................................................ 13
Sensor Learn Cycle..................................................................................................................................... 13
Crash Sensitivity ......................................................................................................................................... 14
Sensitivity and Gain Control ........................................................................................................................ 14
Display Settings ............................................................................................................................................. 15
Graph Time ................................................................................................................................................. 15
Graph Type ................................................................................................................................................. 15
Peak Detect ................................................................................................................................................. 15
Screen Scale Y ........................................................................................................................................... 15
Full/Clip View .............................................................................................................................................. 15
CNC Signal Time ........................................................................................................................................... 15
CNC Crash Latch ........................................................................................................................................ 16
Channel Name ............................................................................................................................................... 16
Menu Entry .................................................................................................................................................... 16
Verify Normal Operation ................................................................................................................................ 16
Process Monitoring ............................................................................................................................................. 17
Process Defined (Start/Stop) ......................................................................................................................... 17
Process Zones ............................................................................................................................................... 18
Process Teach Mode ..................................................................................................................................... 18
Monitor Mode - Process Evaluation ............................................................................................................... 19
Zones Ignored in Evaluation .......................................................................................................................... 20
Hardwire Interface ............................................................................................................................................... 20
Hardwire Control Interface – ExactDress™ Card .......................................................................................... 20
SBS ExactDress™ System

Input Pin Names and Functions .................................................................................................................... 21
Output Pin Names and Functions .................................................................................................................. 21
ExactDress™ Analog Output ......................................................................................................................... 23
Software (USB or Ethernet) Interface ................................................................................................................. 23
Interfacing ...................................................................................................................................................... 23
Software Commands and Responses ........................................................................................................... 24
Displayed Error Messages .................................................................................................................................. 26
Support................................................................................................................................................................ 27
Appendix A: Specifications ................................................................................................................................. 28
Appendix B: Replacement Parts List .................................................................................................................. 29
Appendix C: ExactDress™ Card Installation ...................................................................................................... 30
Appendix D: ExactDress™ System Connection Diagram .................................................................................. 31

SBS ExactDress™ System

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

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

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

SBS System – ExactDress™ Operation1

System Theory and Connection
The ExactDress™ system consists of an electronic control, and an acoustic emission (AE) sensor. This
electronic control is packaged as a separate device card installed and operated in the SB-5500 series Control
unit. The AE sensor is mounted on the grinding machine and located to detect high frequency acoustic
emissions generated in the machine structure resulting from wheel contact in the dressing process. The levelof this signal is monitored and referenced against known background levels at the same frequency, allowing
key events to be automatically and quickly detected on the grinding machine as they occur. These events
include: Initial contact of the dresser to the grinding wheel (gap control), or abnormal or severe contact
between the wheel and dresser (crash protection).
Process monitoring is provided that assures that either a maximum or minimum degree of wheel contact ismaintained throughout a dress or grind cycle. Monitoring results are then reported via the hardwire andsoftware interfaces, and the Control’s front panel display. Machine CNC controls can be programmed to use
this information to minimize Gap time, protect against damage resulting from wheel crash, and especially tomonitor the quality and consistency of the dressing process.

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SBS System – ExactDress™ Operation

System Installation
Acoustic Sensor Location
Choose an appropriate sensor location on the grinder for testing. The Sensor must be mounted to the machine
casting or some other rigid machine structure. Do not mount acoustic sensors on thin or loosely attachedmachine components such as wheel guards. The mounting spot should be reasonable flat, and must be freeof foreign matter such as swarf. Paint removal is advisable but not required.
The critical issue to be considered in placing the sensor is acoustic transmission quality. The sensor should
be location on a rigid part of the grinder so that the high frequency noise resulting from contact between thewheel and work part, or between the wheel and dresser, will travel to the sensor with minimal loss of signal.
Signal loss will occur both with distance traveled through the machine structure, and especially with eachpart to part mating junction in the machine. What is desired is a short path of travel for the acoustic signal,
through as few parts of the machine as possible, with all parts of this travel path being rigid, solid, andclosely coupled and firmly mated portions of the machine structure.
For Bolt-on sensor, it is advisable to use superglue (Loctite 401 or equiv.) to try some different mounting
locations, until the best location is found.
It may be possible to mount the ExactDress™ sensor on the spindle housing, near where the balancer sensor
would be located, and use this location for monitoring both Dressing and Grinding. If this does not work on aparticular machine structure, the alternative is to mount the sensor on the dresser structure for dressing
monitoring. One sensor can be used by the ExactDress™ system.

SBS System – ExactDress™ Operation

3

AE Sensor Types
A variety of Sensor configurations are available to fit your installation requirements. The Main types of
sensors are pictured below. Each sensor type is available in various models and the user should consult the
SBS Product catalog for details on all available models.

Bolt-on Sensor

Non-Contact Sensor

Fluid Sensor

Bolt-On Sensor – The sensor is attached by use of a M6 or ¼” screw directly to the machine structure, near
the contact point between the grinding wheel and the work piece or the wheel dresser.
Non-Contact Sensor – The sensor comes in two parts to allow mounting directly to the rotating wheel ordresser spindle. A rotating part is mounted to the spindle to pick up the AE signal from wheel contact. A
non-rotating part is mounted directly opposite the rotating part, where the AE signal is detected andtransferred to the AE monitor.
Fluid sensor – The sensor allows detection of AE signal direct from the work piece or the wheel. A fluid
stream (usually the filtered machine coolant) is directed to flow onto the target area. The AE signaltransmitted up the fluid stream is detected by the sensor.
Balancer mounted Sensor – The sensor can be integrated into Non-Contact mechanical SBS balancers(external or internal).

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SBS System – ExactDress™ Operation

Control Unit Operating Instructions
The following is an overview of the control and interface features of the SBS SB-5500 Control Unit.
Front Panel Controls

1

5

2

3

4

The above figure 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 power stand-by, 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. Also clears any displayed error message.
3) LCD DISPLAY. The display is not a touch screen. Do not press on the display screen. The screen
is used to display data and assign functions to the function buttons.
4) FUNCTION BUTTONS. Operation of the Control unit is accomplished via the four function buttons to
the right of the display. The menu bar area of the display, to the left of these buttons, assigns the current
function to each button. Use these buttons to make all operational selections.
5) SLOT STATUS LED. A three color LED on the left side of the display shows the operational status of
the installed device card in each of the four corresponding card slots. The front panel slot status LED for
any installed ExactDress™ Card has the following assignments: GREEN indicates the AE signal is
below the CRASH limit, and RED indicates the AE signal is above the CRASH limit.
Power-On Display
The Front Panel of the control can be removed and remotely mounted using a SB-43xx series cable. Whenswitched on in either configuration the Control Unit performs self-analysis which defines its status, and thesetting of operating parameters. Operator information is then shown on the LCD display following thestartup sequence described below:

SBS System – ExactDress™ Operation

5

1)

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

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

3)

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

4)

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

SETUP
At Power-on, press the SETUP button to enter control setup. The Setup screens allow the user to select:
1. Operational language
2. Ethernet settings
3. Profibus Station ID (if installed)
While in Setup:

Press ENTER to save current settings on the screen and/or proceed to the next Setup screen
Press CANCEL to cancel unsaved settings on the screen and/or proceed to the next screen
Press START to cancel unsaved settings, exit Setup, and start operation.

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

6

SBS System – ExactDress™ Operation

Rear Panel Connections
The following figure shows the rear of the control. The following connections are located on the rear panelof the Control Unit and are common to any cards installed in the control.

1)
POWER SUPPLY. Connection for line power input (AC input model shown)
Caution: Before applying power to the Control, make sure the supply voltage is within specified
range.
AC Input Models: 100-120V AC, 200-240V AC, 50-60 Hz
DC Input Models: 21 VDC to 28 VDC. 5.5A max at 21 VDC.
2)FUSE HOLDER. Contains the line fuses. AC Input Controls use (2) 5x20 3A time lag, DC Input
Controls use (1) 5x20 6.3A.

3)

ETHERNET. Provides TCP/IP Connection to host device, such as CNC Controller.

4)

USB CONTROLLER. Allows USB flash drive to be connected for Firmware update. Latest
firmware for the control and update instructions are available on the SBS website.

5)

USB DEVICE. Provides connection to another USB 2.0 host, such as a CNC Control.

6)

PROFIBUS. Provides connection to Profibus DP host device, such as CNC Control (option).

7)

REMOTE. This DB-15 connector receptacle is a duplicate of the connector on the font side of thebox, used to connect the optional cable for remote front panel installation.

S1-S4 DEVICE SLOTS. Numbered Slots are available for installation of ExactDress™ cards or otherdevice card products supplied by SBS. Unused Slots are covered with blank panels.
ExactDress card rear panel connections
The control comes standard with one card, and others can be purchased and added to the control unit asrequired. Each card has three connections on the rear panel of the control.
9a)
9b)
9c)

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

7

SB5580
The SB-5580 is a smaller chassis version of the SB-5500 control series, which has been designed for the
space constraints of mounting inside the electrical cabinet of the grinding machine. It supports four device
cards of the same series (S1-S4), and requires power input of 24 VDC, with the same specification as SB5500. The panel connectors are the same and are labeled in the same way as SB-5500 above, except for the
USB DEVICE connector which is located on the bottom of the control instead of the back panel.
A 3-slot version is available and both sizes are also available in a Profinet configuration. For the Profinet,
connection 3 is maintained for the standard Ethernet communications and connection 6 is changed to an
Ethernet connector for the Profinet communication. See the Profibus manual.

SB-5575 – 3 slot version
Profinet configurations:SB-5576 – 3 slots
SB-5581 – 4 slots
SB-5580 – 4 slots

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SBS System – ExactDress™ Operation

ExactDress™ Operation
The SHOW ALL button on any control card main screen displays the system-wide status screen, showing asummary status view of all control card channels installed in the SBS control unit. From the SHOW ALL
display, select the ExactDress™ control card to view the main screen with detailed interface.

Main Screen
In the upper left of the main screen, the user assigned channel name for the ExactDress™ card is displayed.
Following the channel name is the number of the currently selected job (01 to 32), followed by the AE sensor
number assigned to the current job (or).
The main screen can display two distinct operation modes. The first screen shown is the Run view. The
second screen shown is the Process view, which shows the current results of process monitoring.
The displayed view is changed by using the VIEW toggle button, third from the top. If no Process Reference
has been established using the Teach mode, then the Process view is not available.
Error HThis error message is displayed when the VIEW button is pressed when no existing Process Reference exists,indicating the need to perform a Process Teach before the Process View can be used.
Run View
A scrolling graph of the AE signal is displayed, with thecurrent AE signal level shown as a numerical value atbottom left. The current graph time (number of seconds ofdata represented by the AE graph) is shown at bottom right.
The GAP limit shown in green is adjusted using the LIMIT
edit menu. The CRASH limit shown in red defines the topof this screen, and is adjusted using the CRASH Sensitivity
setting under the Sensor Parameters menu. When either ofthese limits is exceeded, the corresponding “G” or “C”
symbol is displayed to the right of the current AE signal
level. The bottom of this graph represents an AE signal
value of 80% of the learned Air value (see Sensor Learn).

Run View

The START/STOP toggle button on the Run view screen starts and stops the display from scrolling the realtime acoustic signal. It is possible to stop the display, so that recent signal levels can be reviewed by theoperator. When the screen is stopped, all monitoring functions are still enabled, and real-time results are still
provided via the CNC Interfaces.
Process View
The Process view screen shows the results of theevaluation of the most recent process run, compared against
the current saved job. Each bar on the screen represents azone of the process, and the color of each bar indicates its
status. Each zone of the process is also represented by thestatus bar at the bottom of the screen. The bottom of thisgraph always represents an AE signal value of 0, so thenoise floor is included in the display.
Process View
SBS System – ExactDress™ Operation

9

EDIT button
The Edit button on the Process View screen accesses editingof the key Process Parameters. The Process Parameters
determine the evaluation criteria used to compare a current
run of a process against the saved Process Reference. The
EDIT button is only available onscreen when data exists forboth the Process Reference (see Teach Mode), and for acurrent run of the process.
Process Parameters
All Process parameters are set using a percentage scale where 0% represents the bottom of the screen (0signal level), and 100% represents the height of a zone or zones on the Process Reference (shown in grey).
Maximum Limit (MAX)
Sets a linear limit on the AE Signal value for the entire
process, regardless of zone, and is shown as a red line on thisscreen. This limit is set as a percent of the current Process
Reference peak value (100% represents the highest zone in
the Process Reference). This limit is shown as a red line on
this screen. If this value is exceeded for any zone during theprocess, then an error is indicated at process completion.
Default = 120%, Range = 0-320%
Zone Minimum (MIN)
Sets the low acceptable limit for AE signal for each separate
process zone. The limit is set as a percent of each separatezone’s value in the current Process Reference, and each zoneof the current process run is compared separately to thecorresponding zone in the Process Reference (100%represents the height of each individual Process Referencezone). As this limit is adjusted the color showing the error
condition of individual zones will be updated onscreen. An
error is indicated at process completion if any active zone
fails this evaluation. Default = 50%, Range = 0-100%
Ignore Level (IGN LEVEL)
Sets the noise floor for monitoring the process, as a percentof the Process Reference peak value (100% represents thevalue of the highest zone in the Process Reference). This
limit is shown as a blue line on this screen. While editing
this limit, zones where the Reference level is below the IGN
Limit will be displayed in BLUE, and zones where thecurrent Process level is below the IGN Limit will be displayed in RED, both with a height equal to the IGN
Limit. This same display behavior is exhibited during the run of any Process while in monitor mode. Whilethe current process is monitored, any zones in the current process with a value below this limit are ignored in
evaluation of the process. Default = 10%, Range = 5-80%

10 SBS System – ExactDress™ Operation

Zone Edit (ZONE)The Zone edit menu allows individual zones to be turned off
for purposes of all process evaluation.
 Press ALL OFF to turn off evaluation for all zones which
are currently marked in red in the graph. If zones areshown in grey at the end of the graph (Reference valueonly), but with the status bar in red for those zones, thisindicates these zones did not receive data during the mostrecent process run because the process time was shorter
than the expected time set in the Teach process. Zones inthis condition are not turned OFF by this button.
 Press ALL ON to turn back on evaluation of all zones which had been previously turned off.
 Press EDIT ZONE to bring up another screen which allows the user to select individual zones byscrolling a cursor on the bar at the bottom of screen, and then turn on/off evaluation for the selected zone.
Any zones in Ignore condition (Blue) which are outside the block of active zones (to left or right of allactive zones) cannot be edited using this menu.
Only zones which have been turned off using the Edit menu can be turned back on under this menu. Zones
in the Ignore condition because of the current Ignore Level setting are editable, but results will not be shown
until the IGN level is revised.

Setup
The SETUP button on the main screen displays the Setup screen. From this screen the user can access either
the Menu or the Limit screen.
Limit Screen
The LIMIT button on this screen displays the Limit screen.
From this screen you first select the limit you want to edit,
either G (Gap) or C (Crash). Selecting C only displays thecurrent signal level associated with the C limit on screen, but
the C limit cannot be moved. Changes to the C limit must be
made using the Crash Sensitivity adjustment under theSensor Parameters menu. Selecting the G limit for editing
allows the G limit to be repositioned on the screen.
G Limit Edit
This screen allows the G (Gap) limit to be repositioned
relative to the displayed AE signal level. The G limit isdisplayed in yellow and flashes. The corresponding signal
level of the current G limit position is shown in yellow atbottom right. Also shown at bottom middle of the screen is
the corresponding G limit Sensitivity setting A(x.xx). This
number represents the G limit position as a multiple of the
AIR level recorded during the last sensor Learn cycle.
Sensitivity is the saved value for the G limit, so if a new
Learn cycle is performed and the system gain is changed, thelimit will still be positioned at the same sensitivity level. The
G limit can be positioned anywhere onscreen. The bottom of
the screen represents A(0.80).

Limit Signal Level
G Limit Sensitivity

SBS System – ExactDress™ Operation

11

Menu
The MENU button on the Setup screen displays the Menu.
This Menu contains user selectable operation settings for thesystem.
Job Defined
Each job includes a Process Reference, and its relatedparameters listed below. The job is used to evaluate current
iterations of the same process in order to determine if theprocess falls within expected normal tolerances. Thirty-two
distinct jobs can be saved for use in evaluation of distinct
processes (see Process Defined).
 Process Reference - The saved AE signature of the process which has been determined by the operator
to represent a known good process Process Parameters (set under the EDIT menu from the Process view screen) Sensor Parameters (set under Setup menu/Sensor Parameters)
 Display Settings (set under Setup menu/Display Settings)
Job#
This menu allows the operator to select the current active job
which will be used for process control, from the available
positions (01 to 32). Use the up and down arrows to selectthe job#. The
orindicated next to the job number
shows if an AE sensor number is currently assigned to thejob, indicating that settings exist for that job#. Where no
settings have been saved under a job#, there is no sensor
number assignment shown.
On this screen the operator can also see and select whichjobs have been assigned to CNC input positions A and B.
Job select input positions A and B are the two available
hardwire inputs to the ExactDress™ card which allow
selection of the active job. A job can be assigned to either
input position A or input position B. Current job# selection
and Job Select input position assignment can also be
accomplished via the software interface.
Press ENTER to set the currently selected job# as active.
Press EXIT to discard any changes. When a job# is selectedusing this menu, the following screen allows the operator toassign Job Select position A or B to the current job#, or to make no changes in the input assignment.

12 SBS System – ExactDress™ Operation

Sensor Parameters
Settings found under the Sensor Parameters menu allow a
Learn cycle to be run. A Learn cycle will assign a sensor# to
the job, set the correct gain for measuring AE signals for thatjob, as well as setting the most responsive frequency range
for AE monitoring. This section also provides for adjusting
Gap sensitivity and Crash sensitivity. New settings are saved
at the completion of each menu section.
Sensor Learn Cycle
The system needs to be setup for proper operation byinitiating a learn cycle for each job. Each job setup should
represent a distinct process to be monitored (see Process
Defined). Running the learn cycle will first assign a sensor
number (or). The Sensor Select screen is displayed,showing which sensor positions are currently connected to
the ExactDress™ card. Select which sensor should be
assigned from the options presented.
The learn cycle will next set the system gain and overallmeasurement scale, as well as help determine which of theeight frequency bands should be selected for best operation results. During the learn cycle the backgroundacoustic emission signal levels for each of the eight frequency bands will be compared with the signal levels
that occur during normal dressing or grinding for the same frequencies, and the frequency with the best
Work/Air signal ratio will be suggested as the frequency to be monitored. If the results of the Learn process
produce Work/Air ratios that are 1.2 or below, then the system has been unable to see any significant
difference between the AE signal during wheel contact and prior to wheel contact. This is usually a result ofeither an improperly performed Learn cycle, or a poor AE sensor location.
The next screen of the learn cycle is titled AIR PASS, andwill show eight bar graphs, representing the real time signal
levels occurring in each of the separate frequency bands
covered by the unit. The bar graphs will rise and fall as
signal levels change. The VIEW DATA button allows theuser to view the results of the most recently completed learn
cycle, and choose an alternate frequency band based on thoseresults. To perform a new learn cycle, the first step is tolearn the background or AIR signal level. To do this thegrinder should be operational, with all systems running, but
without wheel contact with the part or dresser. Once thegraph has settled after machine startup, press START to
begin learning. Move the wheel though a mock grind or dress
movement, but without wheel contact (the bar graphs may
rise a little during this process due to axis motion). When
finished, press the ►► button to store the maximum
background/AIR levels recorded in each frequency band, andto move to the next learn cycle step.
The screen should now be reversed in color from theprevious screen, and titled NORMAL WORK PASS. The operator should initiate wheel contact with the
dresser or part, and complete one or more cycles, until the bar graph is stable. This process records the
SBS System – ExactDress™ Operation13

maximum signal levels during normal grinding or dressing. The bar graphs will show the highest levels
recorded during this current learning cycle. Once the bar graph has stabilized, press the ►► button to store
this information and display the resulting data screen.
The data screen will show the current active filter band at the
top of this screen. Acoustic levels recorded for all eight filter
bands during the most recent Air and Work passes are shown
as a table. The resulting ratio between Work and Air levels is
displayed, and also the filter band suggested by the control
system as most responsive is highlighted, which is the bandwith the largest W/A ratio. Press ENTER to accept thischoice, or override the ExactDress™ system selection bychoosing another filter band, and then pressing ENTER, orpress Cancel to exit the screen leaving the currently active
filter band selected. The maximum W/A ratio is suggested as the best starting point in determining the most
responsive filter for an application, however the installer may find another filter to be more effective. Very
low signal levels can produce a good W/A ratio but with little effective difference between Work and Air
values. In such a case it is may be best to look at the largest difference between Work and Air levels andselect that band as being more responsive. Once the most responsive filter has been selected for an
application, this selection should not change. It is based on the machine structure, sensor location relative tothe wheel contact point, and type of wheel contact. All these things should remain relatively constant for agiven application. If Air noise levels rise significantly, or Work signal level falls significantly, SBS suggests
troubleshooting to determine the cause of these changes.
Press EXIT twice to exit the setup menu, and return to the Main Screen.
Crash Sensitivity
This setting determines the C (Crash) limit, based on a fixed
multiple of the maximum work level recorded during the lastlearning cycle. A higher Sensitivity setting means the Crash
limit will be set nearer the work level (more sensitive), whilea lower Sensitivity setting will move the Crash limit further
above the work level (less sensitive). Use the up/down arrow
buttons to achieve the proper sensitivity for your job
requirements.
Sensitivity and Gain Control
Changing the sensitivity setting will change the effective signal gain of the unit. To ensure ease of setup, thesignal gain is set automatically, based on the current results of the last learning cycle, and the current
sensitivity setting. By increasing the sensitivity setting, the Crash Limit will be assigned a lower value, andscreen scale will be recalculated to compensate, producing higher displayed signal levels. By lowering thesensitivity setting, the Limit will be assigned a higher value, and the new screen scale will then produce
lower displayed signal levels. Note - the screen scale of the ExactDress™ system is logarithmic, not linear.
This allows fairly large changes in signal level to be displayed on screen, without overrunning the screen
limits.

14 SBS System – ExactDress™ Operation

Display Settings
Graph Time
Graph Time adjusts the time scale the ExactDress™ system
uses to display data on the screen in Run view. The Graphtime set represents the number of seconds taken to scroll
across the display screen, so the width of the screen reflects
the data taken in this same time period. The default time is11.4 seconds and can be set up to 365 seconds. A longer
Graph Time will display data over a longer period of time,
but at a lower resolution.
Graph Type
This setting allows the Run View (scrolling real-time acoustical signal levels) to be displayed as either a line
graph or a filled bar graph.
Peak Detect
When this setting is turned ON, peak AE signal levels are displayed on the Run View screen. Peak values
are defined as the highest signal value seen during the period of time that the signal rises above the G limit,
and then falls again below the G limit and remains below that limit for a minimum of 10 effective screen
pixels of display. The effective screen pixel size (each discrete displayed signal level) will vary in size basedon the screen graph time.
Screen Scale Y
Sets the vertical scale of the Process View screen as a percent of the current job’s peak zone value. This
screen updates as the value is changed.
Full/Clip View
This setting determines if the full process time (from Process Start to Stop) is displayed on the Process View.
When in Clip mode, any continuous block of leading or trailing zones which fall below the Ignore Level areclipped from the display.
CNC Signal Time
Sets the minimum hold time, in milliseconds (msec.), thatrelay contacts are opened or closed to indicate an event
signal. Important – The purpose is to make an event's
signal last long enough to assure signal detection by themachine control used. The factory default settings are 1
msec, but PLCs or similar devices typically will often
monitor at timed intervals of about 5 msec. In such cases thesignal time must be set to exceed the polling cycle time.
Affects PROCESS MIN., PROCESS MAX., GAP, andCRASH (if not latched) signals of the CNC interface.

SBS System – ExactDress™ Operation15

To change settings, select SETUP from the Main screen. From the Setup screen, select MENU with thecorresponding button, then select CNC SIGNAL TIME from the menu. The two screens that follow control
the ON and OFF contact hold times. Times can be set from 1 to 250 msec.
To set the desired time for the N.O. contact closed time, use the left arrow button to select digits, and the up
and down arrow buttons to change the selected digit. Press ENTER to accept the entry and proceed to the
OFF-TIME screen. In the same manner, set the time that the
N.C. contact will be closed and press ENTER.
CNC Crash Latch
This menu option sets how the CRASH output signals willreact to crash conditions. Use the up and down arrow
buttons to toggle the cursor between the OFF or ON
selections. Press ENTER to have the entry accepted.
OFF Crash not latched, subject to ON/OFF times like
GAP, PROCESS MIN., PROCESS MAX.
ON

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

Channel Name
Selecting the CHANNEL NAME menu item will display an entry screen. Use the right arrow button to selectcursor position, and the up and down arrow buttons to toggle through the alphanumeric list to label the
ExactDress™ card device. Distinct names can be used to identify each card device installed in the SBS
control unit with this feature. Up to Five characters can be used to name the ExactDress™ card. Press
ENTER to accept the entry.

Menu Entry
This selection on the menu list provides for use of a standard access code for menu protection. Setting thechannel to “protected” denies access to the menu list unless the access code is entered. This setting ensuresthat system settings will not be accidentally compromised. The screen displays ENABLED when Menu
access is available, and PROTECTED when menu access is controlled by the access code. Function buttons
are assigned the numbers 1, 2, 3, and ENTER, which are used to input the access code. The standard accesscode is 232123. Once the code has been entered and the ENTER button has been pressed the MENU
selection is protected. Re-entry to the menu list will now require entry of this code. The message MENUACCESS PROTECTED will be displayed notifying the user that the menu is password protected, and theuser will be given the opportunity to enter the code. Entering a code other than the correct number willproduce 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.
Verify Normal Operation
The Run view main screen can be stopped or started by toggling the lower right hand button. When running,
the screen will display real time acoustic level information, as it occurs. When stopped, the screen shows thelast time period recorded. When the wheel is not making contact, the screen should show signal levels below
the G (Gap) limit line. If the signal level is above the G limit with no wheel contact, you should repeat
the learning cycle to achieve proper results. The C (Crash) limit level is set automatically during thelearning cycle and vary according to the results of the learning process and the sensitivity setting selected by

16 SBS System – ExactDress™ Operation

the operator (Crash sensitivity is described in the following section). The Gap level can be adjusted onscreen
by using the LIMIT edit on the Setup screen.
Initiate wheel contact with the dresser or work-piece, and observe the running display. You should see theacoustic levels falling mid-screen during full wheel contact, and dropping off below the G level between
passes. If results are not as described, then one of the following should be tried.
a) Try adjusting the G level.
b) Adjust the scale of the screen by adjusting the Crash Sensitivity setting. Running the Learn processagain is not required. Note that higher sensitivity selections are more sensitive to noise as well as
signal.
c) Try an alternate Sensor location, and perform a new Sensor LEARN cycle. Try moving the sensor
closer on the machine structure to the point of wheel contact, as described in the Acoustic Sensor
Location section.

Process Monitoring
Before the system can be used for Process Monitoring, it must first be setup with the proper system gain andsensitivity, using the Learn Cycle and other settings under the Sensor Parameters menu.
Process Defined (Start/Stop)
The ExactDressTM allows the AE signal signature of a known good dress or grind process to be saved as a
Process Reference, along with the desired evaluation settings. The resulting job can then be used to evaluate
subsequent runs of the same process. A process is likely distinct when anything is changed on the machineor process which will vary the AE signature of the process. Key variables which will create a distinct
process include: Wheel type, size, speed or position Dresser or work piece speed, type or position
 AE sensor type or position
 job settings (Process Parameters, Sensor Parameters, Display settings)
The process is a time window of interest for evaluation in a repeating dress or grind cycle. The timing of theprocess is defined as what occurs between the process START and the process STOP. The START/STOP
input on ExactDressTM is used to establish the timing of these events. The input is held active at the process
START, and deactivated to indicate the process STOP. This input on the ExactDressTM card is intended to
be set using a programed output from the machine PLC/CNC. While the START/STOP input is active, it isindicated on screen by thesymbol.
The START/STOP input should be programed to capture the whole of the dress or grind process to beevaluated, usually based on the cycle start, or a subsequent point, where the machine slide or stage
movement will begin from a known and repeatable position. The START/STOP input indicates timing of
the start and stop of the process. For best results it is essential that the timing of this input be as consistent as
possible in relation to the timing of actual wheel position in the process. If the timing of the process START
is not consistent, then each zone of the current process may not line up with the corresponding zone of the
saved job, leading to ineffective evaluation. For this reason the output should be programed in such a
way as to minimize or eliminate any loop time or other cycle timing variations on the CNC.

SBS System – ExactDress™ Operation17

Process Zones
For evaluation purposes the entire process is broken into equal
time slices called zones. Each zone represents the average AE
signal level for that time slice of the process. It is essential thatthe timing of the START/STOP input be very consistent, sothat AE signal levels are not time shifted from one run of theprocess to the next. Each zone will represent a certain numberof process time milliseconds, depending on the overall lengthof the process. You can refer to the chart shown and lookup
your process time to see how much process time is devoted toeach zone (x). Also you can determine how many zones are
created for your process by calculating (P•1024)/x.

P=Process time sec.
0 <= P < 0.5
0.5 <= P < 1
1 <= P < 2
2 <= P < 4
4 <= P < 5
5 <= P < 8
8 <= P < 16
16 <= P < 32
32 <= P < 64
64 <= P < 128

x=ms/zone
16
32
32
64
128
64
128
256
512
1024

zones
1-32
16-32
32-64
32-64
32-40
80-12864-12864-12864-12864-128Process Teach Mode
Once the process timing is established by the Start/Stop
input to the ExactDressTM, the Process Reference can be
captured. The dress or grind process should be run
repeatedly until the desired degree of wheel contact is madeconsistently throughout the defined process cycle. Oncethe process has been validated, then it should be taught tothe ExactDressTM.

Start/Stop Input Indication
Teach Input Indication

TEACH: This relay input is held active to put the unit into
teach mode. The first completed cycle of the process while
in Teach mode defines the process time for the saved
Process Reference (the saved signal levels for each zone ofthe process). Any time at the end of the process run which
is not sufficient to complete a full zone is discarded, so only fully complete zones are retained. While theTeach input is held active, it is indicated on screen by thesymbol. The Teach process can be repeated as
many times as desired, using the START/STOP input to start and stop each cycle while keeping the Teach
input active. The grey bars displayed on the screen show the saved Process Reference for the currently
selected job. While the system remains in teach mode and this job remains selected, the last three complete
iterations of the process are averaged and saved into the current Process Reference. The orange line isdisplayed to indicate the most current iteration of the process. This display allows the user to see how muchchange is occurring from one iteration of the process to the next, and to gauge how stable the process is.
If teach mode is interrupted before the completion of any process run, the remaining zones in that process
run will receive a data value of zero, and therefore this will affect the saved average for those zones in theprocess reference.
Changing the job will interrupt the teach mode. If the unit remains in teach mode, a new average will thenbe started for the newly selected job. Resetting the teach input to inactive and then to active again will alsointerrupt teach mode, and start a new average for the currently selected job.
This averaging feature can be used to help ensure that the saved Process Reference is a good representationof the process, and will be useful as the master against which future cycles of the process are evaluated.

18 SBS System – ExactDress™ Operation

Monitor Mode - Process Evaluation
When ExactDressTM is not in teach mode, it is in
Monitor mode. In this mode, each zone of thecurrently run process is compared to thecorresponding zone in the Process Reference of thecurrent job. The process results are displayed asfollows.

PROCESS-MAX Output Indication
PROCESS-MIN Output Indication

Blue – Zones in Ignore condition, where thecurrent Process Reference is below the Ignore
limit. In the case where a zone’s reference level isabove the Ignore limit, but the signal level in aprocess run falls below the Ignore level, that zone
will fail process evaluation, and the zone will beshown in red with a height equal to the Ignore
limit to indicate why it failed.
Grey – The grey bars indicate the Process Reference of the saved job. If zone evaluation is manually turned
off using the Edit menu, the zone will show only the grey bar and no other color. The status bar at thebottom of screen will also show the zone in grey. If a process run time falls short of the Process Referencetime (START/STOP is deactivated early), then the final zone(s) in the process may not have any data toevaluate. Such unprocessed zones are also shown as only the grey reference bar for the zone(s), but thestatus bar at the bottom of the screen will show that zone(s) status as red.
Green – Zones where the current process is above the Zone Minimum limit.
Yellow – Zones where the current process is marginally above the Zone Minimum limit. If the zone’s signal
level is above the ZONE MINIMUM, but falls within the first 1/3 of values between the ZONE MINIMUM
setting and 100%, then the screen bar is displayed in yellow, indicating the zone is in tolerance but is near thelimit.
Red – Zones where the current process is below the Zone Minimum limit. If the current process signal levelis lower than the ZONE MINIMUM limit, then that zone is out of tolerance and the screen bar is colored red.
For example if the ZONE MINIMUM is set to 70%, then any zones falling below 70% of that zone’s job
value are red. Any zones with values from 70% up to 80% are yellow, and zones with values of 80% or
higher are green. If any zones are evaluated as out of tolerance, then the process is considered out of
tolerance, and the PROCESS-MIN relay is activated.
The current process is displayed in color on top of the grey bars of the Process Reference. Where the current
process signal level rises above the grey job bars, then the green color is displayed in a brighter shade ofgreen, showing where the signal has risen above the job level.
PROCESS-MIN: This relay indicates if all the zones active for evaluation in the current process are above
the minimum threshold set for the most recently completed process. The ZONE MINIMUM limit defines
the minimum acceptable value for each zone to be considered in tolerance, which is set as a percentage of thevalue seen in the corresponding zone of the Process Reference. This current relay status is indicated onscreen next to the SETUP button by the lower bar turning red when the relay is active.
PROCESS-MAX: This relay indicates if the current process has exceeded the maximum threshold set forthe most recently completed process. The maximum limit for the process is not based on evaluation ofindividual zones, but is a simple linear limit for the entire process. The limit is defined by the MAXIMUM
LIMIT setting. If at any time during the process an AE signal is measured above this limit, then the process

SBS System – ExactDress™ Operation19

is considered out of tolerance and the PROCESS-MAX relay is activated. This current relay status isindicated on screen next to the SETUP button by the upper bar turning red when the relay is active.
Zones Ignored in Evaluation
Zones are ignored in evaluation of the process for two reasons:
Ignore Level. A zone will be ignored in process monitoring if the signal level for that zone in the current
process reference is below the user set IGNORE LEVEL. This setting is based on a percentage of the peakzone signal value saved in the current job. Zones in the condition are not considered part of the process to bereviewed. For instance, this allows the period of time before and after wheel contact normally occurs in theprocess to be ignored.
Zone Edit. The EDIT menu can be used to edit the saved job to turn off evaluation of the PROCESS-MIN
status for any zone(s) within the process. This can allow any zone(s) that represent a portion of the processthat does not require process control to be ignored in this determination of process status. This can havebenefits where a portion of the process does not produce consistent AE signal levels and where this portionof the process is outside the area of concern for monitoring.

Hardwire Interface
Interfacing the SBS System with a CNC or PLC
machine controller is supported via a hardwire
interface or software interface. The hardwire
interface is provided via a standard DB-25
connector located individually on the rear panelof the ExactDress™ Card, while the Softwareinterface is supported via either the USB or
Ethernet connections, which are common to thewhole control unit. Because of the many possible
variations and configurations 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 thegrinding machine's controller must operate
the SBS System. It is not possible for the SBS
System to control the grinding machine.

SB5523 DB-25
For ExactDress™ card in SB-5500
SUP-COM

Out: PROCESS MAX-NO

Analog-OUT

Out: PROCESS MAX-R

Out: N/C

Out: PROCESS MAX-NC

Out: N/C

Input: JOB SELECT

Out: ERROR-R

Input: CRASH RESET

Out: ERROR-NO

Input: START/STOP

SUP-COM
Out: CRASH-NC

SUP-OUT
Input: TEACH

Out: PROCESS MIN-NC

Out: PROCESS MIN-R

Out: PROCESS MIN-NO

Out: CRASH-R

Out: CRASH-NO
Out: GAP-NO
SUP-COM

Out: GAP-R
Out: GAP-NC

Shell (Shield Ground)

Carefully read this entire manual before attempting to interface the SBS System with any machine controller.
Sections covering the interface of other SBS device card products installable in the SBS Control are covered
separately in the manual for each product.
Hardwire Control Interface – ExactDress™ Card
The hardwire interface consists of three sections: interface power supply, the inputs, and the outputs.
The interface power supply is provided exclusively for use with the hardwire interface inputs. It consists ofthree common pins and one output pin. The common pins are internally connected to chassis and earth
ground. The output provides a maximum of 30 mA at approximately +15VDC. Any external power used
for interface I/O must be from a SELV (Safety Extra Low Voltage) source or supply.
20 SBS System – ExactDress™ Operation

The inputs provide noise immunity and robustness. The inputs are activated by being pulled high, either by
connection to the SB-5500 hardwire interface power supply output or by connection to a customer supplied
signal. Activating the inputs requires at least 8 mA at a voltage between 10 and 26 volts +DC, referenced to
the SB-5500 hardwire interface power supply common. The inputs are deactivated by removing theconnection to the power or signal source.
The outputs consist of optically isolated, solid state, single-pole/double-throw relays. These contacts may be
used to supply an output signal by connection to a voltage source supplied by the customer. The contacts areelectrically isolated from all other circuits and are rated for 24 Volts DC or AC, 50 mA maximum. Inductive
loads must be protected against flyback to 50VDC.
The three contacts of a single-pole/double-throw relay are 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” is used below to indicate the common contact of the relay.
Input Pin Names and Functions
Pin#

Name

Description

17

JOB
SELECT

Use this input to select which of the two jobs assigned to relay positions A and B is active (forprocess monitoring or teach mode). Inactive = job# assigned to position A, active = job#
assigned to position B). Switching jobs will erase current analyzed data from memory.

18

CRASH
RESET

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

19

START/
STOP

Activate this Input to set the start of the process time window to be monitored. Deactivate theinput to indicate the end of the process. It is critical that the timing of the START/STOP
signal be very consistent relative to the dress/process cycle being monitored. See Process
Defined section.

21

TEACH

Activate this Input to enable Process Teach mode.
selected job is taught a Process Reference signal.

While in Teach mode, the currently

Output Pin Names and Functions
Pin#

Name

Description

2

AnalogOUT

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

6

ERRORNO

Output is system error flag. Open indicates error condition, Closed indicates system is innormal monitoring condition. If control is OFF or in any condition not able to monitor, thisrelay is open to indicate that the monitoring function if offline. This output is open when inProcess Teach, Sensor Learn, MIN editing, MAX editing, IGN level editing, zone editing,during front panel access of any setup menu, and during any error condition. When the
CNC Error is opened, existing status output for the most recent process (MIN and MAX)
will clear and indication on screen will also clear.

5

ERROR-R

Common return connection for the ERROR contact.

11

CRASH-NO

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

8

CRASH-NC

Closed whenever CRASH-NO is open (no error condition detected). It is also closed whenpower is off and during standby, initialization, self-test, and LEARN modes.

23

CRASH-R

Common return connection for the CRASH contacts.

12

GAP-NO

Closed whenever the AE signal is at least at the GAP setting (wheel contact detected).
SBS System – ExactDress™ Operation

21

25

GAP-NC

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

24

GAP-R

Common return connection for the GAP contacts.

10

PROCESSMIN.-NO

Closed at the completion of a process run when the results of the process run fall below
the zone minimum limit set. Indicates that some process zones in the most recently
completed process run have produced lower than expected AE signal. This output isopen during the process run and when in Teach mode.

9

PROCESSMIN.-NC

Closed whenever the PROCESS MIN.-NO relay is open.

22

PROCESSMIN.-R

Common return connection for the PROCESS MIN. contacts.

14

PROCESS
MAX.-NO

Closed at the completion of a process run when any of the zones in the most recent
process run have exceeded the AE signal level set for the Process Maximum Limit(excessive AE signal). This output is open during the process run and when in Teach
mode.

16

PROCESS
MAX.-NC

Closed whenever the PROCESS MAX.-NO is open.

15

PROCESS
MAX.-R

Common return connection for the PROCESS MAX. contacts.

20

SUP-OUT

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

1,7,13

SUP-COM

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

10ms Min.

10ms Min.

TEACH
10ms Min.

10ms Min.

START/STOP
10ms Min.

10ms Min.

JOB SET0-10msProcess MIN. or
Process MAX.

22 SBS System – ExactDress™ Operation

0-10msExactDress™ Analog Output
The analog output voltage is presented at pin 2 of the 25 pin CNC connector of the SB-5523 card. Pin 1 is
the ground reference for this voltage. The analog output on the ExactDress™ system is not calibrated to a
fixed level. The gain of the system is auto scaling, so that the analog signal output always falls in the 0-10
VDC range. This auto scaling gain is needed to accommodate the huge variation in signal level, which canbe measured on various types of grinders with different applications and sensor placements. This auto
scaling gain corresponds to the gain used for the display of AE level on the front panel. This scale willchange every time a learning cycle is run or when the Crash sensitivity setting is changed.
Following is an explanation of the process that sets this voltage and the effects of that process on other event
threshold settings in the system. During the LEARN process, the WORK value is measured. This WORK
value, along with the CRASH SENSITIVITY setting, is then used to compute the system’s Crash Eventlevel. The CRASH SENSITIVITY (CS) selects a multiplier for the measured WORK level that yields the
Crash Event level (CRASH).
(CRASH) = (WORK)(CS)
The internal amplifier gain is set such that a Crash Event would generate a voltage of about 9.7 volts at theanalog output. The values selectable for CRASH SENSITIVITY (CS) produce multipliers ranging from 3.55
to 1.05 (with LOW=3.0 and HIGH=1.5). This multiplier is applied to the WORK level to set the amplifier
gains.
(VCRASH) = 9.7 VDC = (VWORK)(CS)In an example where sensitivity is set higher (e.g. CS = HIGH), the incoming AE signal needs only to rise to
50% higher than the normal WORK level to trigger a crash event. With the system set to a lower sensitivity
setting (e.g. CS = LOW), a signal increase of 200% is needed to generate the event.
Assuming that normal work processes can have a minimum AE level of approximately 1/2 of the learned
work level, the analog output voltage representing WORK can be approximated using the following table:
Crash Sensitivity
Min. WORK Voltage
Max. WORK Voltage

Low
1.50
3.00

Medium
2.25
4.50

High
3.00
6.00

The voltage levels representing AIR and GAP levels are much lower than the WORK level. On the same
voltage scale, the WORK voltage will be W/A (from the LEARN screen) times the AIR voltage. The GAP
voltage will be AIR voltage times the GAP SENSITIVITY (GS) level selected. The range of GS settingscorrespond to multipliers from 3.55 to 1.05 (with LOW=2.5 and HIGH =1.5).
(VWORK) = (W/A)(VAIR)(VGAP) = (VAIR)(GS)

Software (USB or Ethernet) Interface
The SBS System provides a software interface via either Ethernet TCP/IP or USB. The software interface
allows the same control capability as the hardwire interface plus system status monitoring. The following
description applies to all SB-5500 models.
Interfacing
The software interface provides a serial interface emulation which connects the Control to a Windows
computer over either Ethernet TCP/IP or USB. For TCP/IP, use Telnet at the Windows command prompt
SBS System – ExactDress™ Operation

23

pointed to the IP address of the Control, or use HyperTerminal or similar serial communications software
pointed to port 23 with any baud rate setting. When connecting via USB, Windows will assign a COM port
to the control. If the SB-5500 is not automatically assigned a COM port, a driver for Windows installation of
USB-Serial communication is available on the SBS website at https://accretechsbs.com/. COM port
assignment is controlled by Windows, and a unique COM port will be assigned for each detected SB-5500
control. The port assigned can be determined by viewing Windows Device Manager. Use HyperTerminal orother serial communications software to interact with the Control over USB connection.
Software Commands and Responses
When the Control unit is first powered up, the following message is transmitted via the software interface.
/SB-5500, Copyright (c) 2020, Accretech SBS, Inc.<CR>
V0.85<CR>
Commands - A message preceded with the digit ‘1’ through ‘4’ is a command or response referring to Slot
Cards 1 to 4, respectively. A message starting with any other character refers to the System Control.
Examples following use “1” as the card slot number.
The following commands from the Software Interface are available:
Control Unit Commands (Cards are Individually Controlled)
CommandC

Response

Meaning/ Example:
Control Panel Status Inquiry.

<Esc>C<CR>
CI

Control Panel is Inhibited

CI<CR>
CE

Control Panel is Enabled

CE<CR>CX

Control Panel is not installed

CX<CR>
CE

Control Panel Enable.

<Esc>CE<CR>K

Command Acknowledged

K<CR>
CX

Control Panel is not installed

CX<CR>CI

Control Panel Inhibit.

<Esc>CI<CR>
K

Command Acknowledged

Q

Command Not Accepted (Panel in use?)

K<CR>
Q<CR>
CX
V

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

<Esc>V<CR>
Vn.nn

Firmware Version

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

Response

Meaning/ Example:
Type (of slot card) Request.
< Esc >1X<CR> Start Slot 1 Info Request.

24 SBS System – ExactDress™ Operation

ExactDress™ Card Commands (Cards are Individually Controlled)
Command

ResponseX6.xxVv.vv[sss]/text

Meaning/ Example:
Slot info response. 6 is ExactDress™ type. xx is specific model type. v.vv is gap
firmware revision. sss is the user specified name for this card. Text briefly
explains the card type.

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

Snn,aaaa[,CIP][,AIP][,FPI] [,GAP][,MIN] [,MAX][,CRASH][,A][,
B], ERR=eee

Status Request command. If ‘C’ present then previously reported errors
conditions will be cleared before the status is reported.
<Esc>1S<CR> Report Slot 1 Status.
Status response. nn indicates active job# (01 to 32), aaaa is AE level (dynes).
CIP is Cycle In Progress. AIP is Process mode active. FPI is Front Panel Inhibit.
GAP, PROCESS MIN., PROCESS MAX., and CRASH the corresponding relay
output is closed, A and B indicate that that the job# nn is also selectable by the
CNC job select input, eee represent individual error letters representing error
conditions. If the first character is ‘@’ then an error condition requires clearing(use SC command or press clear on front panel).

1S1,2.905,CRASH,ERR=@AB<CR><ESC>1SC<CR> Report Slot 1 Status.
1SD2.912,ERR=B<CR>
C[S|A|nn[,A|B]]

n<sp>dddd

L
Lnn,gggg,cccc

P[O|F]

P{O|F}

Cycle Command: If nn will change to corresponding job# (nn range 01 to 32). If S
or A then will Start or Abort the measurement process, correspondingly. No
response to A or nn. If an A follows the job number nn, the job nn will be assigned
to the CNC job select input position A. If an B follows the job number nn, the job
nn will be assigned to the CNC job select input position B.
<ESC>1C2<CR> Set dataset to 2.
<ESC>1CS<CR> Start Cycle.
Cycle data. n is slot#. dddd is AE level in dynes. These will be sent whenever acycle is running. There will be no response if the command is not allowed.
1 0.023<CR> slot 1<sp>dyne level.
1 0.120<CR> slot 1<sp>dyne level.
2 0.134<CR> slot 2<sp>dyne level.
<ESC>1CA<CR> Abort Cycle.
(no response)
Level request:<ESC>1L<CR> Request Current AE Levels.
Level response. nn indicates active job# (nn range 01 to 32). Levels (dynes) are
gggg for Gap and cccc for Crash.
1L1,0.023,3.112<CR> dataset 1 mode levels.
Request current display peak dynes enable status. If O present then enable theonscreen display of each peak AE signal value. If F present then disable thisdisplay. No response to O or F.
<ESC>1P<CR> Request current status of peak dyne display mode.
<ESC>1PO<CR> Enable display of peak dynes.
<ESC>1PF<CR> Disable display of peak dynes.
Display Peak AE signal value mode response. O indicates display mode is on, F
indicates display mode is off.
1PO<CR> Displaying of peak dynes is enabled
1PF<CR> Displaying of peak dynes is disabled

SBS System – ExactDress™ Operation25

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

B

E

F

G

Message

Definition

ActionSENSOR 1 DEFECT
OPEN – CHECK CABLE
AND CONNECTORSSEE MANUAL

Checked continuously.
Acoustic Sensor 1
presence notdetected. This could
be caused by adefective sensor or by
no sensor being
connected.
Checked continuously.
Acoustic Sensor 1
short circuit detected.

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

SENSOR 1 DEFECTSHORT – CHECK CABLE
AND CONNECTORS SEE MANUAL+15V POWER DEFECTSHORT – CHECK CABLE
AND CONNECTORS –SEE MANUAL

Checked continuously.
15V Auxiliary supply
low – fuse open

CRASH CONDITION

Checked continuously.
Unit has measured
acoustic levels
exceeding the Crash
limit set.
Checked continuously.
Signal acquisition
circuit failed.

CIRCUIT FAILURE
UNABLE TO MEASURE
AE SIGNAL
SEE MANUALHNO TEACHED DATAAVAILABLE PERFORM
TEACHING CYCLEIDISPLAY FIRMWARE
NEEDS TO BE UPGRADEDTO SUPPORT SB5523

26 SBS System – ExactDress™ Operation

Checked with eachprocess START. No
saved TEACH data isavailable for process.
Checked at power-up.
Firmware for display
PCB is not current for
support of SB5523.

Clears automatically. Disconnect the Control Unit
from AC power before checking cables andconnectors, and sensor for shorts. If the problem
cannot be isolated, the sensor, cable, and/or
Control Unit should be returned for repair.
Check for shorts in Sensor and CNC cables andconnectors and re-initialize the system. If the error
persists return Control Unit and cables for repair. If
you have the SBS system cabled to your CNC
controller, verify that the CNC cable is free ofelectrical shorts. The CNC cable is not suppliedwith the SBS system, and repair is the
responsibility of the user.
Cleared manually by pressing “Clear” button or by
CNC RESET.
Check for part crash. Reset Error.
Clears automatically. No action required otherthan clearing manually from the screen. If the
problem persists, the Control Unit should be
returned for repair.
Cleared manually by pressing “Clear” button or by
CNC RESET. Perform TEACH process toestablish a Process Reference.
Cleared manually by pressing “Clear” button or by
CNC RESET. Perform Firmware upgrade forControl Unit.

Support
For support, contact the machine builder or SBS at:

Accretech SBS, Inc.
2451 NW 28th Avenue
Portland, Oregon 97210 USA
Tel.: +1 503.227.7908
Fax: +1 503.223.1258
TechSupport@accretechSBS.com
https://accretechsbs.com/
IVIS does not support the ExactDress™ card.

SBS System – ExactDress™ Operation27

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

28 SBS System – ExactDress™ Operation

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

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

Appendix B: Replacement Parts List
Part#

Description

ExactDress™ Control
SB-5500-E
Control: ExactDress, AC Input
SB-5501-E
Control: ExactDress, AC Input, No Profibus
SB-5510-E
Control: ExactDress, AC Input, No Front Panel
SB-5511-E
Control: ExactDress, AC Input, No Front Panel, No Profibus
SB-5520-E
Control: ExactDress, 24 VDC Input
SB-5521-E
Control: ExactDress, 24 VDC Input, No Profibus
SB-5530-E
Control: ExactDress, 24 VDC Input, No Front Panel
SB-5531-E
Control: ExactDress, 24 VDC Input, No Front Panel, No Profibus
SB-5523
Control Card: ExactDress
ExactDress™ Sensors
Built in to Non-contact Balancers
SB-42xx
Bolt-on Sensor
SB-41xx
AE-Extension Cable
SB-3208
AE Sensor: Non-contact spindle mounted Mini-Stud Mount – M6x1.0 LH
SB-3209
AE Sensor: Non-contact spindle mounted Mini-Stud Mount – M6x1.0 RH
SB-3225
AE Sensor/ Sender Package: Non-Contact In-Spindle
SB-3210
AE Sensor: Non-Contact In-Spindle w/ slide tube connection
Control Mounting Hardware Options
SK-5000
Rack Panel: SB-5500, Full Wide w/ 1/2 Blank, 3U
SK-5001
Rack Panel: SB-5500, Partial Wide 3U w/ Handles
SK-5002
Rack Panel: SB-5500, 1/2 Rack 3U Bracket
SK-5003
Control Mount: SB-5500, Bottom Flange
SK-5004
Control Mount: SB-5500, 90 Deg. Bracket, Cabinet
SK-5005
Keypad Mount: Flush Panel Frame Kit
Other Parts
EC-5605
EC-5614CA-0009
CA-0009-G
CA-0009-B

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

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

SBS System – ExactDress™ Operation29

30 SBS System – ExactDress™ Operation

Unit is shown upside down with the cover removed.

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

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

Slot Screw
4-40x3/16

Card

Inside View of Rear Panel

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

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

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

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

Blank Slot Cover

Cover Screw
M4x6

Cover

Appendix C: ExactDress™ Card Installation

DC Input
Option:21-28 VDC

USB
DeviceProfibus
DP

START/STOP

SB-5500 Control

Customer CNC / PLC

Use SB-5500 Or
Customer Supplied PowerCRASH RESETJOB SELECT+15V DC OUT

SB5523 Card

D/N/C = Do Not Connect

Customer
Supplied
10-26V +DCMAX.

AE SENSOR
EXTENSION
CABLE

MIN.

SENSOR 1TEACH

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

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

Ethernet
TCP/IP

Standard Cables Customer Supplied

AE SENSORCRASH

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

GAP

ERROR

D/N/C

SENSOR 2(OPTIONAL)

NON-CONTACTBALANCER WITH AE

Appendix D: ExactDress™ System Connection Diagram
ANALOG OUTSBS System – ExactDress™ Operation31