Balancing Theory and Applications

Table of Contents

SECTION TITLE

1 Vector Balancing Procedure

2 Single Plane Field Balancing w/Analyzer
3 Solutions to Potential Problems
4 Ultra Mgr
5 Trim Balance as a One Run Balance Job
6 Multi-Plane Balancing
7 Calculator Mode
8 Trial Weight Calculations

v 6/2002
 Section One
Vector Balancing Procedure

Objectives
< List the steps to prepare for an equipment balance.

< Explain the steps of the balancing procedure.

< Define influence coefficient, system lag and heavy spot.

< Demonstrate knowledge of graphical balancing by successfully performing a

machine balance.

Balancing Procedure 

The most common oversight in the balancing procedure is omitting the first
step -- problem identification. Attempting a corrective balancing job without
first analyzing the machine can result in a very frustrating experience. One of
the easiest methods used to identify potential machine problems is a visual
inspection.

Walk Around Inspection

Before taking any readings, inspect the machine. This should identify any
loose components or structural problems. If either of these problems is found,
they must be corrected before balancing begins.

Machine Readings
Collect data on the machine to confirm unbalance as the problem. An
industry-wide fallacy is that unbalance commonly causes machinery vibration.
Therefore, there is a tendency to do little or no vibration analysis before
attempting to balance a rotor.

Vibration due to unbalance always occurs at the operating frequency. If the

vibration is at any other frequency or at harmonics of operating frequency,
unbalance is not the cause. You cannot correct misalignment, bad bearings,
structural looseness, etc., by balancing the machine.

The machine to be balanced may have multiple problems. For example, there
may be a high 1xTS due to the imbalance and prominent harmonics of 1xTS
due to structural looseness. As a rule, address the worst problem first.

6/98 © Copyright 1997, Computational Systems, Incorporated. All rights reserved. 1-1
Balancing Theory
Balancing Procedure

Check the spectrum, waveform and phase data to determine what is the
problem.

Spectrum Analysis
 Significant amplitude at 1xTS and very little harmonics

 No other peaks with significant amplitude

 Use zoom or synchronous averaging to verify exact character

of 1xTS peak:

< Vibration at 1xTS is not the result of a double peak.

< Frequency and amplitude are the only results of the shaft in
question.

 1xTS amplitudes in the horizontal and vertical are not vastly

different (greater than 3:1) unless highly asymmetric stiffness
in the structure.

 Axial 1xTS vibration levels should be significantly less than

the radial levels.

Waveform Analysis
 Very sinusoidal, symmetric waveform with one event per shaft
revolution

 No truncation or sharp discontinuities

 Beats suggest presence of closely spaced frequencies.

Phase Data
 Horizontal versus vertical readings on the same bearing
housing should be about 90E (±30E).

 The relationship between horizontal readings from end to end

should be about the same as the relationship between the
vertical probes (±30E).

 Phase is relatively steady 15E - 20E.

1-2 © Copyright 1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Theory
Balancing Procedure

Preparing for the Balance Job

Once the analyst decides that unbalance is the forcing function and field
balancing is needed, initial preparations should include the following steps:

U If the rotor has significant environmental or process material adhering

to the surfaces, have it thoroughly cleaned. The rotor may return to
acceptable balance conditions when clean.

U Mount vibration transducers at each bearing. The transducer should be

rigidly mounted to the bearing and should not be moved during the
entire process.

U Determine where on the rotor the correction weights will be placed and
how they will be attached.

U Prepare the equipment needed to read phase within 5E. Take phase
readings from one shaft reference throughout the balancing procedure.

U Ensure that the operating frequency is repeatable run-to-run within 5%.

U Gather correction weights, a means of determining the weight, and a

method of applying the weights.

6/98 © Copyright 1997, Computational Systems, Incorporated. All rights reserved. 1-3
Balancing Theory
Balancing Procedure

Balancing Procedure Overview

Ô Collect an "as is" measurement of vibration and phase. This data will
be used for the reference run.

Õ Shut down the machine and add a known weight at a known location.
This will be the trial run, and it will determine the system response.

Ö The correction weight amount and location can now be calculated.

× Place the correction weight on the rotor and take a new reading.

Ø If the reading produces 1xTS vibration that is in tolerance, the balance

is complete. If the 1xTS vibration is not in tolerance, a trim balance
must be performed.

Ù Perform trim balance runs until 1xTS vibration is acceptable.

1-4 © Copyright 1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Theory
Balancing Procedure

The Balancing Steps

Ô The Reference Run
The reference run will give the machine’s "as is" balance condition.
The 1xTS amplitude and its phase will be plotted on the polar paper.

Machine: Example 1 Date:

0
Scale
330 30

300
60

270 90

240 120

210 150

180
Amplitude Measurement Measurement
Run Phase¾ Point A Point B
Amplitude .25 in/sec
Reference Phase 357
Amplitude
Phase
Amplitude
Phase
Amplitude
Phase
Amplitude
Phase

6/98 © Copyright 1997, Computational Systems, Incorporated. All rights reserved. 1-5
Balancing Theory
Balancing Procedure

Õ Trial Run
The trial run will determine where the correction weight needs to be
placed. This is accomplished by placing a known weight at a known
location and measuring the result.

The plot below displays the effect of a one unit trial weight placed at
270E.

Machine: Example 1 Date:

0
Scale
330 30

TT
300
60

270 90

240 120

210 150

180
Amplitude Measurement Measurement
Run Phase¾ Point A Point B
Amplitude .25 in/sec
Reference Phase 357
Amplitude
Phase
Amplitude
Phase
Amplitude
Phase
Amplitude
Phase

1-6 © Copyright 1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Theory
Balancing Procedure

Ö Determining Correction Weight Location and

Amount
Location
The location of the correction weight is determined by using the information
on the polar plot. The angle between the reference vector (R) and the trial
weight vector (Rt) must be found. This can be done by using a protractor and
measuring the angle or by using the method described below.

M a c h in e : Example 1 Date:
0
Scale
330 30

Rt
300
60
T
R

270 Trial Weight 90

240 120

210 150

180
Amplitude Measurement Measurement
Run Phase ¾ Point A Point B
Amplitude .25 in/sec
Reference Phase 357
Trial Run Amplitude .43 in/sec
Phase 337
Amplitude
Phase
Amplitude
Phase
Amplitude
Phase

6/98 © Copyright 1997, Computational Systems, Incorporated. All rights reserved. 1-7
Balancing Theory
Balancing Procedure

VECTOR SOLUTION METHOD:

Ê Extend vector R on the polar plot. (Opposite to the arrow head)

Ë Transpose vector Rt to the origin. Ensure the vectors are parallel.

Ì Determine the angle by reading the transposed vector’s angle and the
extended vector R angle. Subtract the two angles to determine the
difference. This difference is the needed angle.

Í Use the value of the angle in step Ì and subtract it from the location of
the trial run. This is where the correction weight should be placed.

Machine: Example 1 Date:

0
Scale
330 30

Rt
300
60
T
R

270 Trial Weight 90

240 120

210 150

180
Amplitude Measurement Measurement
Run Phase¾ Point A Point B
Amplitude .25 in/sec
Reference Phase 357
Trial Run Amplitude .43 in/sec
Phase 337
Amplitude
Phase
Amplitude
Phase
Amplitude
Phase

1-8 © Copyright 1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Theory
Balancing Procedure

The plot shows vector R extended and vector Rt transposed to the origin. The
angle is calculated here: 312E - 177E = 135E

Where: 312= angle of the Rt(transposed) vector

177= angle of the extended R vector

6/98 © Copyright 1997, Computational Systems, Incorporated. All rights reserved. 1-9
Balancing Theory
Balancing Procedure

Machine: Example 1 Date:

0
Scale
330 30

Rt
300
60
T
R

270 Trial Weight 90

240 120

Correction
Weight
210 150

180
Amplitude Measurement Measurement
Run Phase Point A Point B
Amplitude .25 in/sec
Reference Phase 357
Trial Run Amplitude .43 in/sec
Phase 337
Amplitude
Phase
Amplitude
Phase
Amplitude
Phase

The calculation yields the location of the correction weight, but the amount
still needs to be calculated.

Correction Wt. = Influence Coefficient X Trial Wt.

Where: The influence coefficient = R vector divided by Rt vector.

1-10 © Copyright 1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Theory
Balancing Procedure

Amount
Review the length of the transposed trial weight vector Rt. To calculate the
change caused by the trial weight, simply measure the length of this vector. In
the example, Rt is .26 in/sec. The one unit used for the trial weight produced
a change in amplitude of .26 in/sec. This amount of change is almost the same
as the amplitude of the reference run. Therefore, approximately one unit
should be used for the correction weight. The exact weight to be used for
correction can be calculated as shown below. (1 unit = The original Trial Wt)

1 unit .25IPS
Correction Weight ' X.25 IPS î ' .96 Units
.26 IPS .26 IPS

Machine: Example 1 Date:

0
Scale
330 30

Rt
300
60
T
R

270 Trial Weight 90

240 120

210 150

180
Amplitude Measurement Measurement
Run Phase Point A Point B
Amplitude .25 in/sec
Reference Phase 357
Trial Run Amplitude .43 in/sec
Phase
337
Amplitude
Phase

Amplitude
Phase

Amplitude
Phase

6/98 © Copyright 1997, Computational Systems, Incorporated. All rights reserved. 1-11
Balancing Theory
Balancing Procedure

For this example, the trial weight will be removed because the amount of
unbalance did not decrease. Attach the correction weight and check the results.

The check run results are shown below for the correction weight placed at
135E. If the calculations were correct, the resulting vibration would have been
0.0 in/sec. What are some potential sources of error?

Machine: Example 1 Date:

0
Scale
330 30

Rt
300
60
T
R

270 Trial Weight 90

C

240 120

210 150

180
Amplitude Measurement Measurement
Run Phase Point A Point B
Amplitude .25 in/sec
Reference Phase 357
Trial Run Amplitude .43 in/sec
Phase 337
Check Amplitude .08 in/sec
Run Phase 100
Amplitude
Phase
Amplitude
Phase

1-12 © Copyright 1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Theory
Balancing Procedure

Potential Problems During Balancing

Any balance job has potential for errors. Knowing the sources of common
errors improves the calculated balance solution. The graphical and automated
method of calculating a balance solution is affected by the following:

< Plotting of vectors

< Calculation of Correction Weight

< Determination of Correction Weight Location

< Effects of System Amplification Factor

< Understanding System Lag

Plotting Vectors
The very nature of the graphical balancing method requires vectors to
represent amplitude and phase readings. It is extremely important to draw and
interpret these vectors accurately. How well this is accomplished directly
affects the precision of the balance solution.

Calculation of the Correction Weight

The amount of the calculated correction weight is directly related to how well
the reference and trial run vectors are plotted. It is also related to the accuracy
of the device used to measure the amount of the trial weight.

Correction Weight Placement

Once the correction weight amount and location have been calculated, the
same care should be used in placing the correction weight on the machine. It
is recommended that the angular positions are marked on the rotor for easy
identification. If the balancing equipment uses the true phase method of
measuring phase, the angular values increase opposite the direction of
rotation. If it is not attached in the proper location, results will be
unsatisfactory at best.

Amplification Factor

6/98 © Copyright 1997, Computational Systems, Incorporated. All rights reserved. 1-13
Balancing Theory
Balancing Procedure

The amplitude of the measured vibration is affected by how close the

machine’s running speed is to resonance. This amount of amplification is the
amplification factor. As the rotational frequency approaches resonance, the
amplification factor increases. The illustration below demonstrates how the
amplification factor changes due to running speed.

At resonance: 25 MILS;f A = 2.5

Free Space: 10 MILS;f A = 1.0

Below resonance: 5 MILS;

f
A = 0.5

System Lag
The mechanical system will have a "lag" between the point where the heavy
spot passes and the point where the maximum vibration (vibratory high spot)
occurs. The amount of lag is dependent upon the amount of damping in the
system. Calculating the system lag allows the continuation of the balance
procedure without having to apply another trial weight. The amount of lag in
the system is used to determine where additional weights, or trim weights, are
required to bring the amount of unbalance into acceptable tolerances. Since
every system’s characteristics are different, a method of estimating the system
lag is discussed on the next page..

1-14 © Copyright 1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Theory
Balancing Procedure

Estimating System Lag from Resonance

NOTE : The actual heavy spot on the rotor is always ahead of the vibratory
high spot in the direction of rotation. The lag angle is this difference.

6/98 © Copyright 1997, Computational Systems, Incorporated. All rights reserved. 1-15
Balancing Theory
Balancing Procedure

Typical System Response

The amount of lag will always be between 0E and 180E. Below resonance, the
lag approaches 0E as the rotational frequency moves further from the
reference. Above resonance, the lag approaches 180E as the rotational
frequency moves further above the resonance. If the system lag is not
known but the rotational frequency is somewhere below the first critical,
estimate the system lag at 45E.

If it is above the first critical, estimate the system lag at 135E.

The system lag should be calculated to continue balancing if the correction

weight did not bring the vibration into tolerance. However, where the
machine is running in relationship to resonance is not the only factor affecting
the displayed reading.

1-16 © Copyright 1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Theory
Balancing Procedure

Trim Balancing

Machine: Example 1 Date:

0
Scale
330 30

Rt
300
60
T
R

270 Trial Weight 90

240 120

Light Spot
210 150

180
Amplitude Measurement Measurement
Run Phase Point A Point B
Amplitude .25 in/sec
Reference Phase 357
Trial Run Amplitude .43 in/sec
Phase 337
Check Amplitude .08 in/sec
Run Phase 100
Amplitude
Phase
Amplitude
Phase

Trim balancing is required if the correction weight does not lower the
vibration amplitude to an acceptable level. Before calculating the trim weight,
determine the system lag. The polar plot below shows a system lag of 40E and

how it was measured. (Draw a straight line from the Correction Wt to the
opposite side of the polar graph. This is the location of the heavy spot on the
rotor. The System Lag is the measured difference between the two angles)

6/98 © Copyright 1997, Computational Systems, Incorporated. All rights reserved. 1-17
Balancing Theory
Balancing Procedure

Trim Weight Placement

Amount Determination

Trim Wt = (Trial Wt amt.) X ( C vector amt. / Rt vector amt.)

To determine the location and amount of the trim weight, the check run data
must be used. By using the previously calculated influence coefficient, the
size of the trim weight can be determined as shown below.

Trim Weight 1 Unit

'
.08 IPS .26 IPS

.08 IPS
Trim Weight '
.26 IPS

Trim Weight ' .31 Units

Location Determination
The location of the trim weight can be determined by using the system lag.
On the previous page, the system lag was determined to be 40E. That means
the heavy spot travels past the vibration transducer before the vibration is
sensed.

In the example from the previous page, the measured phase was 100E on the
“C” vector. Therefore, the heavy spot is 40E ahead of the measured phase
value; since the measured vibration lags the rotor’s heavy spot, the location of
the heavy spot must be subtracted from the angle of the corrected or “C”
vector. The location for the trim weight is 60E.

The trim weight needs to be placed at 240E which is 180E opposite the heavy
spot.

1-18 © Copyright 1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Theory
Balancing Procedure

Machine: Example 1 Date:

0
Scale
330 30

Heavy Spot
Rt
300
60
T
R
40E
System Lag

270 90
C

240 120

Trim Weight
Location

210 150

180
Amplitude Measurement Measurement
Run Phase Point A Point B
Amplitude .25 in/sec
Reference Phase 357
Trial Run Amplitude .43 in/sec
Phase 337
Check Amplitude .08 in/sec
Run Phase 100
Amplitude
Phase
Amplitude
Phase

The location of the heavy spot was determined by using the system lag of 40E
and the check run phase of 100E. To correct the unbalance, a .31 unit trim
weight should be placed at 240E.

6/98 © Copyright 1997, Computational Systems, Incorporated. All rights reserved. 1-19
Balancing Theory
Balancing Procedure

Additional Considerations
The balancing example that was shown did not have any special equipment
concerns. There are some cases where the machine to be balanced will have a
limited number of starts, or the amount of stress due to balancing needs to be
addressed. It is always a good practice to reduce the machine stress due to
balancing.

Estimating Trial Weight Location

By estimating the location of the trial weight, a reduction in the amount of
unbalance may occur from the trial run. This is extremely beneficial if the
weights will be welded on, or if the machine has a limited number of starts per
day. The following information is required to perform the estimation:

Ê Vibration amplitude units

Ë Transducer placement in relation to phototach
Ì System lag

Vibration Units Affect Phase Readings

Transducer characteristics affect the phase of the readings. If the user wants to
calculate the placement of trial weights or the location of the heavy spot, then
the effect of the transducer or the units used must be considered.

If the user acquires data with a transducer, the only phase change to consider is
that of the amplitude units. This factor is:

< Displacement - 0E
< Velocity - 90E
< Acceleration - 180E

These fundamental phase relationships are the result of peak acceleration

leading peak velocity by 90E and leading peak displacement by 180E.

A mechanical (spring mass) velocity transducer has a phase difference in the

design of the transducer which needs to be determined from the manufacturer
or through testing.

1-20 © Copyright 1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Theory
Balancing Procedure

The following figure illustrates the phase readings which were obtained using
three different vibration amplitude units. Both the reference transducer (a
phototach) and the vibration transducer were at the same location (0E).
Although, there is a slight variation due to the normal variation in the
measurement process, the general relationship can be observed.

Effects of Using Displacement, Velocity, and

Acceleration on Phase Angle

Vibration
Transducer

Displacement Phase Photo-Tach

333 E

Tape
Rotation
Heavy
Spot

Velocity Phase
241E

Acceleration Phase
151E

6/98 © Copyright 1997, Computational Systems, Incorporated. All rights reserved. 1-21
Balancing Theory
Balancing Procedure

Transducer Placement Affects Phase

In the example illustrated below, the phototach and the vibration transducer
are not in same location. The vibration transducer is at 90E relative to the
phototach as measured against rotation. This 90E separation between the
transducer and the phototach must be included to determine the location of the
heavy spot.
Estimation of Heavy Spot Location

The rotor’s heavy spot can be estimated by evaluating the transducer amplitude
units, system lag, displayed phase and the angle between the phototach and
vibration transducer. By using this estimation, the trial weight can be placed
in a location that will reduce the rotor’s vibration.

Heavy Spot ' Angle Between Transducer and Phototach % Displayed Phase % Amplitude Units & System Lag

1-22 © Copyright 1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Theory
Balancing Procedure

Heavy Spot Estimation Example

In the example shown below, the system lag is approximately 15E. The
amplitude measurement was taken in displacement.

Displacement Phase Photo-Tach

333 E

Tape
Rotation
Heavy
Spot

Vibration
Transducer

Heavy Spot ' Angle Between Transducer and Phototach % Displayed Phase % Amplitude Units & System Lag

Heavy Spot ' 90E % 255E % 0E & 15E

Heavy Spot ' 330E

6/98 © Copyright 1997, Computational Systems, Incorporated. All rights reserved. 1-23
Balancing Theory
Balancing Procedure

Õ Job Documentation
Additional Benefits
Now that the machine is properly balanced, what’s next? Documenting the
balance job is the first step to establishing a balance program that can manage
the balance process for all machines instead of just doing a balance.

This historical record should not only provide management reports, but also
help to answer questions such as, how often the machine required balancing
and the proper machine settings. By determining the system lag and the
influence coefficient, the machine can be balanced in the future by recording
this information. The balancing procedure is simplified because no trial run is
required. Simply take the reference run and apply the necessary correction
weight based on the previous information.

Ö System Characteristics
It is not uncommon to have a rotor that reaches a certain amplitude and cannot
seem to be balanced any further. Two potential causes of this problem are:

Non-linearities in the System

One of the main sources of non-linearities in the system is looseness. As the
1xTS forcing function is reduced, the rotor has less force acting upon it and
begins to "float." This characteristic is easily identified by an unsteady phase.

Influence Coefficient Changes

As the 1xTS forcing function is reduced, the rotor balance may stall at some
point. When the balancing procedure began, a strong 1xTS vibration was
present. As the rotor is balanced, it is more susceptible to other sources of
machinery vibration. These other sources introduce changes into the system
and affect system calculations. If amplitude is still above the acceptable level
and the phase is steady, a new influence coefficient may need to be calculated.

1-24 © Copyright 1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Section Two
Single Plane Field Balancing w/Analyzer

Goals of the Balancing Procedure

Ô Reduce the vibration amplitudes due to unbalance to acceptable levels (which will
not accelerate machine deterioration during extended operation). (See Appendix
C.)

Õ Achieve acceptable balance with the minimum number of starts and stops.

Ö Minimize the downtime of the machine.

× Minimize the stress on the machine during the balancing operation.

Field Balancing
Field Balancing is a straightforward procedure which involves very logical steps once
the analyst has determined that unbalance is the root cause of the vibration problem:

Ô Measure the machinery vibration caused by unbalance (1xRPM magnitude and

phase).

Õ Apply test weights (trial weights) to the rotor assembly.

Ö Measure the response of the mechanical system to the application of these trial
weights.

× Calculate the best correction weights to remove the unbalance based on the
measured system response data (influence coefficients).

Ø Verify the desired balance condition with measurements and repeat the procedure
until satisfied.

What is a Plane?
A plane is a cross section through the rotor.

Correction or weight planes are sections through the rotor that provide locations for
the balance weights.

Measurement Planes are cross sections through the rotor where the vibration
measurements will be made. These are usually the bearing locations.

The locations of these planes must be defined during the balance set-up procedure.
6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 2-1
Balancing Applications
Field Balancing

First Time Balancing Procedure

A first time balancing procedure is one for which no previous balancing data exists.
If the machine had been balanced previously, then the data from the previous balance
could have been loaded into the balancing instrument so that a one-run balance might
have been possible. One-run balances are discussed later. Assuming the proper
preliminary steps have been taken, the basic steps for any balance job are:

Ô Define the balance job. Most computer programs for balancing require the user
to:
< Describe the job (i.e., job number, machine ID, etc.)
< Identify weight planes.
< Identify measurement planes.
< Identify measurement points.
< Provide number of and approximate balance speeds.
< Provide vibration sensor information.

Õ Acquire data from the as-is condition as the reference run for each measurement
point and speed.

Ö Acquire trial run data.

< Add a trial weight to the rotor in one weight plane.
< Acquire data for all measurement points and speeds.
< Repeat for each weight plane.

× Calculate and install the necessary correction weights.

Ø Record the applied weights.

Ù Check the Result.

Ú Calculate the trim correction.

Û Apply trim weight without removing the correction weight.

Ü Check your results. Repeat trim runs as needed.

Ý Store the job.

2-2 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Applications
Field Balancing

Using FASTBAL II or ULTRASPEC Balance

Fast Bal I/II and UltraSpec Balance all use the same basic program flow and data.
The most visible difference is that Fast Bal II and UltraSpec use numerous graphical
displays, whereas Fast Bal I is entirely text based. There are several other features
which are not as obvious. Check the feature comparison chart in Appendix A for
more information on differences.

These programs are designed to lead the user through all necessary steps. The user
just needs to begin with step 1, Job Definition, and the program will lead the way. If
additional assistance is needed at any point press the Help key for a help message
related to the current task.

As we walk through an example single plane balance procedure, this manual will
display both Fast Bal I and Fast Bal II screens for comparison. UltraSpec screens will
be very similar to the Fast Bal II screens.

6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 2-3
Balancing Applications
Field Balancing

Single Plane Balance Lab

Analyze the Rotor Kit
Using the 2120, press the Analyze key and Acquire Spectrum to collect data for both
rotor kit bearings in the vertical and horizontal directions. Identify the running speed
peak for each measurement and record the amplitude at that frequency. Compare the
amplitude at 1xRPM to any other frequencies in the spectrum. Identify any
other‘frequency peaks present in the spectrum.

Inboard Horizontal ________ Outboard Horizontal ________

Inboard Vertical ________ Outboard Vertical ________

Select Analyze then Monitor Peak and Phase. How stable is the phase at each
measurement point?

Enter the Balance Program

When using FAST Bal I/II enter the balancing program by pressing the UTILITY
key, highlight SPECIAL FUNCTIONS, and then press ENTER.

Highlight ENTER DOWNLOADABLE PROGRAM and press ENTER.

2-4 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Applications
Field Balancing

Select the BALANCE MAIN program overlay from the list of installed programs.
Note that the version of the balance program must match the version of the firmware
in the analyzer or they will not be compatible and will not function properly.

FAST Bal I FAST Bal II

UltraSpec Note: To enter the balance program go to SELECT

APPLICATION under the UTILITY key. Highlight the
ULTRASPEC BALANCE program and press the ENTER
key.

This is the main menu for the balance program. Select JOB DEFINITION and press
ENTER.

6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 2-5
Balancing Applications
Field Balancing

Single Plane Balance

Define the Balance Job: The first screen contains mostly descriptive information
used for job storage and reporting. SPEC is the vibration amplitude you want to
balance to or below.

Although the program defaults to a 2 plane 4 measurement point (MPT) job this lab
will only use one weight plane, one measurement plane, and one MPT. Change all
entries as needed then press ENTER to accept the changes.
At the DEFINE TACH OPTIONS screen the user may:
< Define the default direction of rotation.
< Specify the position of the rotor reference mark relative to top dead center (TDC)
when the tach sensor responds to it.(In degrees measured OPPOSITE rotation)
< Establish a DELTA RPM if the machine to be balanced is variable speeed. This
creates a window about the reference RPM for which data is considered valid.
Using "0" disables this feature.
< Specify 1-6 reference speeds to be used with the delta.
Press ENTER when complete.

FAST Bal I FAST Bal II / UltraSpec

2-6 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Applications
Field Balancing

Define the sensor to be used for the measurements. All sensors must conform to the
same definition. Be sure all settings conform to the screen shown. Press ENTER
when all changes are complete.

The final page to be defined for this job is the location of each sensor (measurement
points). Each sensor must be identified as to the measurement plane, the angle from
TDC, and when using the MUX, channel. Up to 4 planes and 8 sensors may be
defined. For purposes of this lab use only the IBV (inboard vertical) at measurement
plane 1 and channel 1.

FAST Bal I FAST Bal II / UltraSpec

This completes the job definition. We will look at multiple planes and sensors, as
well as discrete weight planes later. The information you have provided enables this
job to be stored and later recalled without being re-entered. Re-using the same set-up
will enable later trim balancing of the machine. Often default set-ups can be used and
very little input required, even on new jobs, except for changes to Job #, Machine ID,
and the like.

6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 2-7
Balancing Applications
Field Balancing

When the last screen of the job definition has been completed the program returns to
the Main Balance menu. Notice the first step is marked as complete and the next
logical step is highlighted. All you need to do is press ENTER to continue.

Make Measurements: Reference Run

A list of measurements displays. This list will vary depending on how the job has
been configured. The first data needed is the Reference Run. This reveals the as-is
condition. No weights are added yet. Since only one MPT is defined, the data
acquisition begins as soon as Reference Run is selected. Be sure the sensors are
connected and ready before pressing ENTER.

No matter what program is being used, the goal is to obtain steady, repeatable
readings. Erratic Readings will result in erratic balance solutions. CSI’s balance
programs use vector averaging to improve the reliability of the data even when some
variation is present. Look for the amplitude to average to less than 10% variation, and
the phase to average to a 5E window.

2-8 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Applications
Field Balancing

When the data has stabilized, press ENTER to accept the data. When multiple MPT’s
are used data will have to be acquired for each one. All MPT’s will be shown with the
data recorded for those points. When all data has been acquired, press ENTER to
continue.

FAST Bal II / UltraSpec

FAST Bal I

6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 2-9
Balancing Applications
Field Balancing

Make Measurements - Trial Run

Select TRIAL RUN 1 for the next set of readings. A trial weight will need to be
added before proceeding so the response of the system may be measured. Press
ENTER.

FAST Bal I FAST Bal II / UltraSpec

Use this screen to tell the analyzer the amount and location of the trial weight. The
weight units are not specified but must remain consistent throughout the procedure.
Location is specified in degrees, measured against the direction of rotation, starting at
the leading edge of the reference mark (reflective tape).

Since there is only one MPT, pressing ENTER to accept this trial weight information
will begin data acquisition. When satisfied with the data press ENTER to stop data
acquisition. Review the data then press ENTER again to continue to the next step.

Once all data has been collected for the reference and trial run, the program again
returns to the Main Menu. Press ENTER to calculate the balance correction.

2-10 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Applications
Field Balancing

Balance Correction
The balance solution is automatically calculated. Solutions are available for adding or
removing weight with the last trial weights either removed or left in place. For this
lab, use the solution showing weight to be added with the trial weight off.

FAST Bal I FAST Bal II / UltraSpec

After reviewing the balance solution, simply press ENTER to return to the Main
Menu. You will need to install the needed correction and perform a check run to see
the results. Press ENTER to accept TOLERANCE CHECK / TRIM.

Check the Results - Applied Weight

Press ENTER with APPLIED WEIGHTS highlighted.

6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 2-11
Balancing Applications
Field Balancing

The actual weights applied often differ from the recommended solution due to
limitations of measurement, obstructions, use of materials on hand, etc. This entry
allows the applied weights to be recorded and stored with the job. Press ENTER
when complete.

FAST Bal I FAST Bal II / UltraSpec

Check Result

Accept CHECK RESULT to acquire data after the correction weight has been added.
Again, since there is only one MPT be ready to acquire data as soon as you press
ENTER.

Data acquisition proceeds the same as before. However, after the data is accepted and
you press Enter to proceed, a summary of results is displayed before you. Return to
the menu. Use this table to judge whether further correction is needed. Press
ENTER when finished.

2-12 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Applications
Field Balancing

Trim Correction

Even if you feel no further correction is needed, you must view the Trim Correction
so the program knows to complete this Check Run and automatically store the data.

The Trim Correction will have the same format as the earlier Balance Corrections,
except there is no need for considering trial weight removal any longer. If the Trim
Corrections are used, this weight is added in addition to the previous balance
correction (i.e., don’t remove the balance correction weight when adding the trim
correction weight).

FAST Bal I FAST Bal II / UltraSpec

FAST Bal I FAST Bal II / UltraSpec

6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 2-13
Balancing Applications
Field Balancing

Repeat Check Runs / Trims as Needed

After viewing the recommended trim correction resulting from Check Run data, the
program automatically records all data from the Check Run and returns to the Main
Menu. Now the user can apply the recommended trim weight and repeat the Check
Runs as needed. When finished, select OPTIONS and store the current job.

Store the Current Job

From the Balance Options Menu select STORE JOB.

If the current Job # has already been stored you will be asked if you want to store the
current job under a new number or overwrite the existing job. Otherwise, the current
job is immediately stored.

2-14 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Applications
Field Balancing

The Application of Field Balancing

Overview
The balancing of rotating assemblies in the field has several significant advantages:

< The rotor is balanced in its own bearings.

< The rotor is balanced at normal operating frequency.

< The rotor is balanced at normal load.

< The rotor is driven as it is driven during normal operation.

< Tear down, re-assembly, and re-alignment are not necessary.

< Down time is greatly reduced.

Field balancing is not only a valuable procedure for equipment which has seen
extended service in the field, but frequently for new installations or rebuilds, even
when the rotor has been shop balanced. Operating frequency, rotor stiffness, the
bearing support and its stiffness, load, and drive conditions all contribute to the final
running condition of the assembly. Specifications which are met in the shop may not
be satisfied on-site under final conditions. Once put into service, the rotor balance
may change due to stress relieving, erosion, buildup, etc.

Field Balancing: Before You Begin

Since an industry-wide fallacy exists that states imbalance is the most common cause
of machinery vibration, there is a tendency to do inadequate or no vibration analysis
before attempting to balance a rotor. If the field balancing procedure does not work,
it is because the vibration analysis was not carefully done or the rotor dynamics were
not understood.

Unless using the balancing procedure itself as a diagnostic tool, never attempt field
balancing until you have determined that the forcing function is rotor imbalance. In
addition, investigate the rotor resonance, bearing support resonance, and other system
resonances to understand where the rotational frequency is in relation to these natural
frequencies.

As the operating speed approaches a resonance, factors such as amplification and

phase shifts can make the balance job difficult, if not impossible, to perform
successfully. A general rule is for the operating frequency to be 15-20% above or
below these resonances.

6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 2-15
Balancing Applications
Field Balancing

A Few Basics to Keep in Mind

The following facts are the principles which form the basis for the balancing of
machinery:

< The vibration caused by imbalance occurs at 1xRPM of the unbalanced rotor.

< The vibration is directly proportional to the amount of unbalance. Doubling the
amount of the unbalance doubles the amount or amplitude of the vibration.

< A shift in the heavy spot results in an equal shift in the phase angle.

< All weights in a single plane sum vectorially to equal a single heavy spot.

< The amount of unbalance is measured in weight and distance from the center of
the rotor (radius); e.g., oz./in., gm/in., or gm/cm. Increasing the weight or the
radius increases the amount of the unbalance in direct proportion.

< Rotors operating below their first critical are called rigid rotors. These can be
balanced in any two planes. Rotors operating above their first critical are called
flexible rotors and may require balance weights in more than two planes.

Preparing for the Balance Job

Once you have determined through careful analysis that imbalance is the forcing
function and that field balancing is needed, your initial preparations should include:

< If the rotor has significant material environmental or process material adhering to
the surfaces, then have it thoroughly cleaned. The rotor may return to acceptable
balance conditions when clean.

< Check all hold-down / mounting bolts for looseness.

< Mount vibration transducers at each bearing. The transducers should be rigidly
mounted to the bearing, never hand-held, and should not be moved during the
entire process.

< Provision to read phase within 5E. Take phase readings from one shaft reference
throughout the balance operation, even if there is more than one correction plane.
A rigidly mounted reference transducer, such as a phototach or magnetic
proximity pickup is preferred rather than a strobe, whenever possible.

< The operating frequency should be repeatable run to run.

2-16 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Applications
Field Balancing

< Assurance that the vibration and phase data are repeatable. If balance from a
balance run cannot be repeated, it may be due to loose parts, chips, water soluble
lubricant, rust, water, or other types of foreign matter in the rotor.

< Availability of correction weights and a means of determining the weight.

The goal is for all variations in phase and amplitude to be due to changes arising from
the movement or application of weights, not due to poor technique. Good technique
will minimize the required runs and improve the final precision of the balance job.

Identification of Correction Planes

Ô The vendor may supply standard positions such as balance rings.

Õ For a uniform rotor operating below the first critical, locate a single plane
anywhere for an adequate balance.

Ö If the rotor operates above the first critical and two-plane balancing is being used,
locate the correction planes 25% of the distance between bearings.

× For non-uniform rotors, apply the correction weights to planes in order of their
mass moments of inertia.

Ø Do not add correction weights at any location that affects the rotor stiffness or
modifies the aerodynamics of the flow of the system.

How Many Correction Planes?

A rotor system can be exactly balanced in N+2 planes (where N=the number of shaft
criticals below operating speed).

Most mechanical systems are designed to operate below their first shaft critical;
therefore use 0 + 2 = 2 planes.

Virtually all systems operate below their fourth critical; 3 + 2 = 5 planes.

However, frequently only two balance planes are available on a single shaft. This will
normally allow an acceptable balance compromise, even if not exact.

Uniform rotors operating below the first critical can often be balanced in a single
plane.

6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 2-17
Balancing Applications
Field Balancing

Common Problems
The greatest problems in most field balancing operations are:

Ô Ensuring that balance is the problem.

Õ Starting and stopping the machine.

Ö Adding or removing weights.

When the field balancing procedure does not give the desired results, it is generally
because of:

Ô Measurement errors.

Õ Weight Placement errors.

Ö Vibration caused by something other than the unbalance.

× Lack of understanding of the rotor dynamics of the system.

2-18 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Section Three
Solutions to Potential Problems

Resonance
All machine components have resonant frequencies. A tuning fork vibrates at its
resonant frequency when hit with another object. This produces an audible tone. If
the first tuning fork is not vibrating, and a second tuning fork of the same frequency is
struck and held against the first, then the first begins vibrating as well. In the same
way, if the resonant frequency of a structure is close to the running speed of the
machine it will tend to resonate, or vibrate, in response.

The frequency at which the resonance occurs, and how it affects vibration from
unbalance, depends on the stiffness, mass, and damping characteristics of the
machine. As machine speed approaches the resonant frequency, the vibration from
unbalance will tend to increase significantly. As speed is increased beyond the
resonant frequency, the amplitude will decrease to a steady level. The phase will shift
180E through resonance and will shift 90E at resonance.

Structural resonance presents a problem when diagnosing unbalance only if it occurs

close to the operating speed of the machine. When a machine is operating near
structural resonance, high vibration levels at 1xRPM result from relatively small
amounts of unbalance.

When this condition is present the problem will appear to be a pure unbalance.
However, attempts to balance the rotor may be unsuccessful since slight changes in
machine speed will cause changes in the amplitude and phase which can distort the
balance calculations. Even if you are able to balance the rotor, it may prove difficult
to keep balanced as only slight changes in condition will drive the unbalance response
up again. Before attempting to balance any rotor, tests should be conducted to
determine if the machine is operating near a resonance.

Shaft Critical Speeds

A shaft critical speed can be described as a resonant frequency of the shaft.
Therefore, the characteristics of a shaft critical speed will be identical to those for
resonance. For machines designed to operate above the critical speed of the rotor, the
machinery manufacturer will provide the calculated critical speed. Prolonged
operation at a shaft critical speed must be avoided.

Repairs or alterations to the rotor may change the critical speed of that rotor.
Although a rotor operating above a critical speed can be balanced, balancing of a rotor
operating at the shaft critical frequency should not be attempted.

6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 3-1
Balancing Applications
Problems

Resonance

Typical System Response

The resonant frequency of a system is determined by the system’s:

< Stiffness
< Mass
< Damping

3-2 Copyright ©1997, Computational Systems, Incorporated. All rights reserved.

 Balancing Applications
Problems

Measuring Resonant Frequencies

There are several single channel methods for detecting the presence of critical
frequencies. These include:

< Peak Hold Averaging

< Impact Tests

< Bode and Nyquist Plots

< Waterfall Plots

< Ratio of Radial Amplitudes

Test Descriptions
Peak Hold Averaging allows the highest vibration amplitude occurring at each
frequency from several data blocks to be displayed on a single plot. Varying the
1xRPM frequency during data acquisition allows the user to observe how the
amplitude related to 1xRPM changes with speed. This can be done by manually
varying the speed at a controller, or during a long coastdown.

An Impact Test measures the frequencies a machine tends to vibrate at when struck.
Just like a bell rings at its natural frequency when struck. The machine should not be
running and there should be minimal interference from background vibration when
this is done with a single channel analyzer. A 2-channel analyzer can perform this
test in a more sophisticated manner, measuring the force contained in the blow as well
showing whether the frequencies observed are related to the impact, or are from other
sources.

Bode and Nyquist plots show the amplitude and phase relationship to changes in
RPM. A tachometer input is required in addition to the vibration sensor. The speed
of the machine must be varied over a wide range or data acquired during a coastdown.

Waterfall Plots (cascade plots) show several spectra acquired over a wide speed
range. This could be compared to a peak hold plot except that each block of data is
plotted as a separate spectrum.

The Ratio of Radial Measurements at the same measurement plane can also reveal
the presence of structural resonances. If the amplitudes between a horizontal and a
vertical measurement at the same bearing have a ratio greater than 4 to 1 then the
point with the higher amplitude can be suspected to be closer to a resonance than the
other. A similar circumstance can occur when one axis is much more flexible than
another, as could be the case on a vertical pump braced in only one direction. If the
phase change between these 2 readings is either 0 or 180 after adjusting for the angle
between the points, then a resonance is practically certain.
6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 3-3
Balancing Applications
Problems

System Lag
The mechanical system can have a lag between the point where the heavy spot passes
and the point where the maximum vibration (vibratory high spot) occurs. The system
lag does not have to be determined for successful balancing. However, if the user
wishes to calculate trial weight placement so that the trial run will result in reduced
vibration, then the user will need to consider system lag. For most mechanical
systems the high spot will lag the heavy spot. The amount of lag will always be
between 0E and 180E. Below resonance the lag approaches 0E as the rotational
frequency moves further from the resonance. Above resonance the lag approaches
180E as the rotational frequency moves further above the resonance. At resonance the
lag is 90E.

If you have determined the resonant frequency of the machine then you can estimate
the system lag based on how far above or below resonance the rotational frequency is
located. If you haven’t determined resonant frequency, then observe the machine
during the coast down from the reference run. Record coast down data if possible. If
not, then observe the amplitude and phase immediately after shut down. If the phase
changes dramatically at shutdown, then you are near a system resonance. If the
vibration amplitude rises then falls, then the rotational frequency is above resonance.
If the amplitude only falls, then you are just below resonance.

If the system lag cannot be determined and the resonant frequency is not known,
estimate system lag at 90E for any calculations. If the system lag is not known but the
rotational frequency is known to be somewhere below the first critical, then estimate
the system lag at 45E. If above the first critical estimate at 135E. These values will
approximate the location of the heavy spot within 45E.

Location of the Unbalance

Locate the vibratory high spot by locating the reference mark at the tach pick-up.

Then starting at the vibration transducer from which the phase was obtained, measure
an angular distance equal to the phase reading against the direction of rotation. This
is the vibratory high spot.

Now move around the rotor in the direction of rotation an angular distance equal to
the estimated system lag from the vibratory high spot. This is the location of the
heavy spot.

In summary:

Heavy Spot = Angle of Vib Transducer + Phase + Units Type Adj. - System Lag

3-4 Copyright ©1997, Computational Systems, Incorporated. All rights reserved.

 Balancing Applications
Problems

System Lag Example

In the example illustrated below the system lag was determined to be approximately
15E. The vibration transducer is at 90E relative to the phototach as measured against
rotation. An unbalance weight was placed at 330E. The actual acquired phase data
was as follows: 255E using displacement, 166E using velocity, and 75Eusing
acceleration.

Angle of Phase Units System Lag Location

Vibration + Reading + Adj - = of Heavy
UNITS transducer Factor Spot

Disp 90E + 255E + 0E - 15E = 330E

Vel 90E + 166E + 90E - 15E = 331E
Acc 90E + 75E + 180E - 15E = 330E

6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 3-5
Balancing Applications
Problems

Calculate the TW Location

Using the phase and amplitude data from the reference run of the Single Plane Balance
Exercise, estimate where the trial weight should have been placed. How does the
estimate compare with the location of the final correction weight?

1. Calculate the heavy spot.

a. Measure angle between position of the reference mark on the rotor
when the tachometer senses it, and the position of the vibration
transducer. Remember to measure angles against rotation.
b. Add the phase reading.
c. Add the adjustment for the units
i. Displacement = 0
ii. Velocity = 90
iii. Acceleration = 180
d. Subtract System Lag
i. Estimate 45 degrees if below the first critical
ii. Estimate 135 degrees if above the first critical
iii. If close to the critical use 90E.

2. Calculate the light spot - add 180E to the heavy spot.

Angle of + Phase + Adjust for - System = Heavy + Light

Vib Reading Units Lag Spot 180 Spot
Sensor

Helpful Hint: When using displacement a quick calculation is to just add 180
degrees to the phase reading.

3-6 Copyright ©1997, Computational Systems, Incorporated. All rights reserved.

 Balancing Applications
Problems

Mechanical Looseness
Most machines are constructed so that the supporting structures do not move freely.
If bolts loosen or grouting deteriorates, movement may occur between the surfaces.
This is the condition normally described as mechanical looseness.

When mechanical looseness occurs, high vibration at the rotating speed and
harmonics of the rotating speed usually are present predominantly in the radial
directions. When the stationary component is loose, small amounts of unbalance can
result in large amounts of vibration. The amplitude and phase of the vibration at the
rotating speed may be unsteady; varying in a random manner. When rotating
component looseness is present, the amplitude and phase of the vibration may shift
randomly.

A closely related condition exists when loose materials or fluids are trapped inside a
rotor. While the response to the unbalance may not be higher than normal, the
amplitude and phase are affected. This can be especially noticeable when the rotor is
started and stopped. A repeatable vector may not be obtainable.

Removing the looseness first may eliminate the need for the balance procedure to be
performed at all.

6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 3-7
 Section Four
UltraMgr

UltraMgr - Dump Data to Computer

UltraMgr is the information manager for alignment and balancing data. It may be
accessed directly from the MasterTrend Menu or run as a stand alone program. In
addition to providing long term storage for this data, UltraMgr also prints reports and
allows existing jobs to download from the computer back to the analyzer for future uses
such as trim balancing.

The purpose of this exercise is to demonstrate the process of storing balance jobs to the
computer from the balance analyzer. To begin the program, either select UltraMgr
from the MasterTrend menu, or, if running as a stand alone:

< Change to the directory containing the program (for example: type CD C:\ULTRA,
then press the Enter key)
< Type LOAD then press Enter.
< Type ULTRAMGR then press Enter.

From the MasterTrend main menu screen, click on the “CORRECTIVE” button to
toggle the Ultramanager programs on. Then click on the Ultramanager icon to start up
the Ultramanager program.

6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 4-1
Balancing Applications
Ultra Mgr

When the above screen appears, click on the “Balance” tab to switch to the balance
functions in Ultramanager. Now click on the Communication button on the right hand
side of the screen to continue the process.

To check the communication setup, click on the “COMM SETUP” button and match
the computer to the analyzer baud rate and number of stop bits.

4-2 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Applications
Ultra Mgr

Set the “Number of Retries” and “Timeout Delay” to 5 retries and 15 seconds to allow
enough time to answer all questions asked by Ultramanager during the process of
uploading jobs from the computer to the analyzer.

On FAST Bal I/II select LOAD/DUMP DATA from the Balance Options Menu
(shown below left). Then select HOST CPU LOAD/DUMP from the Dump/Load
Functions Menu. If using UltraSpec press the Utility Key, select Communications,
then select Host PC Load/Dump. Press ENTER to start the communication process on
the analyzer.

6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 4-3
Balancing Applications
Ultra Mgr

Click on the “Upload Jobs to the Database” button to start the computer
communication program. Several messages will be displayed in succession on the
computer screen. “Initializing Comm Port”, “Attempting Communication with the
Balance Analyzer”, “Attempting To Read the Buffer” , and the Analyzer version
number with the number of stored balance jobs will all be displayed. When the
messages are completed, the analyzer will dump the stored jobs into an Unassigned
area of the Ultramanager database. We will cover the assignment of the jobs to a
specific machine later in this section.

4-4 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Applications
Ultra Mgr

Click “OK” to return to the Ultramanager main menu.

Ultramanager - Creating a Machine

From the Ultramanager main menu, click on the “Balance” tab to switch to the Balance
functions. Now click on the “Database Management” button to start the DB
management functions.

6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 4-5
Balancing Applications
Ultra Mgr

The following screen will display:

Choose the “Add/Edit” option and click “OK”. For Mastertrend users, the easiest way
to add the Stations and machines to Ultramanager is to click on the “COPY MT
Database” button and the “MT Database” button to select the correct database.With

Check marks in all boxes, Click “OK” to build the information into the Ultramanager
database.

4-6 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Applications
Ultra Mgr

A report similar to the one above will print out.

ADDING NEW STATIONS AND MACHINES

To add a new station for our Balance test case, select the “Station” option under
“Add/Edit” and click “OK”.

When the Station list screen appears, click on the “Add Station” button to add a new
station. We will call the new station TRAINING LAB.

6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 4-7
Balancing Applications
Ultra Mgr

Click “OK” to accept the new station definition.

Click on the “CANCEL” button to return to the “ADD/EDIT” main menu to build our
rotor kit as a new machine.

4-8 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Applications
Ultra Mgr

Highlight the MACHINE option and click “OK”.

Select the “Training Lab” station to build the new machine in.

6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 4-9
Balancing Applications
Ultra Mgr

Since the Ultramanager program knows there are no machines in the station yet, it
displays the message shown above. Click on the message box “OK” button to continue.

Fill in the blanks as shown above and click “OK” when done.

4-10 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Applications
Ultra Mgr

Now we will fill in the Coupling type and machine speed. If the machine is belt drive,
use “UNKNOWN” as the coupling type. Our Machine speed is 1769 RPM. Click “OK”
to continue. This completes the creation of our new machine in Ultramanager.

Assign Jobs In Ultramanager

From the Ultramanager main menu, click on the “Assign Jobs” option.

6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 4-11
Balancing Applications
Ultra Mgr

Highlight “Unassigned Area >>>> Machine” and click “OK”.

4-12 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Applications
Ultra Mgr

The next screen is the station list for the database. Highlight the “TRAINING LAB”
station and click “OK”.

Click “OK” with the “TEST ROTOR” machine highlighted to assign the job to this
machine.

6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 4-13
Balancing Applications
Ultra Mgr

The program will return to the unassigned job selection screen to continue the process.
If there are no other jobs to assign, click on the “Blue Arrow” shortcut key to return the
Ultramanager main menu.

Ultramgr - Print Job

On the Ultramgr Balance main menu, click on the “Summaries” button to display the
choices of Summary reports.

4-14 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Applications
Ultra Mgr

Select the “Integrated Status Report” and click “OK”.

Click the machine criteria selection button and choose the “Entire Station”by double
clicking on your choice. Click “OK” to continue.

6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 4-15
Balancing Applications
Ultra Mgr

Highlight the Tissue Line station and click “OK”.

The summary Integrated Status Report lists the Balance and Alignment jobs for a
specified station or for the entire database.

4-16 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Applications
Ultra Mgr

STORED JOB SUMMARY -

Highlight the “Stored Job Summary” and click “OK” to look at the report. The report
will run and summarize all Balance and alignment jobs stored in the database.

PRINT BALANCE JOBS -

Click on the Balance Reports option button to select a balance report.

6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 4-17
Balancing Applications
Ultra Mgr

Highlight the Balance Job Details option and click “OK”.

Set up the Balance Data tab to print an “Entire Machine”, and the Printing Details tab
on “Detailed”. Click “OK” to run the report.

4-18 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Applications
Ultra Mgr

BALANCE REPORT - DETAILS

************************

STATION: [BAL ] ------- [TISSUE LINE ]

MACHINE: [BB FAN 2 ] - [BLOW BOX FAN 2 ]

Stored Job Sequence Number : 1

Data Taken : 13-MAY-93 11:49:43
Job Number : 4
Shaft Number : 1
Balance Technician : RWP
Tolerance Specification : 1.000

RESULTS (All amplitudes in MILS P-P)

PLANE: 1 1 2 2
MPT : IBH IBV OBH OBV

SPD 1: 0
INITIAL : 3.717 2.329 8.983 1.104
FINAL : .735 1.823 .548 1.460
% REDUCTION : 80 22 94 -32

NUMBER OF TRIAL RUNS = 6 NUMBER OF TRIM RUNS = 2

TOTAL# OF TRIM RUNS = 2

Notes : HIGH VIBRATION

Notes : ROTOR NOT CLEANED BEFORE
BAL
Notes : RATIO HORZ/VERT AMP > 3
OR < .33
Notes : RESONANCE - NEAR 1XRPM

TRIAL WEIGHTS:

TRIAL RUN 1 - WT. PLANE 1: 22.20 @ ( 6) .00 @ (

1)

REFERENCE RUN DATA:

SPD 1:
MAGNITUDE: 3.717 2.329 8.983 1.104
PHASE: 289 16 299 26
RPM: 3048 3047 3047 3048

TRIAL RUN DATA:

6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 4-19
Balancing Applications
Ultra Mgr

TR 1, SPD 1:
MAGNITUDE: 3.545 2.497 7.388 2.446
PHASE: 129 106 118 131
RPM: 3045 3047 3047 3047

BALANCE CORRECTION - APPLIED WEIGHTS:

BALANCE CORR. - WT. PLANE 1: 16.00 @ ( 6) .00 @ (

7)

TRIM RUN DATA (Correction Weights are Applied Weights):

TM 1, SPD 1:
MAGNITUDE: 1.493 2.194 2.504 1.681
PHASE: 130 85 106 114
RPM: 3053 3053 3053 3051

TM COR. PL1: .00 @ ( 5) -1.20 @ ( 6)

TM 2, SPD 1:
MAGNITUDE: .735 1.823 .548 1.460
PHASE: 163 76 128 115
RPM: 3050 3051 3051 3051

The other balance reports would be set up in a similar manner.

4-20 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Section Five
Trim Balance as a One Run Balance Job

Trim Balance
When the results of the original balance correction are not satisfactory, trim balancing
is commonly used to further improve the balance condition without repeating the
reference and trial runs. This has been completed as part of the single plane balance
exercise.

Trim balancing techniques can also be used to perform what is called a one-run
balance procedure. In reality, this is nothing more than another trim balance. The
steps are:

Ô Load the previously stored balance job from UltraMgr back to the balance
instrument.

Õ Acquire new data using the Tolerance Check / Trim menu.

Ö Calculate and install the new trim correction.

This technique can also be applied when shop balancing identical units from a
production line. Balance one unit then use the set-up and influence coefficients from
the first unit to balance additional units. If an occasional unit will not balance with the
base information, this is an indication of a potential problem (i.e., the unit is not the
same structurally as the rest).

If the machine has been structurally modified, this process may not work. The response
of the machine may have been substantially altered.

6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 5-1
Balancing Applications
Trim Balance

Advantages of the One Run Balance

< Reduced Downtime

< Reduced Machine Stress

< Reduced Maintenance Time

< Uses existing setup information

< Trial runs are not required

< Detects if a machine has changed structurally

Requirements
< Previous influence co-efficients or data from the old reference and
trial runs

< All sensors and reference tape at same positions as before

< Machine response the same as before

5-2 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Applications
Trim Balance

One Run Balance - Lab 1

Loading Data From UltraMgr

Use the data stored in UltraMgr from the single plane balance exercise to balance the
same rotor kits again. Remove part of the old balance correction or add an additional
unbalance to the rotor.

For this lab, first clear any previous data from the balance analyzer. Normally, this is
not necessary for loading new data from UltraMgr. Select DELETE JOB(S) from the
Balance Options Menu.

Delete any job in the list by selecting it and pressing ENTER. To delete all jobs press
ENTER until all have been deleted.

When all jobs have been deleted, this message will be displayed.

6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 5-3
Balancing Applications
Trim Balance

Download the previous single plane balance data from UltraMgr to the analyzer. Start
UltraMgr, click on the Balance tab, and click on the Communication button.

On the communications menu, highlight the Download jobs to the Analyzer option
and go to the analyzer to establish communication before clicking “OK” on the
computer.

5-4 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Applications
Trim Balance

On the analyzer, select LOAD/DUMP DATA from the Balance Options Menu, then
press ENTER.

Check the communications setup before initiating communications.

The Communications Setup screen should look similar to the one shown above. Press
ENTER after all changes are complete.

Now select HOST CPU LOAD/DUMP and press ENTER.

6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 5-5
Balancing Applications
Trim Balance

The screen shown below will appear. If communication with UltrMgr is not
established before the time-outs and retries are used, then an error message appears.

HOST LOAD/DUMP
ACTIVE

AWAITING HOST
COMMANDS

NOW click “OK” on the computer to establish communications.

5-6 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Applications
Trim Balance

Select the Station containing the machine to be balanced.

Select the machine to be balanced.

Select the previous balance job which contains the reference and trial run information.

6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 5-7
Balancing Applications
Trim Balance

After selecting the job to load, you are asked to assign a new job number.

Press ESC to clear the default from the input field, type in the desired name, then press
F1.

5-8 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Applications
Trim Balance

When the desired data has been loaded, use F4=Backup to return to the Balance
functions menu in UltraMgr.

6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 5-9
Balancing Applications
Trim Balance

After the desired data is transferred, press the RESET button (MAIN in UltraSpec) to
end. Go to the Balance Options Menu and select RECALL JOB.

Highlight the desired job, and press ENTER.

When asked whether you desire to save the job in the current job area, reply NO for
this lab. In the field, use this opportunity to save any previous work if you have not
already done so.

5-10 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Applications
Trim Balance

The job has been successfully recalled from memory. Press ENTER.

One Run Balancing - Lab 2

Trim Balance the Machine

Once the balance job has been recalled to the current job area, the machine name and
job # will appear on the Balance Functions main menu. The first three steps of a
regular balance job should already be marked as completed. Select TOLERANCE
CHECK/TRIM.

UltraMgr may be configured to load the previous trim run information with the balance
job. Typically, when performing a later trim balance do not bring the old trim run data
back with the job. In this case, the check run # should be 1. If any higher number
appears at this point, it will be because the previous trim data is present. Select
APPLIED WEIGHT.

6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 5-11
Balancing Applications
Trim Balance

Replace any default Applied Weight entries with zeros, then press ENTER.

At the Tolerance Check/Trim menu select CHECK RESULT.

When the vibration sensor and tach are ready, press enter to acquire data. When the
data has stabilized, press ENTER to accept the data.

If the data is satisfactory, press ENTER to continue.

5-12 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Applications
Trim Balance

Choose TRIM CORRECTION when returning to the Tolerance Check/Trim menu,

to view the calculated trim correction.

This trim correction shows how much weight to add to correct the current unbalance
condition, based on the previous influence coefficients of the original balance job. No
previous weights are removed before adding this correction. Press ENTER when
finished.

After looking at the trim correction, the program returns to the main balance functions
menu. Once the trim weight has been added, select TOLERANCE CHECK/TRIM to
check the results.

6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 5-13
Balancing Applications
Trim Balance

You have begun Check Run #2. Select APPLIED WEIGHT.

Input the actual weight and location of the correction weight installed. Press ENTER
when finished.

Once the sensors are ready and the rotor kit is running, select CHECK RESULT.

5-14 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Applications
Trim Balance

Acquire data for the corrected condition.

Press ENTER to proceed.

Using the first check run as the initial data, the program will now display the Tolerance
Check Summary. Press ENTER to continue.

6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 5-15
Balancing Applications
Trim Balance

Remember, even if you are satisfied with the results, you still need to view the Trim
Correction, to tell the program that Check Run #2 is completed and that it may record
the data.

The trim correction is made without removing any previous weight corrections. Press
ENTER when finished.

Once the program has returned to the Balance Functions menu, either continue with
additional trim runs, or store the job by highlighting OPTIONS, then STORE JOB.

Note: If the trim correction does not successfully reduce the vibration amplitudes
at 1xRPM, it is either because the setup is not identical to the original, or
the system response has changed. System response can change due to
structural changes (looseness, cracked shafts, added bracing, etc), or
because the machine has been totally rebuilt.

5-16 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Section Six
Multi-Plane Balancing

How Many Planes?

We have previously given rules based on the modal characteristic of the rotor (the
number of critical speeds below rotational frequency). However, there are many cases
where a two-plane balance will give much better results than a single-plane
procedure, which are not covered by those rules.

Although there are those who would compute the length-to-diameter ratio and use this
to decide whether to use more than one plane, in reality, any rotor, including flat
disks, could require two-plane balancing.

While it is fairly obvious that a long rotor will usually require weight corrections in
more than one plane, it is not as obvious why a very thin rotor might require
adjustments to both sides. The latter case usually arises from the rotor not being
perfectly perpendicular to the shaft resulting in couple unbalances.

Experience usually is the best teacher in these matters. For very narrow rotors, you
may wish to try a single plane solution first. If this does not resolve the unbalance,
then repeat the process with a two-plane procedure. On the other hand, if the rotor is
easy to stop, start, and attach weights, try a two-plane solution to start with.

Rigid Rotor Dynamics

Static Unbalance

Unbalance
Center of Gravity
Central Principal Axis

Shaft Centerline

Displacement of the Central

Principal Axis from the Shaft
Centerline caused by the
unbalance

6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6-1
Balancing Applications
Multi-plane Balancing

Rigid Rotor Dynamics

Couple Unbalance

Unbalance

Center of Gravity
Central Principal Axis

Shaft Centerline

Displacement of the Central Principal

Axis from the Shaft Centerline
caused by the unbalance

Bending Modes

6-2 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Applications
Multi-plane Balancing

Bending Modes Showing Heavy Spots

Best-fit Solutions
The CSI software uses the influence coefficients and least-squared-error method of
balancing. This allows the responses to a balance weight in one plane to be measured
at all sensor locations and simultaneously used in the balance solution. The result is a
best fit solution wherein the goal is to maximize the reduction in vibration at all
points simultaneously. Because some weight corrections may decrease the
amplitudes at one measurement point while at the same time increasing others, a
compromise is made.

While this can be very tedious if calculated by hand, modern balance analyzers and
calculators make it seem easy.

Recommended Two-plane Setup

2 Weight Planes

2 Measurement Planes

4 Vibration Sensors

Horizontal and Vertical at each Measurement Plane

6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6-3
Balancing Applications
Multi-plane Balancing

Two-Plane Balance Outline

Ô Define the Job

a. 2 Weight Planes
b. 2 Measurement Planes
c. 4 Vibration Sensors

Õ Make Measurements - 1 Reference Run

Ö Make Measurements - 2 Trial Runs

× Calculate and Apply Balance Correction

Ø Enter Applied Weights

Ù Make Measurements - Check Result

Ú Calculate Trim Correction

Û Apply Trim Weight, If Needed

Ü Repeat Steps 4-7 as Required

Ý Store Job

6-4 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Applications
Multi-plane Balancing

Two-Plane Balance Lab

Enter the balance program and select

JOB DEFINITION to define a new
balance job.

If a job is already defined, first input

YES at CLEAR JOB. Then clear all
current job data. Once the job is
cleared, configure the screen similar
to what is shown at right. Press
ENTER when finished.

The job should have 2 weight planes,

2 measurement planes, 4 measurement
points, and 1 speed. Press ENTER
when complete.

Define the tach options. Check the

direction of machine rotation. If your
tach angle is different, be sure to
specify the correct angle. This
example shows that the reference tape
triggers the tach input when the tape is
at TDC.

6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6-5
Balancing Applications
Multi-plane Balancing

Define the sensor as shown. If not

using the Model 642 MUX, be sure to
set this to OFF.

Input the correct sensor ID, positions,

and channels, for measurement plane
1.

Do the same for the 2nd measurement

plane. Press ENTER when finished.
This is the final setup screen, so the
program automatically returns to the
Balance Functions menu.

We are now ready to begin making

measurements. Press ENTER to
begin.

6-6 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Applications
Multi-plane Balancing

Note that for a two-plane job there

will be two trial runs. Let’s begin
with the reference run.

Since there are 4 measurement points,

(MPT’s), we must select one from
which to acquire data. Start at the top
one whenever possible and let the
program lead you to each succeeding
one.

Acquire data for the IBH sensor.

After acquiring data, select the next

sensor. Press ENTER when ready for
the next reading.

6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6-7
Balancing Applications
Multi-plane Balancing

Shown at right is data for the second

MPT.

Select the next sensor.

Data is being acquired for the OBH

sensor.

Select the last MPT.

6-8 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Applications
Multi-plane Balancing

Shown at right is data from the OBV

sensor.

After all data is acquired for the

reference run, review the data. To
repeat any point, simply highlight that
point and press ENTER. Otherwise
press ENTER to proceed.

Now select a trial run. Begin with

Trial Run 1.

We must first enter a trial weight.

Install a trial weight in plane 1 for trial
run 1. Try estimating the location of
the light spot for placement of the trial
weight. Use the data from the
reference run for the point you feel is
most likely to be influenced by this
weight plane. When two MPT’s are in
the same plane, try using either an
average of the results or
the highest amplitude MPT.

Heavy Spot = Angle of sensor from tach + Phase + Units Adjustment - System Lag

If using displacement and a sensor in line with the tach, then:

Heavy Spot = Phase - Lag

6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6-9
Balancing Applications
Multi-plane Balancing

We must now acquire data at all 4 MPTs again. Rather than show each of the data
acquisition screens again we will skip to the final screen with all data.

When all data has been acquired, press

ENTER to continue.

The Reference Run and Trial Run 1

have been completed. Now let’s
acquire data for Trial Run 2.

Remove the trial weight used for Trial

Run 1 and install one in Weight Plane
2. The trial weight could be left in
Plane 1 but would have to be shown in
the Trial Weight table for Trial Run 2.

6-10 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Applications
Multi-plane Balancing

We acquired data for each of the 4

MPTs with the new trial weight in
weight plane 1. Press ENTER to
continue.

The program will return to the main

menu. Select CORRECTION
WEIGHTS to see the balance
solution.

The solution calls for 3.7 units of

weight at 71 degrees in weight plane 1
and 4.62 units of weight at 135
degrees in weight plane 2. Press
ENTER to exit this screen.

Once the correction weights are

applied, check the results by going to
TOLERANCE CHECK/TRIM.

6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6-11
Balancing Applications
Multi-plane Balancing

Remember, enter the actual weights

used by selecting APPLIED
WEIGHT first.

These are the weights actually applied

at each weight plane.

We must now acquire a new set of

vibration readings to check the
success of the corrections.

Again, we have skipped all the

intermediate data screens and are
showing the final data. If we proceed
from here, we can get a summary of
the results compared to the initial
data.

6-12 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Balancing Applications
Multi-plane Balancing

When more than one measurement

plane is used, the results are plotted
individually for each plane. Use the
Up/Down arrow keys to change the
scaling of the graphic. Better than
80% reduction was achieved in this
plane. Press ENTER to see the next
plane.

Tolerance Check for measurement

plane 2. Press ENTER to return to
the Tolerance Check Menu.

Remember to always view the Trim

Correction even if you are satisfied
with the results already achieved. The
Check Run is not completed or the
data stored until you look at the Trim
Correction.

The recommended trim correction is

shown at right. Press ENTER when
finished.

6/98 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6-13
Balancing Applications
Multi-plane Balancing

You may now either continue to make

weight adjustments and check runs, or
if finished, go to Balance Functions
and store this job.

6-14 Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 6/98
 Section Seven
Calculator Mode

Calculator Mode

Fast Bal I/II and UltraSpec offer auxiliary balance calculations to assist with special
problems. These are available under the Calculator Mode menu.

Access the Calculator Mode by first going to the Balance Functions menu. Select
Options from the main menu of Fast Bal I/II or press the Options key of the
UltraSpec analyzer.

Select Calculator Mode.

FAST Bal I offers 4 basic calculations. FAST Bal II and UltraSpec have additional
calculations for Trial Weights and Amplification Factors.

Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 7-1

Balancing Applications
Calculator Mode

Calculator Mode Terms

Split Angle calculates the weight to be placed at two locations when the weight
cannot be placed at the original location recommended by the
balance solution. One location must be to each side of the original.

Sum Weights combines multiple weights into a single weight and location.

Adjust Fixed when weights of fixed size are available, this utility
Weights calculates where to place the fixed weights to equal the effect of
the single weight recommended by the balance solution.

Static/Couple interprets the balance solution in terms of its static and

Analysis couple components.

Estimated Trial estimates the size and location of a trial weight which will
Weights reduce the amplitude for the trial run.

Amplification estimates the system lag and amplification factors after

Factor the reference and trial runs are completed.

FAST Bal I FAST Bal II / UltraSpec

7-2 Copyright ©1997, Computational Systems, Incorporated. All rights reserved.

 Balancing Applications
Calculator Mode

Split Angle Screens

Input Screen

Solution Screen

Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 7-3

Balancing Applications
Calculator Mode

Fixed Weights Screens

Input Screen

Solution Screen

7-4 Copyright ©1997, Computational Systems, Incorporated. All rights reserved.

 Balancing Applications
Calculator Mode

Estimated Trial Weight Screens

Setup Screen

Solution Screen
(Any Alpha-Numeric Key Toggles Units Between Oz, Lb, Grain, Gm, Kg)

Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 7-5

 Section Eight
Trial Weight Calculations

Estimating Trial Weights From Amplification Factor

Ô Amplification factor
a. Estimate the amplification factor from resonance testing.

At resonance: 25 MILS; A f= 2.5

Free Splace: 10 MILS; A f= 1.0

Below resonance: 5 MILS; A =f 0.5

b. Use value of 3.

Note: The example above is typical. Actual values will vary with different types
of machinery.

Õ Calculate Trial Weight (TW)

TW = Trial Weight
Dm = Measured Vibration in MILS pk-pk
W = Rotor Weight in oz. ( * 16 for lbs.)
Af = Amplification Factor

Dm(W
TW'
2000(Af'3

A is determined from above.

Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 8-1

Balancing Applications
Trial Weight Calculations

Amplification Factor
The amount the vibration amplitude is amplified by the proximity of a resonance is
the amplification factor. As the rotational frequency approaches a resonance, the
amplification factor increases. In simple terms, if a specific trial weight would have
resulted in 1 mil of displacement, with an amplification factor of 3, the result would
be 3 mils of displacement. If the amplification factor approaches 6-8, then balancing
becomes extremely difficult if not impossible.

After reference run and trial run data have been acquired, the amplification factor may
be calculated. First calculate the free space amplitude in mils PK-Pk (Xf):

Ub (oz. in.)
Xf ' ( 2000
VibratoryWeight (oz.)

Then divide the measured displacement by the calculated free space amplitude to get
the amplification factor (Af):

Effect of TW (Mils pk&pk)

Af '
Xf

Effect of TW ' (Amp2 COS 2 & Amp1 COS 1)

2
% (Amp2 SIN 2 & Amp1 SIN 1)
2

Where:

Amp1 = amplitude (mils pk-pk) from reference run

1 = phase reading in degrees from reference run

Amp2 = amplitude (mils pk-pk) from trial run

2 = phase reading in degrees from trial run

8-2 Copyright ©1997, Computational Systems, Incorporated. All rights reserved.

 Balancing Applications
Trial Weight Calculations

Free Space Amplitude

Perfectly Balanced Plane -- shaft centerline (cL) and center of gravity (cg) are the
same.

Unbalance shifts the cg away from the cL.

If the plane rotates in free space, it revolves around the cg. Therefore, the cL vibrates
in an orbit.

Copyright ©1997, Computational Systems, Incorporated. All rights reserved. 8-3

Balancing Applications
Trial Weight Calculations

You can calculate the amount of shift by the

ratio of the unbalance to the rotor weight:

d= cg to cL in inches
UB = unbalance in oz. in.
W = rotor weight in oz. (*16 for lbs.)

UB
d'
W

For example:
UB = 4 oz. @ 10" = 40 oz. in.

W = 500 lbs. = 8000 oz.

The vibration of the cL in MILS pk-pk equals

d * 2 * 1000:
d= 0.005"
Df = 0.005" *2*1000
= 10 MILS

8-4 Copyright ©1997, Computational Systems, Incorporated. All rights reserved.